bergmann 4010 User manual

Operating instructions
Bergmann Dumper
4010
US
1.0 | © 2/15/2017
50-020-1011-900_EN

Contents
1 Basic data............................................................................................................................... 19
1.1 Manufacturer.......................................................................................................................... 19
1.2 Machine data.......................................................................................................................... 19
1.3 Scope of the documentation (constituent part of the machine).............................................. 20
2 General................................................................................................................................... 21
2.1 Preface................................................................................................................................... 21
2.2 About this documentation....................................................................................................... 21
2.2.1 Target group........................................................................................................................... 22
2.2.2 Explanations of terms............................................................................................................. 23
2.2.3 Usage/storage........................................................................................................................ 24
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2.2.4 Text formats........................................................................................................................... 24
2.3 Signs on the machine............................................................................................................. 25
2.3.1 Type plate............................................................................................................................... 25
2.3.2 Chassis number..................................................................................................................... 27
2.3.3 Position of the signs............................................................................................................... 28
2.4 CE declaration of conformity.................................................................................................. 29
2.5 Declaration on noise emissions.............................................................................................. 29
2.6 Information about vibrations................................................................................................... 29
2.7 Warranty and liability.............................................................................................................. 30
2.7.1 Warranty................................................................................................................................. 31
2.7.2 Copyright................................................................................................................................ 31
2.8 Spare parts/spare part orders................................................................................................ 32
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2.9 Disposal.................................................................................................................................. 32
2.10 Regional regulations............................................................................................................... 33
3 Safety..................................................................................................................................... 34
3.1 Safety concept in the documentation..................................................................................... 34
3.2 Required personnel qualification............................................................................................ 34
3.3 Designated use...................................................................................................................... 37
3.3.1 Application limits..................................................................................................................... 40
3.4 Use not in accordance with the designated use..................................................................... 41
3.5 Applied standards................................................................................................................... 44
3.6 Possible residual hazards...................................................................................................... 44
3.6.1 Overview of residual hazards................................................................................................. 45
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3.6.2 Countermeasures................................................................................................................... 48
3.6.3 Organizational measures by the owner/user.......................................................................... 48
3.7 Safety instructions in the documentation................................................................................ 49
3.7.1 Structure of safety instructions............................................................................................... 49
3.7.2 Hazard classes....................................................................................................................... 51
3.7.3 Note........................................................................................................................................ 52
3.8 Pictograms used..................................................................................................................... 52
3.8.1 Warning symbol...................................................................................................................... 52
3.8.2 Prohibition symbol.................................................................................................................. 54
3.8.3 Mandatory symbol.................................................................................................................. 55
3.9 Safety devices........................................................................................................................ 55
3.10 Safety and information signs.................................................................................................. 56
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3.10.1 Position of the safety signs..................................................................................................... 57
3.11 General safety regulations..................................................................................................... 64
3.12 Safe working when exposed to noise and vibration............................................................... 65
3.13 Safe working on mechanical systems.................................................................................... 65
3.14 Safe working on hydraulic systems........................................................................................ 67
3.15 Safe working on electrical systems........................................................................................ 68
3.16 Safe working when driving and tipping................................................................................... 69
3.17 Safe working in the vicinity of electric cables......................................................................... 71
3.18 Machine-specific danger notes............................................................................................... 73
3.19 Danger areas on the machine................................................................................................ 73
3.19.1 Danger area during operation................................................................................................ 74
3.19.2 Danger area of the bodies...................................................................................................... 78
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3.20 EMERGENCY STOP devices................................................................................................ 83
3.21 Responsibility of the owner/user............................................................................................ 84
3.22 Machine status....................................................................................................................... 84
3.23 Selection of personnel............................................................................................................ 85
3.24 Test by an technical expert.................................................................................................... 86
3.25 Fire protection........................................................................................................................ 86
3.26 Environmental protection........................................................................................................ 87
4 Technical data........................................................................................................................ 88
4.1 Machine.................................................................................................................................. 88
4.1.1 Diesel engine.......................................................................................................................... 96
4.1.2 Electrical system.................................................................................................................... 99
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4.1.3 Hydraulic system.................................................................................................................... 99
4.1.4 Track undercarriage............................................................................................................. 102
4.1.5 Air-conditioning system........................................................................................................ 103
4.2 Optional accessories............................................................................................................ 104
4.2.1 Central lubrication device..................................................................................................... 104
5 Structure and function.......................................................................................................... 106
5.1 Technical description of the machine................................................................................... 106
5.2 Technical description of the basic machine (series production equipment)......................... 108
5.2.1 Track undercarriage............................................................................................................. 110
5.2.2 Drive system......................................................................................................................... 113
5.2.3 Hydraulic system.................................................................................................................. 115
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5.2.4 Electrical system.................................................................................................................. 118
5.2.5 Operator's cab...................................................................................................................... 120
5.3 Technical description of the bodies...................................................................................... 128
5.3.1 Rear tipping trough............................................................................................................... 128
5.3.2 Round tipping trough............................................................................................................ 130
5.3.3 Platform................................................................................................................................ 132
5.4 Technical description of the optional equipment.................................................................. 132
5.4.1 Crane (optional).................................................................................................................... 133
5.4.2 Swiveling operator stand (optional)...................................................................................... 134
5.4.3 Cab with dual seating (optional)........................................................................................... 135
5.4.4 Additional lighting (option).................................................................................................... 135
5.4.5 Hardox reinforced trough (optional)...................................................................................... 136
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5.4.6 Electrical filling pump (optional)............................................................................................ 136
5.4.7 ECO mode (optional)............................................................................................................ 137
5.4.8 Central lubrication device (option)........................................................................................ 138
5.4.9 Reversing camera (option)................................................................................................... 139
5.4.10 Reverse warning device (option).......................................................................................... 140
5.4.11 Rear window roller blind (option).......................................................................................... 140
5.4.12 Radio (option)....................................................................................................................... 140
5.4.13 Electrical filling pump............................................................................................................ 140
6 Transport, packing, storage.................................................................................................. 141
6.1 Safe working when packing, transporting and unpacking at the place of use...................... 141
6.1.1 Transport/setup.................................................................................................................... 142
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6.2 Packing................................................................................................................................. 142
6.3 Transport inspection............................................................................................................. 143
6.4 Storage................................................................................................................................. 144
6.5 Transportation of the subassemblies................................................................................... 144
6.6 Transporting on low loader and by railway........................................................................... 145
6.7 Lifting the machine............................................................................................................... 148
6.7.1 Hand signals for guidance.................................................................................................... 150
6.7.2 Transport components......................................................................................................... 150
7 Installation, initial startup and function test........................................................................... 151
7.1 Safety instructions for installation and initial startup............................................................. 151
7.2 Assembly.............................................................................................................................. 153
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7.3 Initial startup and function test of the machine..................................................................... 153
7.3.1 Preparatory activities............................................................................................................ 153
7.3.2 Carrying out the function test/initial startup.......................................................................... 155
7.3.3 Checks after initial startup/function test................................................................................ 157
8 Operation.............................................................................................................................. 159
8.1 Safety instructions................................................................................................................ 159
8.2 Operation of the machine..................................................................................................... 162
8.2.1 Opening and closing............................................................................................................. 162
8.2.2 Seats, steering wheel, mirrors.............................................................................................. 163
8.2.3 Light and windscreen wiper.................................................................................................. 169
8.2.4 Heating/air conditioning and ventilation................................................................................ 173
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8.2.5 Instrument panel and display............................................................................................... 176
8.2.6 Driving and control elements................................................................................................ 191
8.2.7 Storage and useful information............................................................................................ 202
8.2.8 Optional equipment.............................................................................................................. 205
8.3 Checks before starting work................................................................................................. 208
8.4 Switching on the machine.................................................................................................... 209
8.4.1 Warming up the machine..................................................................................................... 211
8.5 Travel mode......................................................................................................................... 212
8.5.1 On-road driving..................................................................................................................... 214
8.5.2 Selecting the travel mode and driving.................................................................................. 215
8.6 Tipping.................................................................................................................................. 219
8.7 Crane operation.................................................................................................................... 221
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8.8 Checks during operation...................................................................................................... 222
8.9 Refueling the machine.......................................................................................................... 223
8.10 Switching off the machine.................................................................................................... 227
8.11 Recovering the machine....................................................................................................... 229
9 Daily maintenance work....................................................................................................... 230
9.1 Safety instructions................................................................................................................ 230
9.2 Carrying out maintenance work............................................................................................ 232
9.2.1 Opening/closing the maintenance doors on the drive unit................................................... 233
9.3 Maintenance work to be carried out..................................................................................... 234
9.3.1 Visual checks - visual inspection.......................................................................................... 234
9.3.2 Lubricating the machine....................................................................................................... 236
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9.3.3 Checking the fill levels.......................................................................................................... 249
10 Malfunctions and troubleshooting......................................................................................... 255
10.1 General safety instructions for troubleshooting.................................................................... 255
10.2 Malfunctions......................................................................................................................... 256
10.2.1 General malfunctions........................................................................................................... 257
10.2.2 Malfunctions of the electrical system.................................................................................... 261
10.2.3 Malfunctions of the hydraulic system................................................................................... 263
10.2.4 Display error codes.............................................................................................................. 264
10.2.5 Lowering the trough manually.............................................................................................. 265
11 Disassembly......................................................................................................................... 270
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12 Taking out of operation, putting back into operation and disposal....................................... 272
12.1 Taking out of operation......................................................................................................... 272
12.2 Returning to operation.......................................................................................................... 273
12.3 Disposal................................................................................................................................ 274
13 Spare part stocking and customer service........................................................................... 276
13.1 Spare part and customer service addresses........................................................................ 276
14 Appendix.............................................................................................................................. 277
14.1 The most important hand signals for providing guidance..................................................... 277
14.2 CE declaration of conformity................................................................................................ 279
14.3 Tightening torques................................................................................................................ 280
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14.4 Diagrams in original scale.................................................................................................... 284
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1 Basic data
1.1 Manufacturer
Bergmann Maschinenbau GmbH & Co. KG
Essener Strasse 7
D-49716 Meppen-Hüntel
Germany
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Internet: www.bergmann-mb.de
1.2 Machine data
Name Bergmann Dumper
Model 4010, cab, track
Tab. 1.1: Machine data
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1 Basic data
1.1 Manufacturer

Validity of the documentation
This documentation applies to machines with serial number(s):
Serial number(s) from 16-4123
1.3 Scope of the documentation (constituent part of the machine)
Part 1 - Operating instructions
Part 2 - Maintenance/repair instructions
Part 3 - Third-party documentation
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1 Basic data
1.3 Scope of the documentation (constituent part of the machine)