Dynapac D.ONE Operating Instructions Manual
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Dynapac D.ONE Operating Instructions Manual

Multi-purpose compactors
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Operating Instruction
Original Operating Instructions
D.ONE
Multi-purpose compactors
S/N 101 924 90 1001>
DL 008 203 58 EN
© 04/2018

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Summary of Contents for Dynapac D.ONE

  • Page 1 Operating Instruction Original Operating Instructions D.ONE Multi-purpose compactors S/N 101 924 90 1001> DL 008 203 58 EN © 04/2018...

  • Page 3: Table Of Contents

    3.8.2 Driving the machine........................35 3.8.3 Driving up and down slopes....................... 35 3.8.4 Cross slope..........................35 3.8.5 Working with vibration........................ 36 3.8.6 Parking the machine........................36 3.9 Refuelling............................. 37 3.10 Emergency procedures......................38 3.10.1 Actuating the emergency stop switch..................38 D.ONE...
  • Page 4 6.2 Start-up procedure........................74 6.2.1 Preparing the remote control...................... 74 6.2.2 Checking the remote control...................... 75 6.2.3 Checking the BOSS safety system.................... 79 6.2.4 Starting the engine........................81 6.3 Travel operation.......................... 83 6.3.1 Preliminary remarks and safety notes..................83 D.ONE...
  • Page 5 8.8.5 Changing the oil in the exciter housing..................120 8.8.6 Replacing the fuel filter; bleeding the fuel system..............122 8.8.7 Draining the fuel tank sludge....................124 8.8.8 Checking radiator hoses and hose clamps................124 8.8.9 Servicing the battery; checking the main battery shutoff............125 D.ONE...
  • Page 6 10.8 Faults in BOSS safety system....................163 10.9 Fault code display........................164 10.10 Entering input codes via the display unit................165 Disposal............................. 167 11.1 Final shut-down of machine....................168 Appendix............................169 12.1 List of fault codes........................170 12.2 Input codes for BLM control....................181 D.ONE...

  • Page 7: Introduction

    Introduction Introduction D.ONE...

  • Page 8: Foreword

    For your own personal safety you should only use original parts from Dynapac. For your machine we offer service kits to make maintenance easier. In the course of technical development we reserve the right for technical modifications without prior notification.
  • Page 9 Introduction – Foreword The above notes do not 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. D.ONE...

  • Page 10: Machine Type Plate And Engine Type Plate

    Nominal Power Operating Mass Year of Construction Serial-No. Ammerländer Str. 93 D-26203 Wardenburg Made in Germany B-924-0001 Fig. 1: Machine type plate (example) Please enter here: Engine type (Fig. 1) Engine number (2): Fig. 2: Engine type plate (example) D.ONE...

  • Page 11: Technical Data

    Technical data Technical data D.ONE...
  • Page 12 (50) (7.8) (75) (0.6) (33.5) (24) Dimensions in millimetres (Dimensions in inch) Weights Operating weight (CECE) 1595 (3516) (lbs) Basic weight 1585 (3494) (lbs) Mean axle load (CECE) (1759) (lbs) Drum extension (610/850 mm) + 48 (+ 106) (lbs) D.ONE...
  • Page 13 Service brake hydrostatic Parking brake hydro-mechanical Steering Type of steering Articulated joint Steering operation hydrostatic Exciter system Vibrating drum front + rear Drive system hydraulic Frequency (2520) (vpm) Amplitude 1/2 1.12/0.56 (0.044/0.022) (in) Centrifugal force 1/2 72/36 (16186/8093) (lbf) D.ONE...
  • Page 14 Voltage (cable operation) 9 to 30 Voltage (battery operation) Transmitting frequency range 868/916 Safety field antenna IP rating IP 55 Transmitter Frequency band F-band Transmitting frequency range 868/916 Number of channels Current consumption approx. 10 Receiver Receiver frequency range 868/916 D.ONE...

  • Page 15: Noise Data

    = 84 dB(A), determined acc. to ISO 11201 and EN 500. tor's stand WARNING! Loss of hearing caused by too high noise bur- dens! – Wear your personal protective equipment (ear protection). Guaranteed sound power level = 109 dB(A), determined acc. to ISO 3744 and EN 500 D.ONE...
  • Page 16 Technical data – Noise data D.ONE...

  • Page 17: Concerning Your Safety

    Concerning your safety Concerning your safety D.ONE...

  • Page 18: Basic Prerequisites

    WARNING! Danger to life or danger of severe injuries if failing to comply! Sections marked accordingly indicate a dangerous situation that could lead to fatal or severe injuries, if this warning is disregarded. D.ONE...

  • Page 19: Personal Protective Equipment

    Safety shoes To protect against heavy falling parts and slipping on slippery ground. Protective gloves To protect the hands against excoriation, punctures or deep injuries, against irritating and caustic substances as well as against burns. D.ONE...

  • Page 20: Intended Use

    When operating the machine from the opposite side, there is a dis- crepancy between the actuation of the control devices for the travel movements and the respective control movement of the machine. The remote control must be carried in front of the body, as intended. D.ONE...

  • Page 21: Improper Use

    Driving on non-load-bearing subsoil or inadequate contact areas (danger of tilting) Using the machine for towing Operating the machine without visual contact The transport of persons is prohibited. Starting and operating the machine in explosive environments and in underground mining is prohibited. D.ONE...

  • Page 22: Definition Of Responsible Persons

    Observe your local laws and regulations. Rights, obligations and rules of conduct for driver or operator: The driver or operator must: be instructed about his rights and obligations, wear protective equipment as appropriate for the application, have read and understood the operating instructions, D.ONE...
  • Page 23 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. D.ONE...

  • Page 24: Basic Safety Regulations For Safe Operation

    Machines which are not safe to operate or in traffic must be imme- diately taken out of service and shall not be used, until these defi- ciencies have been properly rectified. Safety installations and switches must neither be removed nor must they be made ineffective. D.ONE...

  • Page 25: Handling Fuels And Lubricants

    / personal protective equipment physical and chemical properties stability and reactivity toxicological data environmental data notes on waste disposal information on transport legislation other data D.ONE...

  • Page 26: Safety Regulations And Environmental Protection Regulations For Handling Diesel Fuel

    Diesel fuel is an environmentally hazardous substance! – Always keep diesel fuel in proper containers. – Immediately bind spilled diesel fuel with an oil- binding agent and dispose of properly. – Dispose of diesel fuel and fuel filters according to regulations. D.ONE...

  • Page 27: Safety Regulations And Environmental Protection Regulations For Handling Oil

    Immediately bind spilled oil with an oil-binding agent. ENVIRONMENT! Oil is an environmentally hazardous substance! – Always keep oil in proper containers. – Immediately bind spilled oil with an oil-binding agent. – Dispose of oil and oil filter according to regula- tions. D.ONE...

  • Page 28: Safety Regulations And Environmental Protection Regulations For Handling Hydraulic Oil

    Immediately bind spilled oil with an oil-binding agent. ENVIRONMENT! Oil is an environmentally hazardous substance! – Always keep oil in proper containers. – Immediately bind spilled oil with an oil-binding agent. – Dispose of oil and oil filter according to regula- tions. D.ONE...

  • Page 29: Safety Regulations And Environmental Protection Regulations For Handling Coolants

    Coolant is an environmentally hazardous sub- stance! – Always keep coolant and coolant additives in proper containers. – Immediately bind spilled coolant with an oil- binding agent and dispose of it according to regulations. – Dispose of coolant according to regulations. D.ONE...

  • Page 30: Safety Regulations And Environmental Protection Regulations For Handling Battery Acid

    Do not wear jewellery (watch, bracelets, etc.) when working on the battery. – Wear your personal protective equipment (pro- tective gloves, protective clothing, goggles). ENVIRONMENT! Battery acid is an environmentally hazardous substance! – Dispose of battery and battery acid according to regulations. D.ONE...

  • Page 31: Loading/Transporting The Machine

    When lifting the machine, make sure the load does not move in an uncontrolled way. If necessary, hold the load steady with guide ropes. After the transport loosen the articulation lock again, as otherwise the machine would not be steerable. D.ONE...

  • Page 32: Start-Up Procedure

    After starting, check all display instruments. Do not inhale exhaust fumes, because they contain toxic sub- stances, which could cause damage to health, unconsciousness or even death. For operation in closed or partly closed rooms ensure adequate ventilation. D.ONE...

  • Page 33: Starting The Engine With Jump Leads

    – 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 starter motor, because the machine may start to drive immediately. D.ONE...

  • Page 34: Operation With Radio Remote Control

    The radio remote control must never be left unattended. If several machines are in operation at the same time, the system numbers on the radio remote control and receiver must be com- pared before start-up to ensure another machine within range is not accidentally started up. D.ONE...

  • Page 35: Driving The Machine; Working Operation

    Driving across slopes should therefore be strictly avoided, because of the high risk of tipping over and the related risk of severe or even fatal accidents. Fig. 9: Maximum cross slope D.ONE...

  • Page 36: Working With Vibration

    Mark machines, which could be in the way, with a clearly visible sign. When parking on ascents or descents use appropriate means to secure the machine against rolling. D.ONE...

  • Page 37: Refuelling

    Do not spill any fuel. Collect leaking fuel, do not let it seep into the ground. Wipe off spilled fuel. Keep dirt and water away from the fuel. A leaking fuel tank can cause an explosion. Ensure tight fit of the fuel tank cover, if necessary replace immediately. D.ONE...

  • Page 38: Emergency Procedures

    Danger to the life of persons if they step or stand under a sus- pended load. When lifting the machine, make sure the load does not move in an uncontrolled way. If necessary, hold the load steady with guide ropes. D.ONE...

  • Page 39: Maintenance Work

    Wait until the engine has stopped, then wait approx. another 15 minutes. Keep out of the danger zone during the initial test run. In case of leaks return to the workshop immediately. Drain the engine oil at operating temperature – danger of scalding! D.ONE...

  • Page 40: Maintenance Work On Electric Components And Battery

    Do not guide the water jet into the exhaust pipe and into the air filter. 3.11.6 After maintenance work Reassemble all guards and protective devices. Close all maintenance flaps and maintenance doors again. D.ONE...

  • Page 41: Repair

    Repair Identify a defective machine with a 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 be used. D.ONE...

  • Page 42: Signage

    Concerning your safety – Signage 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. D.ONE...
  • Page 43 Type Nominal Power Operating Mass Year of Construction Serial-No. Ammerländer Str. 93 D-26203 Wardenburg Made in Germany OIL SAE HYDRAULIC OIL 15W40 HV46 DIESEL WATER IN FUEL OIL SAE 15W40 7-9 mm Hydraulik Oil HV 46 B-720-0100 Fig. 10 D.ONE...
  • Page 44 Concerning your safety – Signage Engine Coolant Spec.: • MB 325.5 • Deutz DQC CC-14 Hydraulic Oil B-720-0101 Fig. 11 Warning sticker - Danger of crushing Fig. 12 D.ONE...
  • Page 45 B-DEC-0196 Fig. 13 Warning sticker - Danger of being pulled in by cooling fan, and hot surface Follow operating instructions B-DEC-0197 Fig. 14 Prohibition sticker - High pressure cleaning Fig. 15 Instruction sticker - Wear ear defenders Fig. 16 D.ONE...
  • Page 46 Concerning your safety – Signage Information sticker - Lashing point Fig. 17 Information sticker - Lifting point Fig. 18 Information sticker - Filler opening for diesel Diesel B-DEC-0215 Fig. 19 Information sticker - Filler opening for hydraulic oil Hydraulic Oil B-DEC-0214 Fig. 20 D.ONE...
  • Page 47 Information sticker - Disconnecting the battery B-DEC-0219 Fig. 21 Information sticker - Low travel speed range B-DEC-0272 Fig. 22 Information sticker - Engine start B-DEC-0198 Fig. 23 Brief operating guide START AUTOMATIC START OPERATION AUTOMATIC AUTOMATIC STOP STOP 1-2 MINUTEN AUTOMATIC B-DEC-0195 Fig. 24 D.ONE...
  • Page 48 15W40 7-9 mm Hydraulik Oil HV 46 008 312 84 B-DEC-0255 Fig. 25 Information sticker - Guaranteed sound capacity level Fig. 26 Information sticker - Coolant Engine Coolant Spec.: • MB 325.5 • Deutz DQC CC-14 B-DEC-0275 Fig. 27 D.ONE...
  • Page 49 Concerning your safety – Signage Machine type plate (example) Made by Designation Type Nominal Power Operating Mass Year of Construction Serial-No. Ammerländer Str. 93 D-26203 Wardenburg Made in Germany B-924-0002 Fig. 28 D.ONE...
  • Page 50 Concerning your safety – Signage D.ONE...

  • Page 51: Indicators And Control Elements

    Indicators and control elements Indicators and control elements D.ONE...

  • Page 52: Operating Mode Toggle Switch

    Indicators and control elements – Operating mode toggle switch B-924-0019 Fig. 29 Remote control Operating mode toggle switch Display module Main battery switch 4.1 Operating mode toggle switch Position “left” Cable operation Position “right” Radio operation B-720-0013 Fig. 30 D.ONE...

  • Page 53: Display Module

    Lights when the tipping angle of the machine has reached 45° in lateral direction or 60° in travel direction. The engine is shut down. To continue restart the engine and move the machine carefully out of the danger zone. D.ONE...

  • Page 54: Main Battery Switch

    Main battery 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 B-720-0073 the main battery switch being pulled out Fig. 32 D.ONE...

  • Page 55: Remote Control

    Vibration toggle switch Emergency stop switch 10 Radio operation control light 11 Button for warning horn 4.4.1 Steering lever Shift to the left Machine steers to the left Shift to the right Machine steers to the right AUTOMATIC B-720-0023 Fig. 34 D.ONE...

  • Page 56: Vibration Pre-Selection Toggle Switch

    Travel speed range 2 Position “rear” Travel speed range 1 Vibration is automatically switched off in travel speed range 2. B-720-0021 Fig. 36 4.4.4 Engine speed toggle switch Position “front” Full load position Position “rear” Idle speed position B-720-0020 Fig. 37 D.ONE...

  • Page 57: Travel Lever

    (test function). At low temperatures, the preheating con- trol light lights up on the display module. B-720-0040 Fig. 39 4.4.7 Start button Set the starter switch The engine starts. to position “I” and press it B-720-0076 Fig. 40 D.ONE...

  • Page 58: Vibration Toggle Switch

    The machine will be braked immediately. The engine is shut down. Switching off/ Pull up the emergency stop switch as far unlocking as it will go. B-SWI-1588 Fig. 42 4.4.10 Button for warning horn Press Warning horn sounds B-720-0075 Fig. 43 D.ONE...

  • Page 59: Radio Operation Control Light

    A warning signal also sounds 1 minute prior to shutdown. Fig. 44 Connect the remote control to the cable as soon as it lights up and switch the machine to cable operation (battery is charged) or replace the battery. D.ONE...
  • Page 60 Indicators and control elements – Remote control D.ONE...

  • Page 61: Checks Prior To Start Up

    Checks prior to start up Checks prior to start up D.ONE...

  • Page 62: Notes On Safety

    Before starting work on the machine make sure that the engine can not be started. Park the machine safely Ä Chapter 6.5 „Parking the machine in secured condition“ on page 90. Open the protective hoods and secure them. Close the protective hoods after work is completed. D.ONE...

  • Page 63: Visual Inspections And Function Tests

    Check the cooling system for contamination, damage and leaks. Check the bolted connections are tight and secure. Check the engine and exhaust system for leaks. Check the belt drive for damage. Check the machine and remote control for contamination and damage. D.ONE...

  • Page 64: Checking The Engine Oil Level

    ð The oil level must be between the “MIN” and “MAX” marks. For topping up, clean the area around the filling port. Unscrew the cap and fill with engine oil up to the “MAX” B-720-0083 mark. Fig. 46 Insert the dipstick. Close the cap. D.ONE...

  • Page 65: Checking The Fuel Level; Topping Up Fuel

    Refuel, if required, after first shutting down the engine. Refuelling Protective equipment: Working clothes Safety shoes Protective gloves Clean the area around the filling port. Diesel Unscrew the cap and fill with fuel. Close the cap. B-720-0085 Fig. 48 D.ONE...

  • Page 66: Checking The Hydraulic Oil Level

    Fig. 50 If necessary, check the travel drive or exciter shaft housing Ä Chapter 10 „Troubleshooting“ on page 149. For topping up, clean the area around the filling port. Remove the cap and fill with hydraulic oil. Close the cap. D.ONE...

  • Page 67: Checking The Coolant Level

    Wear your personal protective equipment (pro- B-720-0109 tective gloves, protective clothing, goggles). Fig. 52 For topping up, clean the area around the filling port. Unscrew the cap and fill with coolant up to the “MAX” mark. Close the cap. B-720-0059 Fig. 53 D.ONE...

  • Page 68: Checking The Rubber Buffers

    Fig. 54 Protective equipment: Working clothes Safety shoes Protective gloves Check the six rubber buffers on both the front and rear axle are tight and secure, and check for cracks and tears. Replace damaged rubber buffers immediately. B-720-0070 Fig. 55 D.ONE...

  • Page 69: Operation

    Operation Operation D.ONE...

  • Page 70: Preliminary Remarks

    Depending on how it is equipped, this may be in two operating modes: Cable operation (1) Radio operation (2) In both operating modes, the remote control functions are the same. However, for radio operation special operating instructions and per- formance tests have to be taken into account. B-720-0112 Fig. 56 D.ONE...

  • Page 71: Boss Safety System

    The operator must be familiar with the size of the safety fields and Ä Chapter check the function of the safety device at each start-up 6.2.3 „Checking the BOSS safety system“ on page 79. B-720-0119 Fig. 60 D.ONE...

  • Page 72: Notes On Radio Operation

    To continue travelling move into the radio transmission range of the Ä Chapter 6.2.4 „Starting the machine and restart the engine engine“ on page 81. D.ONE...
  • Page 73 B-720-0029 Fig. 62 Switch to cable operation with the toggle switch. If the engine is off, restart the engine Ä Chapter 6.2.4 „Starting the engine“ on page 81. Continue to operate the machine in cable mode. B-720-0013 Fig. 63 D.ONE...

  • Page 74: Start-Up Procedure

    1.1 yd B-720-0012 Fig. 65 During cable operation, remove the safety cap (1) and con- nect the cable (2) to the remote control. B-720-0029 Fig. 66 Use the toggle switch to select the required operating mode. B-720-0013 Fig. 67 D.ONE...

  • Page 75: Checking The Remote Control

    If several machines are used at the same time, compare the system numbers on the remote control and receiver. ð The system numbers on both devices must match. Exchange the remote control, if necessary. Switch the toggle switch for engine speed to "MIN” position. B-720-0074 Fig. 69 D.ONE...
  • Page 76 Switch the toggle switch for travel speed ranges to the “rear” position. B-720-0104 Fig. 71 Turn the ignition key to position “I”. B-720-0077 Fig. 72 Checking the remote control Shift the travel lever forwards or backwards and hold in place. AUTOMATIC B-720-0022 Fig. 73 D.ONE...
  • Page 77 Shift the steering lever to the left or right. ð Make sure the machine steers in the chosen direction. Release the travel lever. AUTOMATIC ð Make sure the machine brakes until it comes to a stand- still. B-720-0023 Fig. 77 D.ONE...
  • Page 78 If necessary, switch off the engine manually „Switching off the machine manually“ on page 151. If this does not work correctly, shut down the remote control and notify our Customer Service Department. Only operate the machine again after it has been repaired. B-SWI-1588 Fig. 78 D.ONE...

  • Page 79: Checking The Boss Safety System

    Walk behind the machine with the remote control. Let the machine travel towards you slowly until it stops. Measure the distance between the machine and the remote control housing. > 1,2 m > 1.3 yd Nominal value > 1.2 m (1.3 yd) B-720-0056 Fig. 81 D.ONE...
  • Page 80 Repeat the measurement of the safety field in front of the machine. If the distance behind or in front of the machine is too small, check the safety device and have it repaired. > 1,2 m > 1.3 yd B-720-0057 Fig. 82 D.ONE...

  • Page 81: Starting The Engine

    Emergency stop switch is unlocked The travel lever and steering lever are in neutral position Switch the toggle switch for engine speed to "MIN” position. B-720-0074 Fig. 83 Set the vibration toggle switch to "middle" position. B-720-0014 Fig. 84 D.ONE...
  • Page 82 (pre-warming). Press the start button. ð The starter cranks the engine. NOTICE! Danger of engine damage! – Warm up engine for a short while before starting work. Do not operate the engine immediately under full load. B-720-0043 Fig. 87 D.ONE...

  • Page 83: Travel Operation

    Do not drive on gradients exceeding the maximum gradeability of the machine. Soil conditions and weather influences impair the gradeability of the machine. Wet and loose soil considerably reduces traction of the machine on inclinations and slopes. Greater danger of accident! D.ONE...

  • Page 84: Driving The Machine

    Injury caused by the machine turning over! – Do not activate travel speed range 2 when operating without a drum exten- sion. Use the toggle switch for travel speed ranges to select the B-720-0021 required travel speed range. Fig. 90 D.ONE...
  • Page 85 Shift the steering lever to the left or right. ð The machine steers in the corresponding direction. AUTOMATIC B-720-0023 Fig. 92 Set the travel lever to “middle” position to stop the machine. ð The machine decelerates to a standstill. AUTOMATIC B-720-0024 Fig. 93 D.ONE...

  • Page 86: Working With Vibration

    When it stops, the vibration switches off automatically. This avoids the formation of transverse marks caused by vibration with the machine at standstill. 6.4.2 Vibration in automatic mode Switch the toggle switch for travel speed ranges to the “rear” position. B-720-0104 Fig. 94 D.ONE...
  • Page 87 AUTOMATIC B-720-0022 Fig. 97 To switch off vibration return the travel lever towards the “middle” position. ð The vibration is switched off and the machine brakes until AUTOMATIC it comes to a halt. B-720-0024 Fig. 98 D.ONE...

  • Page 88: Manual Vibration

    Switch the toggle switch for travel speed ranges to the “rear” position. B-720-0104 Fig. 100 Switch the toggle switch for vibration pre-selection to the "rear” position. B-720-0027 Fig. 101 Shift the travel lever slowly in the desired travel direction. AUTOMATIC B-720-0022 Fig. 102 D.ONE...
  • Page 89 Do not switch on vibration with the machine at standstill. Use the toggle switch for vibration to switch on the vibration at the required amplitude. B-720-0025 Fig. 103 To switch vibration off switch the toggle switch for vibration to the “middle" position. B-720-0014 Fig. 104 D.ONE...

  • Page 90: Parking The Machine In Secured Condition

    B-720-0024 Fig. 105 Turn the ignition key to position “0” and pull it out. Open the flap. B-720-0028 Fig. 106 Turn the main battery switch anticlockwise and pull it out. B-SWI-0079 Fig. 107 D.ONE...
  • Page 91 Do not cleaning the remote control with water jets. B-720-0029 After work, clean the remote control with a clean cloth or Fig. 108 brush. Place the remote control (2) in the holding fixture (3) and close the flap (1). B-720-0019 Fig. 109 D.ONE...

  • Page 92: Remote Control Battery (Radio Operation)

    Turn the ignition key to position “0” and pull it out. B-720-0028 Fig. 110 Press the battery forwards to insert and downwards to remove it from the battery compartment. Insert the replacement battery into the battery compartment and click into place. B-720-0078 Fig. 111 D.ONE...

  • Page 93: Charging The Power Pack In The Machine

    Remove the safety cap (1) and connect the cable (2) to the remote control. ð The battery starts charging. B-720-0029 Fig. 113 Once the battery is charged, turn the main battery switch anticlockwise and pull it off. B-SWI-0079 Fig. 114 D.ONE...

  • Page 94: Charging The Power Pack With The External Battery Charger

    Connect the battery charger mains unit to a power source. Make sure the two light emitting diodes on the charger and mains unit light up. ð The green LED on the charger flashes when the battery is charged. Fig. 118 D.ONE...

  • Page 95: Loading / Transporting The Machine

    Loading / transporting the machine Loading / transporting the machine D.ONE...

  • Page 96: Preparation For Transport

    Loading / transporting the machine – Preparation for transport 7.1 Preparation for transport Remove all loose objects from the machine or fasten them properly. Close and lock all protective hoods and flaps. D.ONE...

  • Page 97: Loading The Machine

    B-720-0104 Drive the machine carefully onto the transport vehicle. Fig. 120 Observe the centre of gravity. Switch off the engine and remove the ignition key. Ä Chapter 8.2.2.1 „Engaging the Engage the articulation lock articulation lock“ on page 103. D.ONE...

  • Page 98: Lashing The Machine To The Transport Vehicle

    Use lifting tackle only in the specified loading direction. Lifting tackle must not be damaged by machine parts. Fasten the lashing tackle at the marked lashing points. Securely lash the machine to the transport vehicle using four lashing straps. B-720-0103 Fig. 121 D.ONE...

  • Page 99: Loading By Crane

    Attach the lifting tackle to the central lifting point. DANGER! Danger to life caused by suspended loads! – Do not step or stand under suspended loads. Lift the machine carefully and set down again at the intended B-720-0034 location. Fig. 122 D.ONE...

  • Page 100: After Transport

    Switch the toggle switch for travel speed ranges to the “rear” position. DANGER! Danger to life caused by the machine slip- ping or turning over! – Make sure that no persons are in the danger zone. B-720-0104 Drive the machine carefully off the transport vehicle. Fig. 123 D.ONE...

  • Page 101: Maintenance

    Maintenance Maintenance D.ONE...

  • Page 102: Preliminary Remarks And Safety Notes

    After maintenance work is completed reinstall all protective devices. Close all maintenance flaps and doors after maintenance work has been completed. The terms right/left are always in relation to the travel direction. D.ONE...

  • Page 103: Preparations/Concluding Work

    Move the steering to middle position and stop the machine. Switch off the engine and remove the ignition key. Remove the locking bolt and swivel the articulation lock into the eyelet. Let the locking bolt click into place. B-720-0080 Fig. 125 D.ONE...
  • Page 104 Do not step into the articulation area of the machine while the engine is running. Remove the locking bolt and the articulation lock from the eyelet and swivel back into place in the holding fixture. Let the locking bolt click into place. B-720-0081 Fig. 126 D.ONE...

  • Page 105: Fuels And Lubricants

    1 x per year, irre- spective of the operating hours reached. If the sulphur content in the fuel is higher than 0.5 %, the oil change intervals must be halved. D.ONE...

  • Page 106: Fuel

    “flow enhancing additives” (fuel additives) is not permitted. 8.3.2.3 Storage Even traces of zinc, lead and copper can cause deposits in the injection nozzles, especially in modern Common-Rail injection sys- tems. Zinc and lead coatings in refuelling systems and fuel lines are not permitted. D.ONE...

  • Page 107: Coolant

    The anti-freeze agent also contains a corrosion protection agent. If this mixes with cleaning agent it may cause the development of sludge, which could damage the cooling system. Anti-freeze concentration Freezing point 50 % -37 °C (-35 °F) D.ONE...

  • Page 108: Oil For Exciter Shaft Housing

    – After the changeover check the hydraulic oil fil- ters increasingly for contamination. – Have regular oil analyses performed regarding the water content and mineral oil. – Replace the hydraulic oil filter at the latest after 500 operating hours. D.ONE...

  • Page 109: List Of Fuels And Lubricants

    Ä Chapter 8.3.5.2 „Bio-degrad- Specification: able hydraulic oil“ on page 108 Exciter shaft housing Engine oil SAE 15W-40 2 x 1.7 l Ä Chapter 8.3.4 „Oil for exciter Specification: (0.5 gal us) shaft housing“ on page 108 D.ONE...

  • Page 110: Running-In Instructions

    Change the engine oil and oil filter cartridge „Change engine oil and oil filter cartridge“ on page 116. Check the central screw of the drive hubs; retighten if neces- Ä Chapter 8.13.3 „Checking the central screw of the sary drive hub“ on page 139. D.ONE...

  • Page 111: Maintenance Table

    Check the injection valves Every 3000 operating hours 8.12.1 Checking the fuel injection pump As required 8.13.1 Checking/adjusting the scrapers 8.13.2 Cleaning the radiator module 8.13.3 Checking the central screw of the drive hub 8.13.4 Measures prior to extended shutdown period D.ONE...

  • Page 112: Weekly

    90. Allow the engine to cool down. Checking the maintenance indi- cator Check the air filter maintenance indicator. If the yellow pin has reached the red area (1) service the air filter. B-720-0097 Fig. 128 D.ONE...
  • Page 113 (30 psi)) from inside to outside by moving the gun up and down inside the element, until it is free of dust. Fig. 131 Examine the air filter with a torch for cracks and holes in the paper bellows. Replace the air filter if it is damaged. Fig. 132 D.ONE...
  • Page 114 Make sure that the cover locks engage cor- rectly. Reinstall the cover. Fig. 133 Resetting the maintenance indi- cator After maintenance has been completed, press the button (1) on the maintenance indicator. ð The maintenance indicator is reset. B-720-0098 Fig. 134 D.ONE...

  • Page 115: Checking And Cleaning The Water Separator

    Ä Chapter 8.8.6.2 „Bleeding the fuel Bleed the fuel system system“ on page 123. Retighten the bleed screw. Check for leaks; if necessary, use a new seal ring. Dispose of collected fluid in line with environmental regula- B-720-0082 tions. Fig. 136 D.ONE...

  • Page 116: Every 250 Operating Hours/Annually

    Remove any dirt from the sealing face of the filter carrier. Thinly apply oil to the rubber seal of the new oil filter car- tridge. Screw on the oil filter cartridge and tighten by hand. B-720-0091 Fig. 138 D.ONE...

  • Page 117: Checking, Tensioning The V-Belt

    Protective gloves Loosen the tensioning screw (1) and the screw (2) on the generator. Press the generator towards the outside using a lever, until the correct V-belt tension is reached. Retighten clamping screw (1) and screw (2). Fig. 141 D.ONE...

  • Page 118: Replacing The Air Filter

    Fig. 143 Slide the new air filter carefully into the housing. NOTICE! Danger of engine damage! – The dust discharge valve must point vertically downwards. – Make sure that the cover locks engage cor- rectly. Reinstall the cover. Fig. 144 D.ONE...

  • Page 119: Check The Air Intake Lines

    90. Allow the engine to cool down. Check the condition and tight fit of all air intake lines and hose clamps. If necessary, replace any damaged air intake lines or hose clamps. B-720-0099 Fig. 146 D.ONE...

  • Page 120: Changing The Oil In The Exciter Housing

    103. Attach lifting tackle to the front lashing point. Lift the machine at the front and support the front drum. Secure the rear drum with a wheel chock. 710 mm 28 in B-720-0045 Fig. 147 D.ONE...
  • Page 121 Clean and remove the bleed screw (1) and drain plug (2) from the rear drum. B-720-0049 Drain off and collect all oil. Fig. 151 Lift the machine at the front again, support the front drum securely, and secure the rear drum with a wheel chock. D.ONE...

  • Page 122: Replacing The Fuel Filter; Bleeding The Fuel System

    Protective equipment: Working clothes Safety shoes Protective gloves Ä Chapter 6.5 „Parking the machine Park the machine safely in secured condition“ on page 90. Remove the bolts and washers (2). Open the central electrics (1). B-720-0052 Fig. 153 D.ONE...
  • Page 123 Ä Chapter 8.8.6.2 „Bleeding the fuel Bleed the fuel system system“ on page 123. 8.8.6.2 Bleeding the fuel system Protective equipment: Working clothes Safety shoes Protective gloves Loosen the bleed screw on the fuel filter 2 to 3 turns. Fig. 156 D.ONE...

  • Page 124: Draining The Fuel Tank Sludge

    Protective gloves Park the machine in secured condition Ä Chapter 6.5 „Parking the machine in secured condition“ on page 90. Allow the engine to cool down. Check the condition and tight fit of all fuel lines and hose clamps. D.ONE...

  • Page 125: Servicing The Battery; Checking The Main Battery Shutoff

    Check the condition of the vibration insulation mats; replace if necessary. On serviceable batteries check the acid level; if necessary, B-720-0055 top up to the filling mark with distilled water. Fig. 159 Terminal Battery Battery fastening Vibration insulation mat D.ONE...
  • Page 126 Maintenance – Every 250 operating hours/annually 8.8.9.2 Checking the main battery shutoff Turn the main battery switch counter-clockwise and pull it out. Check by turning the ignition key, whether the battery is dis- connected from the electric system of the machine. Fig. 160 D.ONE...

  • Page 127: Every 500 Operating Hours

    Press the generator inwards, and release and remove the V- belt. Install the new V-belt. Ä Chapter 8.8.2 Tension the V-belt to the specified value „Checking, tensioning the V-belt“ on page 117. Retighten the clamping screw and screw. B-880-0058 Fig. 161 D.ONE...

  • Page 128: Every 1000 Operating Hours

    (0.006 in to 0.007 in) Protective equipment: Working clothes Safety shoes Protective gloves Ä Chapter 6.5 „Parking the machine Park the machine safely in secured condition“ on page 90. Allow the engine to cool down. Preparations Remove the valve cover. B-720-0107 Fig. 162 D.ONE...
  • Page 129 ð The feeler gauge must fit through the gap with little resist- ance. Fig. 164 IN Intake valve EX Exhaust valve Adjusting the valve clearance Loosen the counter nut on the rocker arm. Adjust the valve clearance using the adjustment screw. Tighten the counter nut. B-720-0108 Fig. 165 D.ONE...
  • Page 130 Maintenance – Every 1000 operating hours Concluding work Install the valve cover with a new seal. After a short test run check the valve cover for leaks. B-720-0107 Fig. 166 D.ONE...

  • Page 131: Every 2000 Operating Hours

    Danger of burning on hot components! – Wear your personal protective equipment (protective gloves, protective clothing). – Avoid touching hot components. Unscrew the drain plug. Drain off and collect all hydraulic oil. B-720-0060 Screw the drain plug back in. Fig. 167 D.ONE...
  • Page 132 B-720-0087 Fig. 170 Screw the cap (1) back on. Replace the breather filter (2). After the test run, check the filters for leaks. Dispose of the hydraulic oil and filter in line with environ- mental regulations. B-720-0058 Fig. 171 D.ONE...

  • Page 133: Changing The Coolant

    109 Protective equipment: Working clothes Safety shoes Protective gloves Safety goggles Ä Chapter 6.5 „Parking the machine Park the machine safely in secured condition“ on page 90. Allow the engine to cool down. Unscrew the cap. B-720-0062 Fig. 172 D.ONE...
  • Page 134 Screw the filler cap back on again. Start the engine and run to operating temperature. Let the engine cool down and check the coolant level again; if necessary, top up in the compensation tank. B-720-0109 Dispose of coolant in line with environmental regulations. Fig. 176 D.ONE...

  • Page 135: Replacing Hoses

    Perform this maintenance work at the latest after two years. The following hoses need to be renewed: fuel hoses, air intake hoses. 8.11.4 Check the injection valves This work must only be performed by authorized service per- sonnel. D.ONE...

  • Page 136: Every 3000 Operating Hours

    Maintenance – Every 3000 operating hours 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. D.ONE...

  • Page 137: As Required

    Components may get damaged! – Do not bend or damage cooling fins. – Do not clean with high pressure. Park the machine safely Ä Chapter 6.5 „Parking the machine in secured condition“ on page 90. Allow the engine to cool down. D.ONE...
  • Page 138 Spray the engine and radiator with a suitable cleaning agent, let it soak in for a while, and then wash off with a strong water jet. Warm up the engine for a while to prevent corrosion. D.ONE...

  • Page 139: Checking The Central Screw Of The Drive Hub

    After shutting down store the machine under cover in a dry and well ventilated room. Check the anti-freeze concentration and the coolant level. Disconnect the ground strap from the battery (this avoids self-discharge caused by closed-circuit consuming devices). D.ONE...
  • Page 140 Measures before restarting Replace the fuel filter. Replace the air filter. Change engine oil and oil filter. Check the coolant level. Check the charge condition of the batteries, recharge if nec- essary. Check the battery fluid level before and after charging. D.ONE...
  • Page 141 Start the engine and run it for 15 to 30 minutes with idle speed. While the engine is running keep an eye on the gauges for oil pressure and coolant temperature. Check the oil levels. Check the function of electric system, steering and brakes. Clean the machine thoroughly. D.ONE...
  • Page 142 Maintenance – As required D.ONE...

  • Page 143: Setting Up / Refitting

    Setting up / refitting Setting up / refitting D.ONE...

  • Page 144: Drum Extension

    90. Unscrew the fastening bolts (1). Remove the washers. Remove the drum extension (2). B-720-0032 Fig. 181 To protect the threads, remount the fastening bolts (1) and 572 Nm washers; tightening torque: 572 Nm (422 ft·lbf). B-720-0031 Fig. 182 D.ONE...

  • Page 145: Attaching The Drum Extension

    Safety shoes Protective gloves Unscrew the fastening bolts (1) and remove the washers. B-720-0033 Fig. 183 Remount the drum extension (2) with the fastening bolts (1) 572 Nm and washers; tightening torque: 572 Nm (422 ft·lbf). B-720-0030 Fig. 184 D.ONE...

  • Page 146: Teaching The Boss Safety Field System

    Take up position in the safety field at the machine. ð Distance: < 1.2 m (1.3 yd). B-720-0029 Fig. 185 Turn the toggle switch for operating mode to the “left” posi- tion. B-720-0013 Fig. 186 Turn the ignition key to position “I”. B-720-0077 Fig. 187 D.ONE...
  • Page 147 Leave the safety field with the remote control. ð Distance: > 1.2 m (1.3 yd). > 1,2 m > 1.3 yd B-720-0017 Fig. 191 The safety device warning light goes out after approx. 2 seconds. The machine is now ready for operation. B-SYM-0226 Fig. 192 D.ONE...
  • Page 148 Setting up / refitting – Teaching the BOSS safety field system D.ONE...

  • Page 149: Troubleshooting

    Troubleshooting Troubleshooting D.ONE...

  • Page 150: Starting The Engine With Jump Leads

    Start the engine: Ä Chapter 6.2.4 „Starting the engine“ on page 81. After starting, disconnect the minus poles first and the plus 12 V poles after. B-ELE-0027 Close the rear protective hood. Fig. 194 D.ONE...

  • Page 151: Switching Off The Machine Manually

    Turn the ignition key to position “0” and pull it out. Open the front protective hood. B-720-0028 Fig. 196 Move the lever on the engine and hold. ð The engine is shut down. Close the front protective hood again. Open the flap. B-720-0114 Fig. 197 D.ONE...
  • Page 152 Troubleshooting – Switching off the machine manually Turn the main battery switch anticlockwise and pull it out. Close the flap again. Shut down the machine and inform our Customer Service Department. Only operate the machine after it has been repaired. B-SWI-0079 Fig. 198 D.ONE...

  • Page 153: Decrease In The Hydraulic Oil Level

    Park the machine safely in secured condition“ on page 90. Lift the front or rear of the machine 145 mm (5.7 in), support it securely and secure it with a wheel chock. 145 mm 5.7 in B-720-0005 Fig. 200 D.ONE...
  • Page 154 If a significant quantity flows out of the drain bore, inform our Customer Service. Screw the drain and ventilation plugs back in. B-720-0006 Lower the machine. Fig. 201 If necessary, dispose of the collected oil in line with environ- mental regulations. D.ONE...

  • Page 155: Fuse Assignment

    F103 10 A Fuse for potential 15 25 A Fuse for engine shut-down solenoid Fuse cable remote control F243 Fuse for TELEMATIC potential 30 25 A Fuse control potential 30 30 A Fuse for pre-heating F275 Fuse for ECONOMIZER D.ONE...

  • Page 156: Main Fuse

    Troubleshooting – Fuse assignment 10.4.3 Main fuse B-720-0111 Fig. 203 Fuse Amperage Designation 80 A Main fuse D.ONE...

  • Page 157: Engine Faults

    Engine over- Cooling fins on radiator are extremely Clean the cooling fins heating, engine dirty (the warning lamp for engine oil tem- must be shut down perature lights) immediately! Engine oil level too low Check, fill up if necessary D.ONE...
  • Page 158 The charge control Generator speed too low Check the generator belt for tension, light lights during replace the belt if necessary operation, the Generator or regulator defective Have examined by a specialist warning buzzer sounds D.ONE...

  • Page 159: Remote Control Faults (Cable Operation)

    Replace defective battery Cross-slope sensor defective Check the cross-slope sensor signal, input code 1405 Have examined by a specialist; replace if necessary Relay K39 defective Check the relay control signal, input code 5070 Have examined by a specialist; replace if necessary D.ONE...
  • Page 160 Check the relay control signal, input code 5050 Have examined by a specialist; replace if necessary Control defective Have examined by a specialist; replace if necessary Cable defective Check cable for tight fit Have examined by a specialist; replace if necessary D.ONE...

  • Page 161: Remote Control Faults (Radio Operation)

    Reduce the distance remote control is too great Operating mode toggle switch defective Have examined by a specialist; replace if necessary Emergency stop switch actuated or Pull out the emergency stop switch defective Have examined by a specialist; replace if necessary D.ONE...
  • Page 162 Troubleshooting – Remote control faults (radio operation) Fault Possible cause Remedy Receiver or radio remote control defec- Have examined by a specialist; replace if tive necessary Wiring loom defective Have examined by a specialist; replace if necessary D.ONE...

  • Page 163: Faults In Boss Safety System

    Safety device control not connected prop- Check the plug-in connection of the con- erly or defective trol; replace if necessary Radio remote control defective Have examined by a specialist; replace if necessary Wiring loom defective Have examined by a specialist; replace if necessary D.ONE...

  • Page 164: Fault Code Display

    If a fault code is displayed, read out and have the fault rectified by specialists authorised by the operating company. If necessary, con- tact our Customer Service. Ä Chapter 12 „Appendix“ on page 169. Overview of fault codes B-720-0090 Fig. 204 D.ONE...

  • Page 165: Entering Input Codes Via The Display Unit

    Fig. 205 Press function keys F1 and F2 at the same time. ð The display shows „0000“ . The first digit flashes. B-720-0093 Fig. 206 Set the first digit of the input code by pressing function key B-720-0094 Fig. 207 D.ONE...
  • Page 166 ECO mode off or on), further codes must Ä Chapter 12 be entered „Appendix“ on page 169. B-720-0096 Fig. 209 To terminate the input function, enter the input code „0000“ or turn the ignition key to the "0" position. D.ONE...

  • Page 167: Disposal

    Disposal Disposal D.ONE...

  • Page 168: Final Shut-Down Of Machine

    Safety goggles Remove the batteries and dispose of in compliance with legal regulations. Empty the fuel tank. Drain the hydraulic oil tank. Drain the coolant from the cooling system and engine. Drain engine oil from the engine and exciter housing. D.ONE...

  • Page 169: Appendix

    Appendix Appendix D.ONE...

  • Page 170: List Of Fault Codes

    Current path connected to 1032 of this output +12V 1033 Engine is shut Output valve travelling for- Current path connected to X3:22 1030 down ward, Y 16 +12V 1031 Although the output is 1032 switched off, voltage is present D.ONE...
  • Page 171 Output brake valve, Y 04 Excessive current flow in X3:40 off, function no current path, probably Too high current flow out of longer possible because of a defective coil this output Output was or a short circuit to ground switched off! D.ONE...
  • Page 172 Output is switched Output valve vibration high Short circuit to ground in X3:13 off, function no ampl., Y 57 the current path longer possible Short-circuit current flow out Lines rubbed through of this output Output was Valve defective switched off! D.ONE...
  • Page 173 Output valve steering left, Y Excessive current flow in X3:21 off, function no current path, probably longer possible because of a defective coil Too high current flow out of or a short circuit to ground this output Output was switched off! D.ONE...
  • Page 174 1.11! an machine too big 2611 Engine is shut down. CANopen – fault in bus communication 2612 Engine is shut down. CANopen – fault in bus communication 2613 Engine is shut down CANopen – fault in bus communication D.ONE...
  • Page 175 Generator regulator defective X3:41 from the generator regu- Line between regulator and lator control interrupted Only warning 5031 Machine standing Engine stops, engine Lack of fuel stalled Engine stopped even though the BLM control did not submit a corresponding command D.ONE...
  • Page 176 X3:09 5050 switched off, speed solenoid +12V 5051 engine runs only Although the output is with idle speed 5052 switched off, voltage is present 5054 Input AUX – signal engine Wire breakage in current path X3:04 solenoid Y 13 D.ONE...
  • Page 177 +12V 5072 5073 All outputs Output relay K 39, starter Current path connected to X3:06 5070 switched off, +12V Although the output is 5071 engine stopped, switched off, voltage is safety relay 5072 present switched off D.ONE...
  • Page 178 (machine has turned over) The diesel engine is shut + Start lock activated down because the input on Wire breakage in current path the control does not receive a signal from the inclination Switch defective sensor + Start lock activated D.ONE...
  • Page 179 Fault in safety field control Internal fault in safety field control only steering (A115) 6015 Travel movement not possible, Fault in bus communication Wire breakage in current path only steering between safety field control and transponder 6016 Reception quality safety field control D.ONE...
  • Page 180 Faults in parameterization Code Fault reaction Description of Possible cause Terminal Input code fault on BLM for diag- nose 7010 Machine cannot be started, No machine type Module is new, 0725 module is not completely parameters werede- initialized leted D.ONE...

  • Page 181: Input Codes For Blm Control

    0000 = Output not triggered 0001 = Output triggered Logic level of control 0000 = Output not triggered 0001 = Output triggered 1035 Valve control, travel system 0100 = Driving forward 0010 = Drum stopped 0011 = Driving reverse D.ONE...
  • Page 182 Display value = output current in Amperè Current at output Display value = output current in Amperè 1307 Output valve vibration low amplitude, Y 56 0000 = Output not triggered 0001 = Output triggered Logic level of control 0000 = Output not triggered D.ONE...
  • Page 183 0001 = Engine oil pressure OK Shows status of input engine oil 0000 = No engine oil pressure pressure 0001 = Engine oil pressure OK 5030 Inclination sensor, B 56 0000 = No signal, machine inclined more than 45°, or switch defective D.ONE...
  • Page 184 1 = ECO-mode on 5060 Output relay K 11, potential Display value = output voltage in Volt changeover Voltage at output Display value = output voltage in Volt 5061 Output relay K 11, potential Display value = output current in Amperè changeover D.ONE...
  • Page 185 0000 = Output not triggered 0001 = Output triggered Logic level of control 0000 = Output not triggered 0001 = Output triggered 5100 Coolant temperature sensor, B 53 0000 = Temperature too high, excessive temperature 0001 = Temperature OK D.ONE...
  • Page 186 If the engine starts, the spiral cable is OK. System information Fault description Cause Remedy 0555 Software Version 3-digit version number Shows the software version number. 3-digit version number D.ONE...
  • Page 187 Display of minutes, operating hour meter The minute digits of the operating hour meter are displayed Setting the machine type Fault description Cause Remedy 7010 Switches on function "Set machine type" See adjustment instructions 7011 Confirms entered machine type See adjustment instructions D.ONE...
  • Page 188 Appendix – Input codes for BLM control Fault description Cause Remedy 7103 Preselect machine type BMP 8500 with protection bow See adjustment instructions 7104 Preselect machine type BMP 8500 without protection See adjustment instructions D.ONE...

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