bergmann 3012 PLUS User manual

3012 PLUS
BERGMANN Dumper
Operating Manual
English
XX-XXX-XXXX-XXX - 04/2015

Bergmann Maschinenbau GmbH & Co. KG
Essener Strasse 7
49716 Meppen-Hüntel
GERMANY
www.bergmann-mb.de
[email protected]
Phone [phone] – 7292 – 0
Fax [phone] – 7292 – 92
Contact
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

Document information
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Operating manual, Dumper – 3012 PLUS
Status 28 April 2015
Bergmann Maschinenbau GmbH & Co. KG
Published by:
Copyright: This document is protected by copyright law. The
reproduction of this document in part or in 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 7
49716 Meppen-Hüntel, GERMANY

Table of contents
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Table of contents
1. Preface _________________________________________________________________ 12
2. About this document ______________________________________________________ 13
3. Additional information _____________________________________________________ 15
4. Intended use _____________________________________________________________ 16
4.1. Possible foreseeable misuse ___________________________________________________ 18
5. Safety __________________________________________________________________ 19
5.1. Safety signs and symbols ______________________________________________________ 19
5.2. Emergency actions ___________________________________________________________ 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 cables __________________________________ 24
5.8. Working near overhead power lines ____________________________________________ 25
5.9. Vehicle inspection prior to start-up _____________________________________________ 26
5.10. Underground operation and operation in enclosed spaces ___________________________ 26
5.11. Use of lifting gear ____________________________________________________________ 26
5.12. Vibration __________________________________________________________________ 26
5.13. Before starting work with the dumper ___________________________________________ 27

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5.14. In the event of defects or damage ______________________________________________ 27
5.15. Driving on public roads _______________________________________________________ 27
5.16. Starting engine _____________________________________________________________ 27
5.17. Handling of fuel and other chemicals____________________________________________ 28
5.18. Travel speed / brake power ___________________________________________________ 28
5.19. Exiting the dumper __________________________________________________________ 28
5.20. Loading / unloading _________________________________________________________ 28
5.21. Operating personnel _________________________________________________________ 29
5.22. Multi-shift operation / maintenance ____________________________________________ 29
5.23. Instructions and regulations 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 _____________________________________________________ 30
5.28. Risks from electric power and residual energy ____________________________________ 31
5.29. Maintenance, troubleshooting and repair ________________________________________ 31
5.30. Modifications to dumper _____________________________________________________ 32
5.31. Valves and hydraulic hoses ____________________________________________________ 32
5.32. Fire _______________________________________________________________________ 32
5.33. Safety of operating personnel – requirements ____________________________________ 33
5.34. Compliance with instructions in this manual, safety signs and symbols _______________ 34
5.35. Safety precautions when working with Bergmann dumper __________________________ 35

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5.36. Safety instructions for driving on public roads _____________________________________ 39
5.37. Safety instructions for maintenance and repair ____________________________________ 40
5.38. Switching off battery main switch ______________________________________________ 44
5.39. Setting dumper to safe state ___________________________________________________ 45
5.40. Securing lifted trough ________________________________________________________ 46
5.41. Securing dumper against rolling away (wheel chocks) ______________________________ 47
5.42. Transport safety device _______________________________________________________ 48
5.43. Transporting and towing dumper _______________________________________________ 49
5.44. Pulling of trailer _____________________________________________________________ 50
5.45. Safety and warning signs ______________________________________________________ 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 ____________________________________________________________________ 66
6.1.2. Fuel tank _______________________________________________________________________ 66
6.1.3. Electrical system _________________________________________________________________ 67
6.1.4. Travel drive _____________________________________________________________________ 68
6.1.5. Travel speed ____________________________________________________________________ 68
6.1.6. Operating pressure of hydrostatic drive ______________________________________________ 68
6.2. Axles ______________________________________________________________________ 69
6.2.1. Tyres / tyre pressure ______________________________________________________________ 69
6.2.2. Brakes _________________________________________________________________________ 69

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6.3. Steering system _____________________________________________________________ 70
6.4. Working hydraulics __________________________________________________________ 71
6.5. Weights ___________________________________________________________________ 71
6.6. Noise emission _____________________________________________________________ 71
7. Approvals and certificates _________________________________________________ 72
7.1. Occupational health & safety: _________________________________________________ 72
7.2. Noise: _____________________________________________________________________ 72
7.3. Approval for driving on public roads: ____________________________________________ 72
7.4. Dimensions ________________________________________________________________ 73
7.4.1. Dumping height _________________________________________________________________ 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 ______________________________________________________ 75
8.1.2. Diesel engine and accessories ______________________________________________________ 76
8.1.3. Hydrostatic travel drive ___________________________________________________________ 76
8.2. Brake system _______________________________________________________________ 77
8.2.1. Service brake ___________________________________________________________________ 77
8.2.2. Secondary and parking brake ______________________________________________________ 77
8.2.3. Auxiliary brake __________________________________________________________________ 78
8.3. Working and steering hydraulics _______________________________________________ 78
8.4. Electrical system ____________________________________________________________ 80

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8.4.1. Electrical consumers ______________________________________________________________ 80
8.4.2. Only in models equipped for travel on public roads: ____________________________________ 80
8.4.3. Beacon _________________________________________________________________________ 80
9. Operator stand / cab ______________________________________________________ 81
9.1. Access to operator stand ______________________________________________________ 81
9.2. Description of operator stand and cab ___________________________________________ 82
9.3. Functions and operation of steering column switch and joystick ______________________ 87
9.4. Functions of switches on side console ___________________________________________ 89
9.5. Dashboard _________________________________________________________________ 91
9.5.1. Displays and indicators on dashboard ________________________________________________ 92
9.5.1.1. Rev counter ___________________________________________________________________ 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 ________________________________________________________________________ 98
10. Start-up ________________________________________________________________ 100
10.1. Checks to be performed prior to start-up ________________________________________ 101
10.1.1. Oil level in engine _______________________________________________________________ 101
10.1.2. Fuel tank ______________________________________________________________________ 101
10.1.3. Fluid level in hydraulic fluid tank ___________________________________________________ 101
10.1.4. Tyre pressure ___________________________________________________________________ 102
10.1.5. Electrical system ________________________________________________________________ 102
10.1.6. Brake fluid _____________________________________________________________________ 102
10.1.7. Coolant _______________________________________________________________________ 102

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Bergmann Maschinenbau GmbH & Co. KG
10.2. Steps for starting dumper ____________________________________________________ 103
10.3. Starting the diesel engine ____________________________________________________ 104
10.4. Heating up hydraulic system _________________________________________________ 105
10.5. Shutting down diesel engine _________________________________________________ 105
10.6. Travel operation ___________________________________________________________ 106
10.6.1. Preparing the dumper for travel operation ___________________________________________ 106
10.6.2. Selecting travel speed/mode ______________________________________________________ 107
10.6.3. Travel direction switch ___________________________________________________________ 108
10.6.4. Brake pedal ____________________________________________________________________ 108
10.6.5. Parking brake __________________________________________________________________ 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 ______________________________________________________ 113
11.1.1. Preparing dumper for travelling on public roads ______________________________________ 114
11.1.2. General notes for driving on public roads ____________________________________________ 114
11.2. Transport by low-loader or rail _______________________________________________ 115
11.2.1. Securing centre pivot ____________________________________________________________ 117
11.3. Recovering and towing dumper _______________________________________________ 118
11.3.1. General information for towing ____________________________________________________ 118
11.3.2. Towing restrictions ______________________________________________________________ 120
11.3.3. Release the parking brake. ________________________________________________________ 121

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11.3.4. Manually lowering trough in the event of a hydraulic failure _____________________________ 124
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 ___________________________________________________________________ 130

Preface
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Bergmann Maschinenbau GmbH & Co. KG
1. Preface
Dear customer,
To make best use of your Bergmann dumper and to operate it in the safest and most economical 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 Bergmann dumper.

About this document
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Bergmann Maschinenbau GmbH & Co. KG
A copy of this operation manual must be available at all
times at the site of operation of the dumper!
Before starting the machine, all operating personnel
must have read and fully understood the 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 instructions in this document must be strictly adhered to. This
applies in particular to all safety instructions.

About this document
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Operating manual, Dumper – 3012 PLUS
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Bergmann Maschinenbau GmbH & Co. KG
Before starting the Bergmann dumper, you must make sure that the machine
meets the general safety requirements.
 This operating manual is an integral part of the CE documentation of your Bergmann dumper.
 For details regarding the engine, please refer to the enclosed operating manual 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 must only be operated when in
proper working order and for the intended
purpose (see chapter 4)!
Bergmann Maschinenbau GmbH & Co. shall not
be liable for damage caused by improper
operation or use.
NOTE

Additional information
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3. Additional information
Please note that we shall not be liable for any damages and operational failures resulting from non-
compliance with the instructions in this operating manual.
Working on 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 recognised technical
regulations for safe and proper work, and the operating and maintenance instructions.

Intended use
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4. Intended use
The Bergmann 3012 PLUS dumper is a self-propelled work machine (dumper with articulated frame). It is
equipped with one (1) seat for the driver. The driver seat features a lap belt (safety belt).
The Bergmann 3012 PLUS dumper must only be used for the transportation, distribution and
unloading/spreading of excavation material (e.g. soil, rocks) and other bulk material. If the machine is
used for the transportation of hazardous materials, the relevant safety regulations must be complied with
(e.g. type of material, quantity, number of extinguishers to be carried on the vehicle).
Unless the vehicle has been approved for 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, soil, etc. to a
maximum payload of 12,000 kg (on construction sites) and to a maximum payload of 8800 kg(on public
roads).
The tipping trough is designed as a swivel tipping trough and can be swivelled for loading and unloading
(tipping) to the right and left to a maximum angle of 90° from the direction of travel.
Proper use of the machine includes compliance with the instructions in this operating and maintenance
manual.
Any other use is deemed improper. The dumper manufacturer shall not be liable for damage resulting
from improper use.

Intended use
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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

Intended use
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4.1. Possible foreseeable misuse
Operator:
 Transportation of person in trough
 Loading by volume, ignoring permissible weight
 Transportation of hazardous goods without 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 on dumper while engine is running
 Work under unsecured tipped trough

Safety
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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

Safety
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5.2. Emergency actions
 Cordon off site of accident
 Provide first aid
 Alert doctor, rescue services
 Look after casualties