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have made himself familiar with the operation of the machine,

be physically and psychologically able to drive and operate the

machine.

Persons under the influence of alcohol, medication or drugs are not

allowed to operate, service or repair the machine.

Maintenance and repair work requires specific knowledge and

must therefore only be performed by trained specialists.

Concerning your safety – Definition of responsible persons

D.ONE

Содержание D.ONE

Страница 1: ...Operating Instruction Original Operating Instructions D ONE Multi purpose compactors S N 101 924 90 1001 DL 008 203 58 EN 04 2018...

Страница 2: ...2...

Страница 3: ...nvironmental protection regulations for handling diesel fuel 26 3 4 3 Safety regulations and environmental protection regulations for handling oil 27 3 4 4 Safety regulations and environmental protect...

Страница 4: ...er 57 4 4 6 Starter switch 57 4 4 7 Start button 57 4 4 8 Vibration toggle switch 58 4 4 9 Emergency stop switch 58 4 4 10 Button for warning horn 58 4 4 11 Radio operation control light 59 5 Checks p...

Страница 5: ...sing the articulation lock 103 8 3 Fuels and lubricants 105 8 3 1 Engine oil 105 8 3 2 Fuel 106 8 3 3 Coolant 107 8 3 4 Oil for exciter shaft housing 108 8 3 5 Hydraulic oil 108 8 4 List of fuels and...

Страница 6: ...43 9 1 Drum extension 144 9 1 1 Preliminary remarks and safety notes 144 9 1 2 Removing the drum extension 144 9 1 3 Attaching the drum extension 145 9 2 Teaching the BOSS safety field system 146 10 T...

Страница 7: ...1 Introduction Introduction D ONE 7...

Страница 8: ...maintenance and repair measures to maintain the functional safety of your machine A description of all necessary maintenance work maintenance intervals as well as information on fuels and lubricants...

Страница 9: ...t constitute an extension of the warranty and liability conditions specified in the general sales and delivery conditions of Dynapac GmbH We wish you successful work with your Dynapac machine Introduc...

Страница 10: ...gine type Fig 1 Engine number 2 Made by Designation Type Nominal Power Operating Mass Year of Construction Serial No Made in Germany Ammerl nder Str 93 D 26203 Wardenburg 1 2 B 924 0001 Fig 1 Machine...

Страница 11: ...2 Technical data Technical data D ONE 11...

Страница 12: ...0 197 7 8 1897 75 16 0 6 850 33 5 610 24 Dimensions in millimetres Dimensions in inch Weights Operating weight CECE 1595 3516 kg lbs Basic weight 1585 3494 kg lbs Mean axle load CECE 798 1759 kg lbs D...

Страница 13: ...f cylinders 3 Rated power ISO 3046 14 5 kW Rated speed 2600 min 1 Drive system hydrostatic Driven drum 4 Brakes Service brake hydrostatic Parking brake hydro mechanical Steering Type of steering Artic...

Страница 14: ...ing IP 55 Safety field frequency 125 kHz Transponder in remote control Voltage cable operation 9 to 30 V Voltage battery operation 3 6 V Transmitting frequency range 868 916 MHz Safety field antenna I...

Страница 15: ...e Directive edition 2006 42 EU n Noise Emission Directive 2000 14 EU Noise Protection Direc tive 2003 10 EU During operation these values may vary because of the prevailing operating conditions LpA 84...

Страница 16: ...Technical data Noise data D ONE 16...

Страница 17: ...3 Concerning your safety Concerning your safety D ONE 17...

Страница 18: ...s n generally accepted safety and road traffic regulations n country state specific safety regulations It is the duty of the operator to be acquainted with the safety regu lations and to apply these a...

Страница 19: ...ctices for safe and environment friendly disposal of fuels and lubricants as well as replacement parts 3 1 3 Personal protective equipment Depending on the work to be carried out personal protective e...

Страница 20: ...e is only to be used for n Compaction of cohesive soils in trench construction n Construction backfills n Earthwork in sewer and pipeline construction n Earthwork in railway and dam construction n Ear...

Страница 21: ...n Work with vibration on hard concrete cured bitumen layers or extremely frozen ground n Driving on liquid soft concrete n Driving on non load bearing subsoil or inadequate contact areas danger of ti...

Страница 22: ...regular safety inspections 3 2 2 Expert qualified person An expert qualified person is a person who based on his her pro fessional education and experience has profound knowledge in the field of const...

Страница 23: ...operate the machine Persons under the influence of alcohol medication or drugs are not allowed to operate service or repair the machine Maintenance and repair work requires specific knowledge and must...

Страница 24: ...be informed about the dangers that arise from the operation of the machine 3 3 2 Regular safety inspections Have the machine inspected by an expert qualified person as required for the conditions the...

Страница 25: ...name of substance n possible dangers n composition information on constituents n first aid measures n fire fighting measures n measures in case of accidental release n handling and storage n limitati...

Страница 26: ...fuel Wear your personal protective equipment pro tective gloves protective clothing Do not inhale any fuel fumes Avoid contact CAUTION Danger of slipping on spilled diesel fuel Immediately bind spill...

Страница 27: ...aused by contact with oil Wear your personal protective equipment pro tective gloves protective clothing Do not inhale any oil vapours Avoid contact CAUTION Danger of slipping on spilled oil Immediate...

Страница 28: ...ontact with hot components Smoking and open fire is prohibited Wear your personal protective equipment pro tective gloves protective clothing CAUTION Health hazard caused by contact with hydraulic oil...

Страница 29: ...r personal protective equipment pro tective gloves protective clothing Do not inhale any fumes Avoid contact CAUTION Danger of slipping on spilled coolant Immediately bind spilled coolant with an oil...

Страница 30: ...l for medical advice in case of cau terization WARNING Danger of injury caused by exploding gas mix ture Remove the plugs before starting to recharge the battery Ensure adequate ventilation Smoking an...

Страница 31: ...y in the specified loading direction Lifting tackle must not be damaged by machine parts Secure the machine on the transport vehicle against rolling slip ping and turning over Loads may only be attach...

Страница 32: ...or other defects the machine must not be operated until these have been rectified Do not operate the machine with defective indicators and control elements 3 6 2 Starting the engine Before starting a...

Страница 33: ...e always connect the ground strap last and disconnect it first A wrong connection will cause severe damage in the electric system Do not start the engine by shorting the electric terminals on the star...

Страница 34: ...e connecting cable on the receiver from the machine socket The radio remote control must only be repaired by the manufac turer or specialists authorised by the manufacturer The radio remote control mu...

Страница 35: ...and down slopes Do not drive on gradients or slopes exceeding the maximum gra deability of the machine Chapter 2 Technical data on page 11 Drive extremely carefully on gradients and always directly up...

Страница 36: ...3 8 6 Parking the machine Park the machine on horizontal level firm ground Before leaving the machine n shift all control levers to neutral position off or 0 n switch off the engine and remove the ign...

Страница 37: ...charging than diesel fuel with a higher sulphur content You should therefore always make sure that the filling system is properly grounded and that there is equipotential bonding to the machine If nec...

Страница 38: ...ing it out of the danger zone Loads may only be attached and hoisted by an expert qualified person Before lifting the machine lock it with the articulation lock Do not use lifting points that are dama...

Страница 39: ...he hydraulic oil at operating temperature danger of scalding Any hydraulic oil must be collected and disposed of in an environ mentally friendly way Always collect and dispose of hydraulic oils separa...

Страница 40: ...insulating material Do not use fuses with higher ampere ratings and do not bridge fuses When working on the battery smoking or open fire is prohibited Do not lay any tools or other metal objects on t...

Страница 41: ...warning sign Only operate the machine after it has been repaired Repairs must only be performed by an expert qualified person When replacing safety relevant components only original spare parts must...

Страница 42: ...3 13 Signage Keep stickers and signage in good and legible condition and comply with their meaning Replace damaged and illegible stickers or signage immediately Concerning your safety Signage D ONE 42...

Страница 43: ...IN MAX AUTOMATIC MIN MAX AUTOMATIC Diesel OIL SAE 15W40 HYDRAULIC OIL HV46 DIESEL WATER IN FUEL OIL SAE 15W40 7 9 mm NEW Hydraulik Oil HV 46 NEW Made by Designation Type Nominal Power Operating Mass Y...

Страница 44: ...Hydraulic Oil Engine Coolant Spec MB 325 5 Deutz DQC CC 14 B 720 0101 Fig 11 Warning sticker Danger of crushing Fig 12 Concerning your safety Signage D ONE 44...

Страница 45: ...of being pulled in by cooling fan and hot surface Follow operating instructions Prohibition sticker High pressure cleaning Instruction sticker Wear ear defenders B DEC 0196 Fig 13 B DEC 0197 Fig 14 Fi...

Страница 46: ...mation sticker Lifting point Information sticker Filler opening for diesel Information sticker Filler opening for hydraulic oil Fig 17 Fig 18 B DEC 0215 Diesel Fig 19 B DEC 0214 Hydraulic Oil Fig 20 C...

Страница 47: ...start Brief operating guide B DEC 0219 Fig 21 B DEC 0272 Fig 22 B DEC 0198 Fig 23 B DEC 0195 START OPERATION STOP 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 AUTOMATIC 0 10s START MAX MIN AUTOMATIC...

Страница 48: ...Information sticker Coolant B DEC 0255 OIL SAE 15W40 HYDRAULIC OIL HV46 DIESEL WATER IN FUEL OIL SAE 15W40 7 9 mm NEW Hydraulik Oil HV 46 NEW 008 312 84 Fig 25 Fig 26 B DEC 0275 Engine Coolant Spec M...

Страница 49: ...plate example Made by Designation Type Nominal Power Operating Mass Year of Construction Serial No Made in Germany Ammerl nder Str 93 D 26203 Wardenburg B 924 0002 Fig 28 Concerning your safety Signa...

Страница 50: ...Concerning your safety Signage D ONE 50...

Страница 51: ...4 Indicators and control elements Indicators and control elements D ONE 51...

Страница 52: ...erating mode toggle switch 3 Display module 4 Main battery switch 4 1 Operating mode toggle switch Position left Cable operation Position right Radio operation B 720 0013 Fig 30 Indicators and control...

Страница 53: ...temperature is too high Run the engine at idle speed or if necessary shut it down and clean the radiator if necessary repair the engine Safety device warning light Lights up when the operator with th...

Страница 54: ...ry switch can be pulled out Disconnects the batteries from the on board electrics e g to prevent unauthor ised use Individual control units may still be con nected to the on board electrics despite th...

Страница 55: ...peed toggle switch 5 Travel lever 6 Start button 7 Starter switch 8 Vibration toggle switch 9 Emergency stop switch 10 Radio operation control light 11 Button for warning horn 4 4 1 Steering lever Shi...

Страница 56: ...tched on or off using the vibration toggle switch 4 4 3 Toggle switch for travel ranges Position front Travel speed range 2 Position rear Travel speed range 1 Vibration is automatically switched off i...

Страница 57: ...control light and engine oil pressure warning light light up test function At low temperatures the preheating con trol light lights up on the display module 4 4 7 Start button Set the starter switch t...

Страница 58: ...cy stop switch immediately by pressing it down fully It automatically locks in end posi tion The machine will be braked immediately The engine is shut down Switching off unlocking Pull up the emergenc...

Страница 59: ...ne is automatically switched off after 10 minutes if the battery is not charged or if it is replaced A warning signal also sounds 1 minute prior to shutdown Connect the remote control to the cable as...

Страница 60: ...Indicators and control elements Remote control D ONE 60...

Страница 61: ...5 Checks prior to start up Checks prior to start up D ONE 61...

Страница 62: ...els and lubricants Safety regulations and environmental protec tion regulations must be followed when han dling fuels and lubricants Chapter 3 4 Han dling fuels and lubricants on page 25 WARNING Dange...

Страница 63: ...nd fuel lines and for leaks 3 Check the cooling system for contamination damage and leaks 4 Check the bolted connections are tight and secure 5 Check the engine and exhaust system for leaks 6 Check th...

Страница 64: ...lothes n Safety shoes n Protective gloves 1 Clean the area around the oil dipstick 2 Pull the dipstick out wipe it off with a lint free clean cloth and reinsert it to the end stop 3 Pull the dipstick...

Страница 65: ...h a screen filter Use only fuel of the permitted specification Chapter 8 3 2 Fuel on page 106 1 Check the filling level in the fuel tank 2 Refuel if required after first shutting down the engine Prote...

Страница 66: ...e inspection glass Normal level Approx 3 cm 1 2 in below the top edge of the inspection glass Minimum level Approx middle of inspection glass 2 If necessary check the lines hoses and units for leaks I...

Страница 67: ...tive gloves n Safety goggles 1 Check the coolant level in the compensation tank The coolant level must be between the MIN and MAX marks WARNING Danger of scalding by hot fluid Open the compensation ta...

Страница 68: ...es n Protective gloves 1 Check the six rubber buffers on both the front and rear axle are tight and secure and check for cracks and tears 2 Replace damaged rubber buffers immediately B SYM 1073 Fig 54...

Страница 69: ...6 Operation Operation D ONE 69...

Страница 70: ...be in two operating modes n Cable operation 1 n Radio operation 2 In both operating modes the remote control functions are the same However for radio operation special operating instructions and per...

Страница 71: ...continue driving the safety field must be left or the machine moved in the opposite direction of travel If the machine moves away from the operator the operator can enter the rear safety field a short...

Страница 72: ...apter 6 2 4 Starting the engine on page 81 6 1 2 2 Radio interference If the radio connection between the remote control and the machine is interrupted or disturbed for more than two seconds the machi...

Страница 73: ...ry is empty the machine stops and the engine is switched off 1 When the control light lights up drive the machine to a safe place and stop 2 Remove the safety cap 1 and connect the cable 2 to the remo...

Страница 74: ...he remote control and hold in front of your body 3 During cable operation remove the safety cap 1 and con nect the cable 2 to the remote control 4 Use the toggle switch to select the required operatin...

Страница 75: ...Prepare the remote control Chapter 6 2 1 Preparing the remote control on page 74 2 If several machines are used at the same time compare the system numbers on the remote control and receiver The syste...

Страница 76: ...peed ranges to the rear position 7 Turn the ignition key to position I 1 Shift the travel lever forwards or backwards and hold in place B 720 0014 Fig 70 B 720 0104 Fig 71 B 720 0077 Fig 72 Checking t...

Страница 77: ...automatic return to neutral position can be impaired by dirt e g mortar concrete res idues 8 If necessary clean the steering lever with a clean cloth or brush 9 Start the engine 10 Before starting to...

Страница 78: ...the engine manually Chapter 10 2 Switching off the machine manually on page 151 16 If this does not work correctly shut down the remote control and notify our Customer Service Department 17 Only opera...

Страница 79: ...is 1 m 1 1 yd 2 Turn the toggle switch for operating mode to the right posi tion 3 Start the engine Chapter 6 2 4 Starting the engine on page 81 4 Walk behind the machine with the remote control 5 Let...

Страница 80: ...of the safety field in front of the machine 8 If the distance behind or in front of the machine is too small check the safety device and have it repaired B 720 0057 1 2 m 1 3 yd Fig 82 Operation Star...

Страница 81: ...earing protection Prerequisites n Main battery switch is switched on n The protective hoods and flap are closed and locked n Emergency stop switch is unlocked n The travel lever and steering lever are...

Страница 82: ...e control as soon as the remote control is ready for operation If the buzzer does not sound there is a fault in the remote control or the battery is empty for radio remote control 4 With cold outside...

Страница 83: ...Always drive straight up or down a slope Do not drive on gradients exceeding the maximum gradeability of the machine Soil conditions and weather influences impair the gradeability of the machine Wet a...

Страница 84: ...ch the toggle switch for engine speed to the front posi tion 3 WARNING Injury caused by the machine turning over Do not activate travel speed range 2 when operating without a drum exten sion Use the t...

Страница 85: ...travel direction 6 Shift the steering lever to the left or right The machine steers in the corresponding direction 7 Set the travel lever to middle position to stop the machine The machine decelerates...

Страница 86: ...e ground Vibration at standstill causes transverse marks n Switch the vibration on only after shifting the travel lever in the desired travel direction n Switch the vibration off before stopping the m...

Страница 87: ...ds The machine travels in the required travel direction and the vibration is switched on 5 To switch off vibration return the travel lever towards the middle position The vibration is switched off and...

Страница 88: ...switch for travel speed ranges to the rear position 2 Switch the toggle switch for vibration pre selection to the rear position 3 Shift the travel lever slowly in the desired travel direction B 720 0...

Страница 89: ...th the machine at standstill Use the toggle switch for vibration to switch on the vibration at the required amplitude 5 To switch vibration off switch the toggle switch for vibration to the middle pos...

Страница 90: ...er of engine damage Do not shut down the engine all of a sudden from full load speed but let it idle for about two minutes 4 Turn the ignition key to position 0 and pull it out 5 Open the flap 6 Turn...

Страница 91: ...by water ingress Do not cleaning the remote control with water jets After work clean the remote control with a clean cloth or brush 3 Place the remote control 2 in the holding fixture 3 and close the...

Страница 92: ...e is approx 6 hours Remote control operating time with a full charge is approx 60 hours 6 6 1 Changing the battery 1 Turn the ignition key to position 0 and pull it out 2 Press the battery forwards to...

Страница 93: ...itch on the main battery switch 3 Remove the safety cap 1 and connect the cable 2 to the remote control The battery starts charging 4 Once the battery is charged turn the main battery switch anticlock...

Страница 94: ...specific plug onto the mains unit 3 Remove the battery from the remote control and insert it in the charger 4 Connect the battery charger mains unit to a power source Make sure the two light emitting...

Страница 95: ...7 Loading transporting the machine Loading transporting the machine D ONE 95...

Страница 96: ...paration for transport 1 Remove all loose objects from the machine or fasten them properly 2 Close and lock all protective hoods and flaps Loading transporting the machine Preparation for transport D...

Страница 97: ...f the machine Distance from middle of front drum Height 475 mm 18 7 in 512 mm 20 2 in 1 Switch the toggle switch for travel speed ranges to the rear position 2 DANGER Danger to life caused by the mach...

Страница 98: ...e lifting points Use lifting tackle only in the specified loading direction Lifting tackle must not be damaged by machine parts 1 Fasten the lashing tackle at the marked lashing points 2 Securely lash...

Страница 99: ...ing gear only in the prescribed direction of load application Lifting tackle must not be damaged by machine components When lifting the machine avoid uncontrolled movements of the load If necessary ho...

Страница 100: ...nto or down from the transport vehicle The instructing person should not be inside the travel range of the machine 1 Loosen the articulation lock Chapter 8 2 2 2 Disengaging the articulation lock on p...

Страница 101: ...8 Maintenance Maintenance D ONE 101...

Страница 102: ...with the engine shut down Make sure that the engine cannot be accidentally started during maintenance work Thoroughly clean the machine and engine before starting mainte nance work Depressurize hydrau...

Страница 103: ...tive hoods are secured against unintentional tipping over by a safety strap and cannot be completely folded open 8 2 2 Engaging releasing the articulation lock 8 2 2 1 Engaging the articulation lock W...

Страница 104: ...step into the articulation area of the machine while the engine is running 1 Remove the locking bolt and the articulation lock from the eyelet and swivel back into place in the holding fixture 2 Let...

Страница 105: ...he SAE class always refer to fresh oils In travel operation engine oil ages because of soot and fuel residues This adversely affects the properties of the engine oil especially under low ambient tempe...

Страница 106: ...ent temperatures below 20 C 4 F and when working at altitudes of more than 1500 m 4921 ft The following fuel specifications are recommended n EN 590 n ASTM D975 Grade No 1 D and 2 D 8 3 2 2 Winter fue...

Страница 107: ...engine damage Do not mix different coolants and additives of any other kind Mixing the coolant n Prepare a mixture of 50 anti freeze agent and 50 low min eral clean water n Stir well before filling i...

Страница 108: ...hydraulic oil The hydraulic system can also be operated with a synthetic ester based biodegradable hydraulic oil The biologically quickly degradable hydraulic oil Panolin HLP Synth 46 meets all demand...

Страница 109: ...Mixture of water and anti freeze agent Specification Chapter 8 3 3 Coolant on page 107 DL 009 940 03 20 l 4 0 l 1 1 gal us Hydraulic system Hydraulic oil ISO HVLP 46 Specification Chapter 8 3 5 1 Mine...

Страница 110: ...ge engine oil and oil filter cartridge on page 116 2 Check the engine for leaks 3 Tighten all bolted connections on air intake exhaust oil sump and engine mounts 4 Retighten the bolted connections on...

Страница 111: ...iator hoses and hose clamps 124 8 8 9 Servicing the battery checking the main battery shutoff 125 Every 500 operating hours 8 9 1 Replacing the V belt 127 Every 1000 operating hours 8 10 1 Adjusting t...

Страница 112: ...lter must be inspected for damage using a torch Do not continue to use a damaged air filter ele ment If in doubt use a new air filter Protective equipment n Working clothes n Safety shoes n Protective...

Страница 113: ...s caused by particles flying around Wear your personal protective equipment safety gloves protective working clothes gog gles 9 Blow the air filter out with dry compressed air max 2 1 bar 30 psi from...

Страница 114: ...int vertically downwards Make sure that the cover locks engage cor rectly 13 Reinstall the cover 14 After maintenance has been completed press the button 1 on the maintenance indicator The maintenance...

Страница 115: ...er 6 5 Parking the machine in secured condition on page 90 2 Loosen the bleed screw by a few turns 3 Loosen the drain plug and drain the fluid until pure diesel fuel starts to run out 4 Collect escapi...

Страница 116: ...king the machine in secured condition on page 90 2 WARNING Danger of burning on hot components Wear your personal protective equipment protective gloves protective clothing Avoid touching hot componen...

Страница 117: ...ne in secured condition on page 90 2 Allow the engine to cool down 3 Check the entire circumference of the V belt for damage and cracks 4 Replace a damaged or cracked V belt Chapter 8 9 1 Replacing th...

Страница 118: ...er and dust discharge valve 4 Pull out the air filter with a slight turning motion and replace 5 Thoroughly clean the filter housing and sealing faces 6 Clean the inside of the drain pipe in the filte...

Страница 119: ...tective gloves 1 Park the machine safely Chapter 6 5 Parking the machine in secured condition on page 90 2 Allow the engine to cool down 3 Check the condition and tight fit of all air intake lines and...

Страница 120: ...ter one year NOTICE Components may get damaged Only change the oil at operating temperature Only use oil of the permitted specification Chapter 8 3 4 Oil for exciter shaft housing on page 108 Filling...

Страница 121: ...front drum with oil via the drain opening 12 Screw the bleed screw 1 and drain plug 2 back in tightly 13 WARNING Danger of burning on hot components Wear your personal protective equipment protective...

Страница 122: ...cleanliness Thoroughly clean the area around the fuel filters Air in the fuel system causes irregular running of the engine a drop in engine power stalls the engine and makes starting impossible Prote...

Страница 123: ...ters beforehand to avoid the entry of dirt into the clean side Thinly apply oil to the rubber seal on the new fuel filter 12 Screw on the new filter cartridge by hand until the seal is in contact then...

Страница 124: ...er 6 5 Parking the machine in secured condition on page 90 2 Clean the area around the filler opening and remove the cap 3 Unscrew the drain plug and drain off approx 5 0 l 1 3 gal US of fuel 4 Collec...

Страница 125: ...ries batteries with formation of sulphate on the plates are not covered under war ranty Protective equipment n Working clothes n Safety shoes n Protective gloves n Safety goggles 1 Park the machine sa...

Страница 126: ...1 Turn the main battery switch counter clockwise and pull it out 2 Check by turning the ignition key whether the battery is dis connected from the electric system of the machine Fig 160 Maintenance Ev...

Страница 127: ...he machine in secured condition on page 90 2 Allow the engine to cool down 3 Loosen the tensioning screw 1 and screw 2 on the gener ator 4 Press the generator inwards and release and remove the V belt...

Страница 128: ...or at least 30 minutes The engine oil temperature must be below 80 C 176 F Valve clearance Intake exhaust valve 0 15 mm to 0 19 mm 0 006 in to 0 007 in Protective equipment n Working clothes n Safety...

Страница 129: ...V belt 7 Check the valve clearance on the valves marked black using a feeler gauge adjust if necessary The feeler gauge must fit through the gap with little resist ance 8 Loosen the counter nut on the...

Страница 130: ...11 Install the valve cover with a new seal 12 After a short test run check the valve cover for leaks Concluding work B 720 0107 Fig 166 Maintenance Every 1000 operating hours D ONE 130...

Страница 131: ...rvice of the respective oil manufacturer or our Customer Service for details NOTICE Risk of damage Perform the oil change when the hydraulic oil is warm Use only hydraulic oil of the permitted specifi...

Страница 132: ...Fill up with fresh hydraulic oil 8 Check the oil level in the inspection glass Nominal value Approx 3 cm 1 2 in below the top edge of the inspection glass 9 Insert a new filter element 2 and new O rin...

Страница 133: ...ctions of the manufacturer If in doubt consult your Customer Service or the engine manufacturer When changing the coolant without any signs of contamination cleaning of the cooling system is not neces...

Страница 134: ...lant level in the compensation tank The coolant level must be between the MIN and MAX marks 11 If necessary fill with coolant up to the MAX mark 12 Screw the filler cap back on again 13 Start the engi...

Страница 135: ...nnel Perform this maintenance work at the latest after two years The following hoses need to be renewed n fuel hoses n air intake hoses 8 11 4 Check the injection valves This work must only be perform...

Страница 136: ...8 12 Every 3000 operating hours 8 12 1 Checking the fuel injection pump This work must only be performed by authorized service per sonnel Maintenance Every 3000 operating hours D ONE 136...

Страница 137: ...the eight scrapers four per drum clean if necessary 3 Replace any worn scrapers 4 Check the gap between the scrapers and drum Nominal value Approx 5 mm 0 2 in 5 If necessary loosen the screws 1 and ad...

Страница 138: ...compressed air from the outside NOTICE Electric components can be damaged by water entering into the system Protect electrical equipment such as generator regulator and starter against the direct wat...

Страница 139: ...me e g winter season the following work must be carried out 1 Clean the machine thoroughly 2 Clean the water separator 3 Fill the fuel tank with diesel fuel to prevent the formation of condensation wa...

Страница 140: ...12 3 V dis charged to 50 3 Recharge the battery immediately after an open circuit voltage of 12 25 V or less is reached Do not perform boost charging The open circuit voltage of the battery occurs ap...

Страница 141: ...ks and leaks 9 Start the engine and run it for 15 to 30 minutes with idle speed 10 While the engine is running keep an eye on the gauges for oil pressure and coolant temperature 11 Check the oil level...

Страница 142: ...Maintenance As required D ONE 142...

Страница 143: ...9 Setting up refitting Setting up refitting D ONE 143...

Страница 144: ...nsider the weight of the drum extensions Approx 28 kg 62 lbs each Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Chapter 6 5 Parking the machine in...

Страница 145: ...shoes n Protective gloves 1 Unscrew the fastening bolts 1 and remove the washers 2 Remount the drum extension 2 with the fastening bolts 1 and washers tightening torque 572 Nm 422 ft lbf B 720 0033 1...

Страница 146: ...uisites n Main battery switch is switched on n Emergency stop switch is unlocked 1 Remove the safety cap 1 and connect the cable 2 to the remote control 2 Take up position in the safety field at the m...

Страница 147: ...safety field with the remote control Distance 1 2 m 1 3 yd The safety device warning light goes out after approx 2 seconds The machine is now ready for operation B SYM 0224 Fig 188 B SYM 0225 Fig 189...

Страница 148: ...Setting up refitting Teaching the BOSS safety field system D ONE 148...

Страница 149: ...10 Troubleshooting Troubleshooting D ONE 149...

Страница 150: ...ttery to the plus pole of the starter battery using the first jump lead 4 Next connect the second jump lead to the minus pole of the energizing external battery and then to the minus pole of the start...

Страница 151: ...damage Do not shut down the engine all of a sudden from full load speed but let it idle for about two minutes 3 Turn the ignition key to position 0 and pull it out 4 Open the front protective hood 5...

Страница 152: ...e and pull it out 9 Close the flap again 10 Shut down the machine and inform our Customer Service Department 11 Only operate the machine after it has been repaired B SWI 0079 Fig 198 Troubleshooting S...

Страница 153: ...leaning cloth underneath the oil level inspection plug and remove the plug Normally there must not be any oil in the travel system housing 4 If a significant quantity flows out of the inspection bore...

Страница 154: ...reaches the bottom edge of the drain bore 5 If a significant quantity flows out of the drain bore inform our Customer Service 6 Screw the drain and ventilation plugs back in 7 Lower the machine 8 If...

Страница 155: ...0 4 2 Fuse box Fuse Amperage Designation F119 20 A Fuse for engine F103 10 A Fuse for potential 15 F14 25 A Fuse for engine shut down solenoid F54 5 A Fuse cable remote control F243 3 A Fuse for TELEM...

Страница 156: ...10 4 3 Main fuse Fuse Amperage Designation F00 80 A Main fuse B 720 0111 Fig 203 Troubleshooting Fuse assignment D ONE 156...

Страница 157: ...wly Check the battery charge condition clean the terminal clamps tighten and cover them with acid free grease Fuel supply too low fuel system clogged by paraffin separation during winter Replacing the...

Страница 158: ...nsufficient cooling air supply to the cooling fan Remove any clogging from the cooling air duct Fan radiator or radiator cap defective Have examined by a specialist Engine has insuffi cient engine oil...

Страница 159: ...ed by a specialist replace if necessary Control defective Have examined by a specialist replace if necessary Ignition key in posi tion I display module operative but engine cannot be started The trave...

Страница 160: ...ntrol defective Have examined by a specialist replace if necessary CTO appears on display module when ignition key in position I Cable defective Check cable for tight fit Have examined by a specialist...

Страница 161: ...er or radio remote control defec tive Have examined by a specialist replace if necessary Ignition key in posi tion I display module operative but engine cannot be started Battery empty or defective Ch...

Страница 162: ...ceiver or radio remote control defec tive Have examined by a specialist replace if necessary Wiring loom defective Have examined by a specialist replace if necessary Troubleshooting Remote control fau...

Страница 163: ...on page 146 Front or rear safety device aerial not con nected properly or defective Check the plug in connection of the aer ials replace if necessary Distance between machine and radio remote control...

Страница 164: ...these will be indicated by flashing codes one after the other If a fault code is displayed read out and have the fault rectified by specialists authorised by the operating company If necessary con tac...

Страница 165: ...view of input codes Chapter 12 Appendix on page 169 1 Shut down the engine 2 Turn the ignition key to position I 3 Press function keys F1 and F2 at the same time The display shows 0000 The first digit...

Страница 166: ...The required function is implemented Depending on the function e g switching ECO mode off or on further codes must be entered Chapter 12 Appendix on page 169 8 To terminate the input function enter t...

Страница 167: ...11 Disposal Disposal D ONE 167...

Страница 168: ...l protec tion regulations must be followed when han dling fuels and lubricants Chapter 3 4 Han dling fuels and lubricants on page 25 Protective equipment n Working clothes n Safety shoes n Protective...

Страница 169: ...12 Appendix Appendix D ONE 169...

Страница 170: ...ut of this output Output was switched off Excessive current flow in current path probably because of a defective coil or a short circuit to ground X3 22 1031 Output is switched off function no longer...

Страница 171: ...41 1042 1050 Output is switched off function no longer possible Output valve 2 gear Y 03 Too high current flow out of this output Output was switched off Excessive current flow in current path probabl...

Страница 172: ...function no longer possible Output valve vibration low ampl Y 56 Short circuit current flow out of this output Output wass witched off Short circuit to ground in the current path Lines rubbed through...

Страница 173: ...ath probably because of a defective coil or a short circuit to ground X3 19 1010 2011 Output is switched off function no longer possible Output valve steering right Y 237 Short circuit current flow ou...

Страница 174: ...e time A remote control with cable and a wireless remote control are oper ated at the same time 2600 Engine stopped emergency stop relay in the control is switched off all outputs on control are switc...

Страница 175: ...engine may be shut down Should this message be displayed even though the engine is not running the fol lowing faults should be exam ined Current path has short circuit to ground Engine oil level not c...

Страница 176: ...rrent path connected to 12V X3 10 5040 5041 5042 5050 Output is switched off engine runs only with idle speed Output relay K 114 engine speed solenoid Too high current flow out of this output Output w...

Страница 177: ...061 5062 5063 Output switched off no potential 15 on machine control is working engine is stopped or cannot be started Output relay K 11 change over of potential 15 Although the output is switched off...

Страница 178: ...rrent path connected to 12V X3 08 X3 36 5080 5081 5082 5090 Machine does not start Input inclination switch B56 The machine cannot be started because the input does not receive a signal from the incli...

Страница 179: ...e only steering Fault of front safety field antenna W12 Wire breakage in current path front safety field antenna defec tive 6011 Travel movement not possible only steering Fault of rear safety field a...

Страница 180: ...le cause Terminal on BLM Input code for diag nose 7010 Machine cannot be started module is not completely initialized No machine type set Module is new parameters werede leted 0725 Faults in parameter...

Страница 181: ...Voltage at output Display value output voltage in Volt 1021 Output valve steering left Y 238 Display value output current in Amper Current at output Display value output current in Amper 1022 Output...

Страница 182: ...ic level of control 0000 Output not triggered 0001 Output triggered 1060 Output brake valve Y 04 Display value output voltage in Volt Voltage at output Display value output voltage in Volt 1061 Output...

Страница 183: ...oil pressure Ground 0 V Oil pressure 1402 Input limit switch engine speed solenoid Aux 12 V Solenoid retracted 0V Ground Solenoid not in end position 1405 Input inclination sensor B 56 12 V Inclinatio...

Страница 184: ...noid Display value output voltage in Volt Voltage at output Display value output voltage in Volt 5051 Output relay K 114 engine speed solenoid Display value output current in Amper Current at output D...

Страница 185: ...lay value output voltage in Volt Voltage at output Display value output voltage in Volt 5081 Output horn H 07 Display value output current in Amper Current at output Display value output current in Am...

Страница 186: ...ated fast speed disabled 2505 Position of switch for engine speed S 134 0100 Switch operated to forward high engine speed 0010 Switch not operated idle speed 2506 Position of button for horn S 03 0000...

Страница 187: ...stment instructions Fault description Cause Remedy 6000 Enable service mode 6000 6001 Service mode active machine travels for 15min without acti vated BOSS safety system Attention Only for servicing p...

Страница 188: ...emedy 7103 Preselect machine type BMP 8500 with protection bow See adjustment instructions 7104 Preselect machine type BMP 8500 without protection bow See adjustment instructions Appendix Input codes...

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