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Operating manual, Dumper – 3012 PLUS

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28 April 2015
Bergmann Maschinenbau GmbH & Co. KG

To mechanically release the parking brake (emergency release)
you need to apply a torque of minimum 40 Nm or 70 Nm
respectively to the adjusting screw!
Tighten the retaining nut and secure the screw cap by a few
revolutions only (to protect the mechanism against dirt).

After the parking brake has been mechanically released, the
dumper must be secured against rolling away with chocks. Before
restarting the dumper, reset the parking brake mechanism.

DANGER

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Summary of Contents for 3012 PLUS

Page 1: ...3012 PLUS BERGMANN Dumper Operating Manual English XX XXX XXXX XXX 04 2015 ...

Page 2: ......

Page 3: ...act Hotlines Rental sales 49 0 5932 0 7292 64 Technical support 49 0 5932 0 7292 29 Warehouse spare parts 49 0 5932 0 7292 19 Please complete before commissioning the machine Type Prod no Year of manufacture Commissioning Dealer This document is protected by copyright law The reproduction of this document in part or in full is prohibited Bergmann Maschinenbau GmbH Co KG ...

Page 4: ...n full is only permitted with the prior consent of the manufacturer Subject to changes We reserve the right to make technical changes to the machine or its components without prior notice There might thus be minor differences between the figures and or information in this document and your actual model Translation of original German operating manual Bergmann Maschinenbau GmbH Co KG Essener Strasse...

Page 5: ...__________20 5 3 General safety instructions ____________________________________________________21 5 4 Danger area ________________________________________________________________22 5 5 Safety distance______________________________________________________________22 5 6 Machine stability ____________________________________________________________23 5 7 Working near underground pipelines and cable...

Page 6: ...lations applicable on site____________________________________ 29 5 24 Tools and accessories ________________________________________________________ 29 5 25 Working in contaminated areas________________________________________________ 30 5 26 Safety devices organisational safety measures___________________________________ 30 5 27 Informal safety measures___________________________________________...

Page 7: ...____________________52 5 46 Other signs_________________________________________________________________56 5 47 Type plate _________________________________________________________________65 6 Technical data____________________________________________________________66 6 1 Power aggregate ____________________________________________________________66 6 1 1 Diesel engine____________________________...

Page 8: ..._ 73 7 5 Admissible slope ____________________________________________________________ 74 8 Description _____________________________________________________________ 75 8 1 General description__________________________________________________________ 75 8 1 1 Frame _________________________________________________________________________ 75 8 1 1 Axles wheels and travel drive _____________________...

Page 9: ...___________________________________________________92 9 5 1 2 Speedometer _________________________________________________________________93 9 5 1 3 Display_______________________________________________________________________95 9 6 Adjustment of driver seat _____________________________________________________97 9 6 1 Lap belt ____________________________________________________________________...

Page 10: ...____________________ 108 10 7 Shutting down dumper______________________________________________________ 109 10 8 Refuelling dumper__________________________________________________________ 110 10 9 Working with the machine ___________________________________________________ 112 11 Transport______________________________________________________________ 113 11 1 Driving on public roads_____________...

Page 11: ... 4 Recovering dumper transport by crane ________________________________________126 12 Dimensions _____________________________________________________________129 12 1 Overview drawing s of dumper_______________________________________________129 13 Accessories _____________________________________________________________130 13 1 Beacon _____________________________________________________________...

Page 12: ...conomical manner please carefully read this operating manual It contains important information regarding the design operation working functions and operating conditions of the machine as well as instructions for its proper maintenance and care The operating manual also contains information on occupational safety The operating manual contains important instructions for the safe operation of the Ber...

Page 13: ...he content of this document 2 About this document Safety instructions are placed in shaded boxes The accident prevention regulations of the relevant trade associations and insurance schemes as well as the operating manual of the drive motor form integral parts of this operating manual Always comply with all applicable statutory regulations in the country of operation of the machine All instruction...

Page 14: ...of the engine manufacturer All repairs must be carried out by suitably trained specialist technicians If maintenance work is not carried out properly and at the prescribed intervals we are not obliged to meet our warranty obligations as laid down in our Terms and Conditions of Sale and Delivery Use only original Bergmann spare parts as they ensure quality of product and exchangeability The dumper ...

Page 15: ...n and with the Bergmann dumper is restricted to qualified and trained personnel Diagrams and specifications in this operating manual may be changed by the authors without prior notice Such amendments might be necessary to reflect changes in technology or in order to improve the safety of the machine and its components Always comply with the applicable statutory accident prevention regulations the ...

Page 16: ...travel on public roads in Germany StVZO approval it must only be used for transportation operations on construction sites The maximum permissible travel speed with load is limited to 40 km h The Bergmann 3012 PLUS dumper is stable on inclines of up to 20 in axial direction and up to 20 in travel direction The tipping trough is designed for the transportation of bulk materials such as sand stones s...

Page 17: ...8 April 2015 Bergmann Maschinenbau GmbH Co KG Even when the machine is operated correctly for the intended use there is always a residual risk as it is not possible to eliminate every risk to life and limb and or damage to the machine or other property NOTE ...

Page 18: ...hout complying with relevant safety regulations Travel on steep slopes Loading and transporting of goods that obstruct driver s view Fast travel especially when loaded and along bends Jumping in and out of the driver s seat failure to wear a safety belt Use of tipped trough as dozer blade Use of trough to push other vehicles Towing another vehicle Personnel Transportation of person in trough Work ...

Page 19: ...aschinenbau GmbH Co KG 5 Safety 5 1 Safety signs and symbols Non compliance might result in serious irreversible injury Non compliance might result in minor reversible injury Non compliance might result in damage to property Important information DANGER WARNING CAUTION NOTE ...

Page 20: ... 131 Operating manual Dumper 3012 PLUS Status 28 April 2015 Bergmann Maschinenbau GmbH Co KG 5 2 Emergency actions Cordon off site of accident Provide first aid Alert doctor rescue services Look after casualties ...

Page 21: ...umstances must they be bypassed disabled or removed If the safety devices are not functional or work incorrectly do not start the dumper It is the responsibility of the machine owner to complement these safety instructions with specific instructions relating to local site conditions For the operation of the dumper personnel must wear personal protective equipment as prescribed by the statutory acc...

Page 22: ...achine operator must warn persons visual or audible signal If a person does not leave the danger area after a warning signal has been given the machine operator must stop the machine If the view of the machine operator travel path working area is obstructed he she must engage a guide or banksman or cordon off the travel path work area with a fixed installation 5 5 Safety distance To prevent damage...

Page 23: ...at all times the operator must adjust the machine s speed and work operations to suit the actual site conditions The stability of the dumper is primarily determined by the ground conditions on site There are special risks associated with tip trucks operated on soft ground and in conjunction with loads that tend to stick to the trough such as wet clay or frozen material Never exceed the maximum per...

Page 24: ...in the working area as they can pose a serious risk to persons If there are underground pipelines or cables in the working area the contractor must contact the owner or operator of the network in order to determine the actual cable location and to implement the necessary safety measures If the machine operator suspects that the equipment has come into contact with a cable or its protective tube he...

Page 25: ...V______________________________________ 1 0 m From 1 kV to 110 kV_________________________________ 3 0 m From 110 kV to 220 kV______________________________ 4 0 m From 220 kV to 380 kV______________________________ 5 0 m If rated voltage is not known__________________________ 5 0 m In the event of electrical contact between the overhead power line and the machine the machine operator must lower or...

Page 26: ...equately ventilated and no additional precautions need to be taken Never let the engine run idle when working in enclosed spaces DANGER OF POISONING 5 11 Use of lifting gear The machine is designed as a transport vehicle Any other use including the use of the machine to lift goods is prohibited 5 12 Vibration It is the responsibility of the machine operator to determine the occupational vibration ...

Page 27: ...rting work with the dumper perform a function test of the safety devices 5 14 In the event of defects or damage Immediately report defects to the head of operations The machine must only be put back into operation when these defects have been eliminated 5 15 Driving on public roads When travelling on public roads adhere to the applicable national motor vehicle traffic regulations Driving on public...

Page 28: ...ced by the ground on which the vehicle is driving When driving down a slope or if the ground is icy or slippery the braking distance is much longer than on dry level ground Therefore always adjust the travel speed to the ground conditions 5 19 Exiting the dumper Before exiting the machine lower the trough Set all control devices to zero and secure them to prevent unintentional operation Apply the ...

Page 29: ...s providing special training for drivers and mechanics For training options please contact our sales department for contact details see cover page 5 22 Multi shift operation maintenance With multiple shift operation appoint a person to be responsible for performing the necessary maintenance procedures 5 23 Instructions and regulations applicable on site For all work with the dumper always comply w...

Page 30: ...cured against inadvertent restarting When replacing parts ensure that the safety devices are reattached properly by the operator The machine owner must provide the necessary personal protection equipment for workers Regularly check all installed safety devices and guards 5 27 Informal safety measures A copy of the operating manual must be kept in the dumper where it is easily accessible to all per...

Page 31: ...electric energy after the dumper has been switched off Take these energies into account and instruct the personnel in the necessary safety measures For detailed instructions see the associated chapters in this manual 5 29 Maintenance troubleshooting and repair Carry out all inspection setting and maintenance work at the prescribed intervals Shut off the compressed air and hydraulic lines and prote...

Page 32: ...the same safety and load specifications 5 31 Valves and hydraulic hoses Changing the nominal pressure settings of the safety and control valves is only permitted with the explicit approval of the manufacturer Replace hydraulic hoses as soon as you detect any visible damage or leakage Use only hydraulic hoses that meet the requirements laid down by the machine manufacturer 5 32 Fire Extinguish fire...

Page 33: ... the minimum statutory age requirements Operating personnel must have the technical skills and knowledge necessary for the safe operation of the machine They must be properly trained and instructed Suitably qualified operating personnel must be given proper instructions regarding the work to be carried out Machine operators are authorised and obliged to refuse to carry out any orders they consider...

Page 34: ...ting manual must at all times be available at the site at which the machine is operated All operating personnel must read and understand this operating manual prior to starting work The operating manual may be complemented with job specific instructions Ensure that all safety and warning signs on the dumper are legible Replace illegible or missing signs without delay For details see section 5 45 ...

Page 35: ...le damage defects or modifications notify your supervisor without delay Before starting any work with the machine the operator must familiarise himself herself with the working environment and the site conditions Always comply with the rules and regulations applicable at the site of operation Owners supervisors and operators are all equally responsible for compliance with the regulations In case o...

Page 36: ...track under the machine must be able to safely support the maximum wheel load Keep a safe distance from excavation banks and embankments Operate the dumper in such a way that its stability is not compromised Watch out for sloping roadways and uneven surfaces observe the maximum working load and operate the dumper carefully Tip the trough sideways only when the dumper is not pivoted so that the sta...

Page 37: ...e transportation of persons Never use the dumper to push other vehicles When mounting and dismounting the machine use the steps and handles provided Before leaving the driver seat lower the trough apply the parking brake and shut down the engine Before prolonged breaks remove the ignition key and lock the engine bonnet In Bergmann dumpers with cabs close the windows and lock the cab door and other...

Page 38: ...mable goods close to the exhaust devices of the diesel engine Always comply with the statutory regulations for the handling of flammable liquids The dumper is designed for operation in temperate climates For prolonged use in other climate zones contact the manufacturer for advice Indoor operation is only permitted if there is adequate ventilation ...

Page 39: ... of category III C1 Before travelling on public roads check the machine s roadworthiness When travelling on public roads comply with the applicable motor vehicle traffic regulations in Germany StVO Maintain the working equipment in the prescribed position If visibility is poor switch on the headlights The transportation of a passenger is not permitted When parking the machine on a slope secure it ...

Page 40: ...f the pressure needs to be changed first contact our customer service department Welding load bearing steel components or changing the safety device settings is not permitted Spare parts must meet with the manufacturer s technical requirements Observe the intervals for recurring checks inspections and maintenance work laid down in this operating manual All such work must be carried out by speciali...

Page 41: ... To do this remove the trough support see fig 5 3 and 5 4 from its holder below the trough and swivel it onto the auxiliary frame Secure the joystick for trough operation against inadvertent operation by engaging it in its bottom position see fig 5 2 item 1 For repair work only use proper lifting gear with an adequate carrying capacity Do not stand under suspended loads Before mounting or dismantl...

Page 42: ...oil collect the escaping liquid e g gear oil hydraulic fluid in a suitable container and dispose of it safely Before carrying out any work on the hydraulic system depressurise it Leaks in the hydraulic and fuel system must be repaired without delay Escaping oil or fuel causes a fire hazard and pollutes the environment Regularly check the electrical system of the dumper Defects such as loose connec...

Page 43: ...ire extinguishers provided Do not extinguish the fire with water When servicing or changing the battery wear safety goggles and protective gloves After completion of the repair work check all screwed connections and fittings for tightness Only start the drive motor after all work on the machine has been completed Before starting the dumper sound the horn ...

Page 44: ...aschinenbau GmbH Co KG 5 38 Switching off battery main switch Fig 5 1 Fig 5 2 Item 1 The battery main switch item 1 is located to the left behind the cab behind the side flap on the front frame Before carrying out work on the vehicle always switch off the battery main switch NOTE ...

Page 45: ...pril 2015 Bergmann Maschinenbau GmbH Co KG 5 39 Setting dumper to safe state Fig 5 3 Item 1 Push the joystick down and engage it to prevent inadvertent operation of the trough Item 2 Actuate the button to set the parking brake to parking position Fig 5 3 ...

Page 46: ...KG 5 40 Securing lifted trough Fig 5 4 Occupational safety with regard to trough For work to be performed under the trough lift it Fold up the securing mechanism and engage it behind the securing plate of the trough so that the trough cannot drop if the pressure in the hydraulic system drops Fig 5 5 ...

Page 47: ...2015 Bergmann Maschinenbau GmbH Co KG 5 41 Securing dumper against rolling away wheel chocks Fig 5 6 Chocks on both sides under trough When transporting the dumper or when carrying out work on the machine secure it with a chock to prevent inadvertent movement ...

Page 48: ... Co KG 5 42 Transport safety device Fig 5 7 Transport safety device Remove the split pins and the bolts from the centre locking device at rear frame Secure the centre locking device to the welded eyes at the front and rear frame insert the bolts and secure them with the split pins Fig 5 8 Fig 5 9 ...

Page 49: ...owing loading or transporting the dumper always comply with the instructions in this operating manual For towing comply with the prescribed transport position and the admissible speed and maximum towing distance Use proper means of transport and lifting gear with adequate load capacity Before towing the vehicle release the parking brake ...

Page 50: ...5 Bergmann Maschinenbau GmbH Co KG 5 44 Pulling of trailer Fig 5 10 Always attach the trailer to a trailer hook approved by the manufacturer 1 RISK OF INJURY FROM CRUSHING To attach a trailer of any type always engage a second person to guide you or use a camera system ...

Page 51: ...wing instructions are strictly adhered to To improve the traction of the dumper place a load 25 of max payload in the trough fig 5 10 Pulling a trailer is only permissible on level ground and on slopes with an incline of maximum 10 Fig 5 11 The maximum permissible trailer load is 500 kg The maximum drawbar load is 100 kg Do not exceed the maximum permissible payload of the dumper the maximum trail...

Page 52: ...us 28 April 2015 Bergmann Maschinenbau GmbH Co KG 5 45 Safety and warning signs Fig 5 13 Caution Ventilator blades Risk of cutting 1 label Item no 50 005 0003 900 Fig 5 14 Caution Risk of crushing in unsecured pivot area 2 labels Item no 50 005 0004 900 ...

Page 53: ...anual Dumper 3012 PLUS 53 131 28 April 2015 Bergmann Maschinenbau GmbH Co KG Fig 5 15 Caution Refer to operating manual 2 labels Item no 50 005 0002 900 Fig 5 16 Caution Electrical hazard 1 label Item no 50 005 0005 900 ...

Page 54: ...2 PLUS Status 28 April 2015 Bergmann Maschinenbau GmbH Co KG Open only when engine is at standstill Fig 5 17 Caution 2 labels Item no 50 005 0014 900 Fig 5 18 Warning sign Open only when engine is at standstill 1 label Item no 50 005 0019 900 ...

Page 55: ...012 PLUS 55 131 28 April 2015 Bergmann Maschinenbau GmbH Co KG Caution For safety reasons the wheel nuts must be checked for proper fixture every 50 operating hours Fig 5 19 Instruction sign wheel nuts 2 labels Item no 50 005 0036 900 ...

Page 56: ...PLUS Status 28 April 2015 Bergmann Maschinenbau GmbH Co KG 5 46 Other signs Fig 5 20 CE mark 1 label Item no 50 005 0000 900 Fig 5 21 Euro Test mark 1 label Item no 50 005 0001 900 Fig 5 22 Information sign Tested 1 label Item no 50 005 0034 900 ...

Page 57: ...3012 PLUS 57 131 28 April 2015 Bergmann Maschinenbau GmbH Co KG Fig 5 23 Information sign Sound pressure level 100 dB 2 labels Item no 50 005 0041 900 Fig 5 24 Caution Ventilator blades Risk of cutting 1 label Item no 50 005 0003 900 ...

Page 58: ...mper 3012 PLUS Status 28 April 2015 Bergmann Maschinenbau GmbH Co KG Fig 5 25 Caution Risk of crushing in unsecured pivot area 2 labels Item no 50 005 0004 900 Fig 5 26 Caution Refer to operating manual 2 labels Item no 50 005 0002 900 ...

Page 59: ...Maschinenbau GmbH Co KG Fig 5 27 Instruction sign ignition Caution Turn ignition key wait 3 seconds start engine 1 label Item no 50 005 0111 900 Fig 5 28 Instruction sign gear shifting 1 label Item no 50 005 0250 900 Fig 5 29 Adhesive label diesel fuel 1 label Item no xxx ...

Page 60: ...bau GmbH Co KG FUEL TANK Regular refuelling prevents air bubbles in Fuel lines Never let tank run dry Diesel Fig 5 30 Information sign fuel tank 1 label Item no 50 005 0015 900 Fig 5 31 Fuel type sign 1 label Item no 50 005 0016 900 Fig 5 32 Refuelling sign 1 label Item no 50 005 0017 900 ...

Page 61: ... Maschinenbau GmbH Co KG Open only when engine is at standstill Fig 5 33 Hydraulic oil sign 1 label Item no 50 005 0018 900 Fig 5 34 Sling points 4 labels Item no 50 005 0006 900 Fig 5 35 Warning sign Open only when engine is at standstill 1 label Item no 50 005 0019 900 ...

Page 62: ...rating manual Dumper 3012 PLUS Status 28 April 2015 Bergmann Maschinenbau GmbH Co KG Fig 5 36 Warning sign Electrical hazard 1 label Item no 50 005 0005 900 Fig 5 37 Warning sign Caution 2 labels Item no 50 005 0014 90 ...

Page 63: ...ction sign brake fluid 1 label Item no 50 005 0035 900 Fig 5 39 Instruction sign tyre pressure 2 labels Item no xxx Fig 5 40 Instruction sign wheel nuts Caution For safety reasons check the wheel nuts must be checked for proper fixture every 50 operating hours 2 labels Item no 50 005 0036 900 Brake fluid Use only Mobil Velocite No 6 ...

Page 64: ...64 131 Operating manual Dumper 3012 PLUS Status 28 April 2015 Bergmann Maschinenbau GmbH Co KG Fire extinguisher label Item no XXXXX Fig 5 41 Fig 5 42 Adhesive label joystick operation 1 label Item no 50 005 0230 900 ...

Page 65: ...15 Bergmann Maschinenbau GmbH Co KG Item 1 Type plate Item 2 Chassis no 5 47 Type plate Fig 5 43 Fig 5 44 The type plate is located on the right hand side of the front frame as seen in the direction of travel and contains all relevant vehicle data Item 2 Item 1 ...

Page 66: ...6 Technical data 6 1 Power aggregate 6 1 1 Diesel engine Manufacturer Cummins Diesel Type QSB 3 3 Power rating according to DIN 6271 63 kW at 2600 rpm Number of cylinders and arrangement 4 cylinders in line Displacement 4500 cm Cooling system Water cooling Air filter Dry air filter 6 1 2 Fuel tank Capacity 190 litres ...

Page 67: ...012 PLUS 67 131 28 April 2015 Bergmann Maschinenbau GmbH Co KG 6 1 3 Electrical system Operating voltage 12 V Battery capacity 110 Ah Alternator 60 A Starter 3 0 kW Vehicle lighting Standard Beacon Optional Working lights Standard front rear ...

Page 68: ...e actual requirements The drive mechanism is connected directly to the engine The machine comes with manual and automatic gear shifting The power is transferred to the axles by means of joint shafts Front axle drive can be switched on when the machine is standing still 6 1 5 Travel speed Travel mode I 0 06 km h forward and reverse Travel mode II 0 09 km h forward and reverse Travel mode III 0 14 k...

Page 69: ...wheel drive 6 2 1 Tyres tyre pressure Diagonal tyres 20 5 R 25 Front tyre pressure 2 50 bar Rear tyre pressure 4 75 bar 6 2 2 Brakes Service brake Encapsulated long life maintenance free multi disk brake with automatic adjustment Hydraulically operated with brake pedal acting on front and rear wheels two circuit brake system Secondary and parking brake Hydraulically operated spring applied brake a...

Page 70: ...ntre pivot steering Drive Hydraulic power steering with Orbitrol valve acting on a double acting working cylinder Oil supply from working hydraulics through valve Steering lock 33 on either side Outside turn radius approx 5033 mm Inside turn radius approx 2892 mm Emergency steering in the event of failure of the diesel engine Blocking mechanism Mechanical lock ...

Page 71: ...ing hydraulics 45 litres Operating pressure 230 bar Working pressure for steering 175 bar Capacity of hydraulic tank 120 litres 6 5 Weights Curb weight with cab 11 200 kg Payload for travel on building sites 12 000 kg Payload for travel on public roads 8 800 kg 6 6 Noise emission Sound power level LWA 100 dB 1pW Sound pressure level LpA lg 81 dB 20 mPa at operator s workplace ...

Page 72: ...enbau GmbH Co KG 7 Approvals and certificates 7 1 Occupational health safety CE tested according to Machinery Directive 2006 42 EC 7 2 Noise EC type approval 7 3 Approval for driving on public roads Optional approval by TÜV with vehicle certificate Emission class engine EPA interim tier 4 EU stage III 3 B ...

Page 73: ...th 7390 mm Overall height with A C system 3120 mm Overall width 2450 mm Overhead load min 2010 mm Overhead load max 2159 mm Axle base 3740 mm Track width 1930 mm 7 4 1 Dumping height Rear 360 mm Side 950 mm Ground clearance 410 mm Trough height fully tipped rear 4710 mm Trough height fully tipped side 3480 mm See overview drawings chapter 12 ...

Page 74: ... Status 28 April 2015 Bergmann Maschinenbau GmbH Co KG 7 5 Admissible slope RISK OF TIPPING OVER The dumper must not be driven across inclines of more than 20 in travel direction and 20 in axial direction as its stability can otherwise not be guaranteed Fig 7 1 WARNING ...

Page 75: ...t in the front frame The front frame bears the diesel engine the hydraulic tank the oil tank the cab with operator stand and the engine bonnet 8 1 1 Axles wheels and travel drive The rear axle is rigidly mounted below the rear frame The front axle is attached to the front frame and is a self aligning flat spring axle The vehicle is driven by a hydro mechanical torque converter with downstream mult...

Page 76: ...ntegrated transfer box The converter serves as wear free starting gearbox and its speed and torque can be continuously adjusted to the actual requirements The drive mechanism is connected directly to the engine The machine comes with manual and automatic gear shifting The power is transferred to the axles by means of joint shafts Front axle drive can be switched on when the machine is standing sti...

Page 77: ... 8 2 1 Service brake When the brake pedal is pushed down the brake cylinder is actuated acting on a hydraulic brake valve The brake acts on both the front and rear axle two circuit brake system 8 2 2 Secondary and parking brake When the parking brake switch is actuated the brake caliper in the gearbox is electrically applied When the brake circuit is depressurised the brake is applied by spring fo...

Page 78: ...by a gear pump The hydraulic steering system for the operation of the steering cylinder is supplied through a priority valve The oil not required for steering is available for the working cylinders of the working equipment The oil flow rate depends on the engine speed at low engine speed the trough movements controlled by the joystick are slower at high engine speed they are faster As the control ...

Page 79: ...nn Maschinenbau GmbH Co KG When the joystick is moved the following cylinder movements are actuated Fig 8 1 Joystick forward Trough is lowered Joystick back Trough is lifted Joystick to the right Trough is turned to the right Joystick to the left Trough is turned to the left ...

Page 80: ...d to the left behind the cab behind the flap near the first step see fig 8 2 8 4 1 Electrical consumers Starter Horn Dashboard Windscreen wiper Beacon optional 8 4 2 Only in models equipped for travel on public roads Vehicle lighting consisting of see fig 8 3 2 headlights 2 indicators front 2 combined brake indicator tail lamps rear 8 4 3 Beacon Special authorisation is required for installation o...

Page 81: ...au GmbH Co KG Item 1 Handle Item 2 Step 9 Operator stand cab 9 1 Access to operator stand The operator stand of the 3012 PLUS dumper is accessed from the left front To access the cab always use the handle item 1 and the step in the bumper item 2 see fig 9 3 Item 1 Fig 9 1 Fig 9 2 Item 2 Fig 9 3 ...

Page 82: ...mn switch Item 3 Dashboard display definition For flash codes of control system see maintenance instructions Fig 12 8 9 2 Description of operator stand and cab The operator stand cab is mounted on the front frame of the dumper It is secured to the frame with hydraulic bushings The operator stand is designed as a separate unit Its main components are shown below Item 3 Item 2 Item 1 ...

Page 83: ...ator stand cab Operating manual Dumper 3012 PLUS 83 131 28 April 2015 Bergmann Maschinenbau GmbH Co KG Item 4 Brake pedal Item 5 Accelerator pedal Item 6 Steering column Fig 9 5 Fig 9 6 Item 5 Item 4 Item 6 ...

Page 84: ...Operator stand cab 84 131 Operating manual Dumper 3012 PLUS Status 28 April 2015 Bergmann Maschinenbau GmbH Co KG Item 9 Side console Item 10 Joystick Fig 9 7 Fig 9 8 Fig 9 9 Fig 9 10 Item 9 Item 10 ...

Page 85: ...Operator stand cab Operating manual Dumper 3012 PLUS 85 131 28 April 2015 Bergmann Maschinenbau GmbH Co KG Item 11 Seat Item 12 Headliner Item 13 Radio Fig 9 11 Fig 9 12 Fig 9 13 Item 11 Item 12 Item 13 ...

Page 86: ...l Dumper 3012 PLUS Status 28 April 2015 Bergmann Maschinenbau GmbH Co KG Item 14 Windscreen washer tank Item 15 Sun protection blind for front windscreen Item 16 Sun protection blind for rear Fig 9 14 Fig 9 15 Fig 9 16 Item 14 Item 15 Item 16 ...

Page 87: ...ght indicator Back Left indicator Down Full beam lights on Up Flashing light Centre position Dipped headlights on 9 3 Functions and operation of steering column switch and joystick Do NOT adjust the steering wheel while driving Fig 9 17 Fig 9 18 Fig 9 19 Fig 9 20 Steering column switch Steering wheel adjusting mechanism Retarder control ...

Page 88: ...tick Switch 1 forward Forward travel Switch 1 back Reverse travel Press switch 2 Gear shift down Press switch 3 Gear shift up Joystick down Lock Joystick up Release Joystick forward Lower trough Joystick back Lift trough Joystick to right Turn trough to the right Joystick to left Turn trough to the left Fig 9 21 1 2 3 ...

Page 89: ...1 Not assigned 2 Light 3 Outside mirror heating 4 Ignition 5 Mirror adjustment 6 Hazard warning light switch 7 Front working lights 8 Rear working lights 9 Beacon 10 Trough lock 11 Gear shifting automatic manual 12 Windscreen wiper 9 4 Functions of switches on side console Fig 9 22 Fig 9 23 1 2 3 4 5 6 7 8 9 10 11 12 ...

Page 90: ...per 3012 PLUS Status 28 April 2015 Bergmann Maschinenbau GmbH Co KG Switches 13 Heating fan speed 14 Heating temperature control 15 Cigarette lighter 16 Parking brake 17 Cruise control 18 Axle activation Fig 9 24 Fig 9 25 Fig 9 26 13 14 15 16 17 18 ...

Page 91: ...12 PLUS 91 131 28 April 2015 Bergmann Maschinenbau GmbH Co KG Item 1 Left buttons Item 2 Left dial indicator Item 3 Right dial indicator Item 4 Right buttons Fig 9 17 Item 5 Display centre 9 5 Dashboard Fig 9 27 Item 3 Item 2 Item 5 Item 4 Item 1 ...

Page 92: ...tors on dashboard 9 5 1 1 Rev counter Item 5 Item 9 Item 6 Item 4 Item 10 Item 1 Change to previous screen Item 2 Change to next screen Item 3 Rev counter Item 4 Pre glowing activated Item 5 Full beam headlights on Item 6 Engine warning Item 7 Engine stop Item 8 Left indicator Item 9 Parking brake activated Item 10 Cooling water temperature Item 1 Item 2 Item 3 ...

Page 93: ...93 131 28 April 2015 Bergmann Maschinenbau GmbH Co KG Item 8 Item 4 Item 1 Item 9 Item 2 Item 5 Item 6 Item 7 Item 10 9 5 1 2 Speedometer Item 1 Fuel level indicator Item 2 Fuel tank at reserve Item 3 Speedometer Item 4 Right indicator Item 5 Working mode ...

Page 94: ... manual Dumper 3012 PLUS Status 28 April 2015 Bergmann Maschinenbau GmbH Co KG Fig 9 29 Item 3 Item 6 Transport mode Item 7 Travel direction forward Item 8 Travel direction reverse Item 9 Actuation switch Item 10 Change to warning screen ...

Page 95: ...bH Co KG Fig 9 30 9 5 1 3 Display Screen 1 Item 6 Item 2 Item 7 Item 1 Item 3 Item 4 Item 5 Item 8 Item 1 Particle filter regeneration off Item 2 Clean particle filter Item 3 Machine in neutral gear Item 4 Clock Item 5 General warning Item 6 Exhaust system too hot Item 7 Operating hours Item 8 Date ...

Page 96: ... 34 Fig 9 35 Screen 2 Gearbox temperature Engine temperature Travel speed Battery status Date Screen 3 Warning and error messages SPN code Next service Operating hours Screen 4 Selection menu To adjust clock Press DOWN and OK buttons simultaneously Screen 5 Setting time UP arrow minutes DOWN arrow hours Confirm with OK Screen 6 Language settings ...

Page 97: ...technician To prevent accidents ensure that all seat controls are fully engaged before the vehicle is started Do not make adjustments to the seat while the machine is in operation Changes to the series design of the driver seat e g upgrading with third party parts might change its functions and voids the test certificate Certain functions of the driver seat might be impaired so that its safety is ...

Page 98: ...at as well as the seat fixture must be inspected by specialist personnel Regularly inspect screwed connections and retighten screws if necessary If the seat wobbles check for loose screw connections and other defects In the event of malfunction of the seat e g if springs don t work contact a specialist workshop and have the seat repaired or replaced Otherwise there is an increased risk of accident...

Page 99: ...ght adjustment 2 Height adjustment 3 Horizontal spring mechanism 4 Horizontal adjustment 5 Seat angle adjustment 6 Seat depth adjustment 7 Backrest extension 8 Lumbar support 9 Armrest 10 Armrest angle 11 Backrest adjustment 12 Turning mechanism 13 Cushioning mechanism Fig 9 36 Fig 9 37 Fig 9 38 Fig 9 39 Fig 9 40 ...

Page 100: ...mper after you have ensured yourself that it is in proper and safe working order Electronic and mechanical adjustments must be carried out by authorised technical personnel Only start the dumper after you have ensured yourself that it is in proper and safe working order The tasks and checks to be carried out in order to ensure that the Bergmann 3012 PLUS dumper is safe to operate are included in t...

Page 101: ... for leakage and damage 10 1 1 Oil level in engine Place the dumper on horizontal ground The oil level must be between the 2 marks on the dipstick For details see maintenance instructions section 9 2 1 2 10 1 2 Fuel tank Read the fuel level on the diesel tank level gauge For details see maintenance instructions section 9 4 1 2 10 1 3 Fluid level in hydraulic fluid tank Place the dumper on horizont...

Page 102: ...ions If necessary check the battery fluid level and add fluid only for batteries that are not maintenance free For details see maintenance instructions section 5 5 2 10 1 6 Brake fluid Check the brake fluid level in the brake fluid tank If necessary add brake fluid For details see maintenance instructions section 7 8 1 10 1 7 Coolant Check the coolant level in the radiator and coolant tank If nece...

Page 103: ... on the joystick to zero position RISK OF INJURY Before starting the machine check that there are no people within the dumper s danger area Before starting the engine sound the horn Never turn the ignition key when the engine is running Start the dumper only if all safety devices and features are in place and working properly In the event of a fault or malfunction immediately shut down the dumper ...

Page 104: ...til the preheat indicator on the display is switched off Set the travel direction switch to zero position Turn the ignition key to position II to start the engine You can only start the engine if the travel direction switch is in zero position If the engine does not start after 15 seconds turn the ignition key to position I Hold it there for 10 seconds to preheat again Actuate the starter If no fa...

Page 105: ...of the dumper warm up for a few minutes by operating the trough tilt cylinder to the stop 10 5 Shutting down diesel engine After heavy duty work let the engine run at idle speed for 1 to 2 minutes Only then shut it down Set the travel direction switch to zero position Turn the ignition key to position 0 Remove the ignition key Apply the parking brake by actuating the switch button CAUTION ...

Page 106: ...er for travel operation Put the trough into transport position i e lower the trough to the stop in centre position Ensure that the securing bracket in front frame preventing the through from swivelling to the side is properly engaged in the grooved plate of the trough securing bracket at through fig 10 1 Hinweis Fotos vom Rundkipper standen nicht zur Verfügung ...

Page 107: ...m h Travel mode V 0 33 km h Travel mode VI 0 40 km h Reverse mode 3 speeds max 14 km h When a higher travel mode is selected and the truck travels at slow speed low engine speed the travel drive automatically switches to the lower travel mode for full engine thrust If the travelling speed increases the transmission automatically switches back to the preselected higher travel mode Thanks to this au...

Page 108: ...hed down the brake cylinder is actuated acting on a hydraulic brake valve The brake acts on both the front and rear axle two circuit brake system 10 6 5 Parking brake When the parking brake switch is actuated the brake caliper in the gearbox is electrically applied When the brake circuit is depressurised the brake is applied by spring force This brake acts on the front axle and is operated mechani...

Page 109: ...umper Lower the trough and lock it at its centre position Apply the parking brake with the switch Shut down the engine Remove the ignition key Switch the main battery switch off and remove the key When parking the dumper on a slope place chocks in front of the wheels Lock the trough operating system push joystick down ...

Page 110: ...t down the engine Remove the screw cap from the fuel filler neck and fill the fuel tank with diesel fig 10 3 RISK OF EXPLOSION Avoid exposure to light and naked flames Use only clean fuel of the prescribed quality For suitable diesel fuel refer to the operating instructions of the engine Refill the fuel tank at the end of each working day to prevent condensation in the tank DANGER CAUTION NOTE ...

Page 111: ...Start up Operating manual Dumper 3012 PLUS 111 131 28 April 2015 Bergmann Maschinenbau GmbH Co KG Fig 10 2 Fig 10 3 The fuel tank is located at the front right below the cab ...

Page 112: ...nbau GmbH Co KG 10 9 Working with the machine When equipping and using the dumper ensure that its stability is not in any way compromised To ensure that the dumper is always in a safe position avoid sudden movements and take special precautions when working on soft ground or on slopes NOTE ...

Page 113: ...val for travelling on public roads has been obtained comply with the applicable motor vehicle traffic regulations in Germany StVO as well as the requirements laid down in the special authorisation documents Observe the requirements stated in the vehicle s registration book For driving on roads outside Germany observe the applicable national regulations NOTE ...

Page 114: ...tion 9 2 Lower the trough completely and secure it in its centre position Engage the trough lock press switch see cab If on switch off the working lights Switch on the vehicle lights 11 1 2 General notes for driving on public roads The transportation of persons is prohibited Using the working lights when driving on public roads is not permitted Use the working lights only when working in the dark ...

Page 115: ...t is necessary use a company experienced in heavy goods transport for loading and transport In this case the transport company operator or its representative is responsible for loading and transport When loading and transporting the machine always adhere to all safety regulations When choosing the transport vehicle observe the weight and the loading dimensions of the dumper see sections 6 5 and 7 ...

Page 116: ...Transport 116 131 Operating manual Dumper 3012 PLUS Status 28 April 2015 Bergmann Maschinenbau GmbH Co KG Fig 11 1 Fig 11 2 Fig 11 3 Fig 11 4 Fig 11 5 ...

Page 117: ...perating manual Dumper 3012 PLUS 117 131 28 April 2015 Bergmann Maschinenbau GmbH Co KG 11 2 1 Securing centre pivot Before securing the dumper to the transport vehicle lock the centre pivot see section 5 42 NOTE ...

Page 118: ...ssary Towing is only permitted for short distances and if the dumper cannot move under its own power Towing over long distances is not permitted To tow the dumper release the parking brake at the gearbox in the event of a diesel engine failure The dumper must only be towed with a tow rod Never tow dumper at a speed greater than 4 km h or for more than 3 minutes Otherwise there is a risk of overhea...

Page 119: ...erating manual Dumper 3012 PLUS 119 131 28 April 2015 Bergmann Maschinenbau GmbH Co KG Engage the tow rod in the rear towing coupling fig 11 16 or the yoke at the front of the vehicle fig 11 15 Fig 11 15 Fig 11 16 ...

Page 120: ... road Load the dumper onto a transport vehicle Tow the dumper only if the brake and steering work properly Always use a tow rod Incorrect towing can lead to serious damage to the dumper and the towing vehicle If the brake or steering does not work Load the dumper onto a transport vehicle Before towing the dumper from a slope secure its wheels with chocks CAUTION CAUTION ...

Page 121: ...sing the brake secure the dumper against rolling away The brake is pressurised from the accumulator As the accumulator is not refilled when the diesel engine is switched off the service brake fails to work properly after it has been actuated a few times When the accumulator is no longer pressurised the brake is permanently applied by the spring mechanism In this case the dumper can only be moved a...

Page 122: ... parking brake proceed as follows to release it mechanically Remove the screw cap Loosen the retaining nut spanner size 24 or 30 and turn the adjusting screw with a size 8 or size 10 Allen key anti clockwise until the brake disk is released Fig 11 17 1 Thrust bolt 2 Disk spring pack 3 Adjusting screw 4 Screw cap 5 Retaining nut 6 Piston P Plane face S Allen key ...

Page 123: ...ply a torque of minimum 40 Nm or 70 Nm respectively to the adjusting screw Tighten the retaining nut and secure the screw cap by a few revolutions only to protect the mechanism against dirt After the parking brake has been mechanically released the dumper must be secured against rolling away with chocks Before restarting the dumper reset the parking brake mechanism DANGER ...

Page 124: ...rough can no longer be lowered hydraulically e g due to a failure of the diesel engine or the electronics the trough must be lowered manually To do this you must operate the respective valve manually Top view Fig 11 18 The valve is located under the bonnet to the right of the diesel engine see figure to the left All electronic and mechanical adjustments must be carried out by authorised technical ...

Page 125: ...2 PLUS 125 131 28 April 2015 Bergmann Maschinenbau GmbH Co KG To operate the valve turn in the screw item 01 to the stop and hold it in that position The trough is gradually lowered by its own weight This process might take several minutes ...

Page 126: ... for the attachment of lifting tackle It can thus be lifted by crane for example to place it on a construction site or to recover the vehicle after an accident To lift the dumper attach suitable lifting tackle cables chains to the marked sling points fig 11 20 To lift the dumper do not attach lifting tackle to the eyes at the trough Never lift the dumper by its ROPS structure NOTE CAUTION ...

Page 127: ... tackle to the marked sling points at the front and rear frame To lift the dumper attach the cables to the sling points marked on the front frame below cover in bonnet frame and the rear frame eyes as shown in the figure to the left Always use a 4 leg string chain cable with a traverse The cables must be arranged in such a way that the vehicle frame and the cabin components cannot become damaged ...

Page 128: ...the vehicle while it is articulated The lifting tackle cables chains must have a minimum load capacity of 20 000 kg The dumper must only be lifted when empty The centre of gravity of the unloaded dumper is located approximately half way between the axles slightly towards the rear Its position might vary depending on the actual equipment of the vehicle The centre of gravity of the dumper must be ta...

Page 129: ...ries Operating manual Dumper 3012 PLUS 129 131 28 April 2015 Bergmann Maschinenbau GmbH Co KG Fig 12 1 12 Dimensions 12 1 Overview drawing s of dumper Hier sollte n die Übersichtszeichnung en eingefügt werden ...

Page 130: ...Accessories 130 131 Operating manual Dumper 3012 PLUS Status 28 April 2015 Bergmann Maschinenbau GmbH Co KG 13 Accessories 13 1 Beacon Fig 13 1 Fig 13 2 Fig 13 3 ...

Page 131: ...Accessories Operating manual Dumper 3012 PLUS 131 131 28 April 2015 Bergmann Maschinenbau GmbH Co KG ...

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