Wacker Neuson DT08-D Operator'S Manual Download Page 59

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BA DT08 SL EN – Edition 1.0 * dt08b410.fm

4-1

Troubleshooting

4 Troubleshooting

The information given in this chapter is provided for maintenance staff, for fast and reliable
detection of malfunctions and their appropriate repair.
Repairs must be carried out by authorised staff.

4.1

Engine trouble

Problem

Possible causes

See

Engine does not start or is not easy to start

Wrong SAE grade of engine lubrication oil

5-24

Fuel grade does not comply with specifications

5-24

Defective or flat battery

5-21

Loose or oxidised cable connections in starter circuit

Defective starter, or pinion does not engage

Wrong valve clearance

Defective fuel injector

Defective fuse

Check the spark plug

5-7

Engine starts, but does not run smoothly or faultless

Fuel grade does not comply with specifications

5-24

Wrong valve clearance

Injection line leaks

Defective fuel injector

Engine overheats

Oil level too low

5-8

Oil level too high

5-8

Dirty air filter

5-10

Defective fuel injector

Insufficient engine output

Oil level too high

5-8

Fuel grade does not comply with specifications

5-24

Dirty air filter

5-10

Wrong valve clearance

Injection line leaks

Defective fuel injector

Dirty carburettor (DT08-P only)

Defective ignition (DT08-P only)

Defective spark plugs (DT08-P only)

Insufficient or no engine oil pressure

Oil level too low

5-8

Too much machine inclination (max. 15°)

Wrong SAE grade of engine lubrication oil

5-24

Engine oil consumption too high

Oil level too high

5-8

Too much machine inclination (max. 15°)

Summary of Contents for DT08-D

Page 1: ...Operator s Manual Track dumper Machine model DT08 P DT08 D Edition 1 0 Language en Article number 1000268368...

Page 2: ...roduced translated or used in any form or by any means graphic electronic or mechanical including photocopying recording taping or information storage or retrieval systems without prior permission in...

Page 3: ...m liability 2 2 General conduct and safety instructions 2 2 Organisational measures 2 2 Selection and qualification of staff basic responsibilities 2 3 Safety instructions regarding operation 2 4 Norm...

Page 4: ...Loader unit operation option 3 18 Parking the machine 3 19 Foothold 3 19 Crane handling the machine 3 20 Loading and transporting the machine 3 21 Tying down the machine 3 22 Towing the machine 3 22 W...

Page 5: ...tions concerning specific components 5 20 Alternator 5 20 Battery 5 21 General maintenance work 5 22 Cleaning 5 22 General instructions for all areas of the machine 5 22 Exterior of the machine 5 23 E...

Page 6: ...the engine oil level 5 8 Checking the hydraulic oil level 5 14 Clean 5 22 Diesel engine maintenance plan 5 27 Electrical system 5 19 Engine lubrication system 5 8 Filling in engine oil 5 9 Filling up...

Page 7: ...t 2 2 Identification 2 1 Maintenance 2 7 Operation 2 4 Special hazards 2 9 Trailers and attachments 2 6 Transport 2 6 Signs and symbols 1 9 Spark plug 5 7 Specifications Coolant compound table 6 40 El...

Page 8: ...1 3 BA DT08 SL EN Edition 1 0 BaDT08en1_0SIX fm Index...

Page 9: ...Safety Instructions as well in order to be prepared for possible dangerous situations as it will be too late for it during operation As a rule keep the following in mind Careful and prudent working i...

Page 10: ...hine Fig 1 Machine outside views 1 Control stand handle 2 Skip 3 Loader unit option 4 Engine 5 Travelling drive 6 Eye hook for loading tying down the machine 7 Undercarriage 8 Track 9 Foothold 10 Engi...

Page 11: ...his feet Danger of accidents Stand on the foothold ensuring that neither your feet nor other limbs pro trude beyond the dimensions of the machine Danger The driver must always firmly hold onto the han...

Page 12: ...ormity assessment procedure Notified body according to Directive 2006 42 EC appendix XI Fachaussch sse Bau und Tiefbau Pr f und Zertifizierungsstelle im BG PR FZERT Landsberger Str 309 D 80687 Munich...

Page 13: ...Dumper Machine model DT08 P Serial no ______________ Output kW 6 6 kW Measured sound power level 100 dB A Guaranteed sound power level 101 dB A Directives and standards We hereby declare that this pro...

Page 14: ...ormity assessment procedure Notified body according to Directive 2006 42 EC appendix XI Fachaussch sse Bau und Tiefbau Pr f und Zertifizierungsstelle im BG PR FZERT Landsberger Str 309 D 80687 Munich...

Page 15: ...Dumper Machine model DT08 D Serial no ______________ Output kW 6 8 kW Measured sound power level 100 dB A Guaranteed sound power level 101 dB A Directives and standards We hereby declare that this pro...

Page 16: ...ine designation COMPACT DUMPER Model Model year CEE no Output Serial no Max payload GWR Operating weight Front GAWR Transport weight Rear GAWR Version Other information see chapter 6 Specifications on...

Page 17: ...BA DT08 SL EN Edition 1 0 dt08b110 fm 1 9 Introduction 1 10 Signs and symbols XX XX...

Page 18: ...level Other information see chapter on page 6 35 Location Protective plate on control stand Meaning Indication of driver perceived sound pressure level LPa sound pressure level Other information see...

Page 19: ...efore carrying out work under the skip Location On left and right of skip Meaning General indication of danger This symbol alerts persons standing or working near the machine of an existing danger of...

Page 20: ...tip skip on page 3 1 and see chapter 3 2 Control stand overview model DT08 D skip and high tip skip on page 3 2 Location On the control stand Meaning Indication of throttle Location On the control sta...

Page 21: ...he machine Environment Failure to observe the instructions identified by this symbol can result in damage to the environment The environment is in danger if environmentally hazardous material e g wast...

Page 22: ...bs on public roads 2 5 General conduct and safety instructions Organisational measures The machine has been designed and built in accordance with state of the art standards and the recognised safety r...

Page 23: ...ervals even if no safety relevant defects have been detected Before working on or with the machine remove jewellery such as rings wristwatches bracelets etc and tie back long hair and do not wear loos...

Page 24: ...tate Operate the machine only if all protective and safety oriented devices e g removable safety devices soundproofing elements and exhausters etc are in place and fully functional Check the machine a...

Page 25: ...ll If the skip is more than half full drive forwards uphill or backwards downhill On sloping terrain always adapt your drive speed to the prevailing ground conditions Never change to lower gear on a s...

Page 26: ...r towing the machine observe the prescribed transport position admissible speed and itinerary Use only suitable means of transport of adequate capacity payload Safely secure the machine on means of tr...

Page 27: ...k do not start machine to the ignition lock steering wheel or to the control elements Remove the ignition key Carry out service maintenance and repair work only if the machine is positioned on firm an...

Page 28: ...oil lines for leaks chafe marks and damage Rectify all defects without delay Always tighten any screw connections that have been loosened during maintenance and repair Any safety devices removed for...

Page 29: ...e safety instructions regarding the battery Gas dust steam smoke Operate the machine only on adequately ventilated premises Before starting the internal combustion engine on enclosed premises ensure t...

Page 30: ...regulations relevant to accident prevention Batteries contain sulphuric acid caustic When charging batteries in particular as well as during normal operation of batteries an oxyhydrogen mixture is for...

Page 31: ...sed for identifying control elements mean figure no 40 control element no 18 or position A in figure no 40 Figures carry no numbers if they are placed to the left of the text 3 1 Control stand overvie...

Page 32: ...information see page 1 Loader unit operation option raise skip option 3 18 2 Skip operation 3 17 3 Normal or high speed lever 3 13 4 Drive lever left 3 13 5 Drive lever right 3 13 6 Throttle 7 Auxilia...

Page 33: ...Engine oil pressure indicator light Caution If the indicator light comes on with the engine running Stop the engine immediately and Check the oil level If it is too low fill up the engine oil If it i...

Page 34: ...ccordance with its designated use and the instructions set forth in the Operator s Manual and only by safety conscious persons who are fully aware of the risks involved in operating the machine Go thr...

Page 35: ...eration or starting the engine Operation checklist After starting the engine and during operation check and observe the following points Parking checklist Check and observe the following points when p...

Page 36: ...cock is open Do not run the starter for more than 5 seconds if the engine does not start Wait about 10 seconds before trying again Procedure After you have completed the starting preparations Open the...

Page 37: ...case of a short circuit or if the battery s terminals are inverted The green indicator in the circuit breaker is ejected to indicate that the circuit breaker has been triggered In this case find out t...

Page 38: ...ulics is switched off Push throttle 6 fully backwards Push lever 2 fully backwards The engine stops Turn the engine switch to position B Machine equipped with electric starter Turn the engine switch t...

Page 39: ...of engine damage Always check the fuel level before starting The engine will not start unless the fuel cock is open Do not run the starter for more than 5 seconds if the engine does not start Wait abo...

Page 40: ...art Repeat the procedure Notice The engine will not start unless the cable is pull fully and firmly Electric starter Turn the ignition key to position 1 Turn and hold the ignition key in position 3 un...

Page 41: ...o not run the engine at full load until it has reached its operating temperature Stopping the diesel engine Check whether the switch for auxiliary hydraulics 7 is in the centre position The auxiliary...

Page 42: ...connect one end of the red jump lead to the terminal of the flat battery then connect the other end to the terminal of the starting battery Connect one end of the black jump lead to the terminal of th...

Page 43: ...two drive speeds which can be selected as follows Push lever 3 forwards see Control stand overview model DT08 P skip and high tip skip on page 3 1 or see Control stand overview model DT08 D skip and h...

Page 44: ...ause the machine to lose its balance and to tip over Avoid this under all circumstances Do not drive on slopes steeper than 15 otherwise the machine can tip over Do not drive across slopes steeper tha...

Page 45: ...en on firm ground on a slope of up to 15 Danger Do not exceed the maximum slope Danger of accidents The driver is not allowed to stand on the foothold when driving on slopes with a loaded machine If t...

Page 46: ...e can tip forwards Unloading on slopes is not allowed Driving with a raised and tilted skip is forbidden regardless of the ground the machine is driving on Raise and dump out the skip only if the mach...

Page 47: ...te the skip when driving on slopes otherwise Danger of accidents Do not actuate the skip when driving across slopes Do not actuate the skip when driving up or down slopes Notice The loader unit also m...

Page 48: ...ration Loader unit operation option Notice Always keep the loader unit 30 40 cm above the ground when driving the machine Fig 50 Loader unit A B 1 Position Function A 1 Push forwards Loader unit is lo...

Page 49: ...nit to the ground Reduce engine speed completely Switch off ignition Remove the ignition key Caution Never stop the engine under full load Let the engine run at idling speed for at least 1 minute befo...

Page 50: ...Ensure that the crane and the lifting gear cables chains have sufficient load bearing capacity Only raise the machine with an empty loader unit and skip Stay clear of suspended loads It is essential t...

Page 51: ...your country Load as follows Secure the transport vehicle with chocks to prevent it from rolling Place the access ramps at the smallest possible angle Ensure that the grade does not exceed 15 27 Use a...

Page 52: ...nd the skip Before transporting the machine through heavy rain Cover the exhaust pipe with a suitable cover Before transporting ensure that the driver of the transport vehicle knows the overall height...

Page 53: ...p next to an excavation secure the machine with suitable wheel chocks or other auxiliary means Always watch the material as you dump out the skip ensure that the material is dumped out evenly and does...

Page 54: ...Push control lever 1 forwards B Caution Do not carry out any steering movements once the bucket has penetrated the material Caution Load the machine only on firm and level ground Drive forwards into...

Page 55: ...eful when driving in rough terrain with a full skip Danger of accidents Pay particular attention to this when cornering or driving on slopes In order to avoid accidents Fully dump in the skip Observe...

Page 56: ...the material as you dump out the skip ensure that the mate rial is dumped out evenly and does not remain stuck in the skip otherwise the machine could tip over Dump out the skip A Push control lever...

Page 57: ...ol lever 2 forwards F Skip dumps out Emergency lowering of the skip Danger Emergency lowering of the skip Danger of crushing and injury Stay clear of the skip Emergency lowering of the skip is only po...

Page 58: ...nd move lever 7 to position A or B depending on the line used as pressure line Regulate the dumper s throttle so as to adapt the output to the equipment connected Caution Switch on the auxiliary hydra...

Page 59: ...Defective fuse Check the spark plug 5 7 Engine starts but does not run smoothly or faultless Fuel grade does not comply with specifications 5 24 Wrong valve clearance Injection line leaks Defective fu...

Page 60: ...o high 5 8 Too much machine inclination max 15 White Engine starting temperature too low Fuel grade does not comply with specifications 5 24 Wrong valve clearance Defective fuel injector Black Dirty a...

Page 61: ...specifically trained driver All other maintenance work must be carried out by trained and qualified staff only The maintenance plans indicate when the maintenance work mentioned below must be carried...

Page 62: ...g out maintenance work with the dumper body dumped out Danger of accidents Use the maintenance strut Mount the maintenance strut as follows Raise the skip Dump out the skip Raise safety rod A The skip...

Page 63: ...level Model DT08 P petrol engine Check the fuel level as follows The fuel level must be between the min und max levels If the fuel level is below min Refuel Notice The machine has no filling level ind...

Page 64: ...l Only refuel from stationary fuel pumps Fuel from barrels or cans is usually dirty Even the smallest particles of dirt can cause Increased engine wear Malfunctions in the fuel system and Reduced effe...

Page 65: ...heck for leaks and ensure that all petrol spills have been wiped away before starting the engine Set the fuel cock to OFF Unscrew filter cup A with a suitable tool Remove filter cup A and O ring B and...

Page 66: ...uel has drained completely Open screw B on the fuel cock Pull filter C out of the filler inlet of the fuel tank Wash filter C with a nonflammable solvent Allow filter C to dry thoroughly Insert filter...

Page 67: ...plug B Dispose of spark plug B if it is worn or if the insulator is torn or cracked Measure the electrode gap with a suitable tool The gap must be between 0 70 and 0 80 mm Check the sealing ring for...

Page 68: ...be checked from either side Notice Check the oil level once a day We recommend checking it before starting the engine After stopping a warm engine wait at least 5 minutes before checking Checking the...

Page 69: ...o collect the engine oil as it drains and dispose of it in an environmentally friendly manner Proceed as follows Clean the area around filler cap A with a clean lint free cloth Open filler cap A Fill...

Page 70: ...se a damaged filter cartridge Ensure cleanliness when replacing the filter cartridge Replace filter cartridge A according to the maintenance plan Caution Filter cartridges degrade prematurely when in...

Page 71: ...g nut D off filter cartridge A Insert the new filter cartridge A Tighten wing nut D on filter cartridge A Ensure that all dirt dust inside the cover C has been removed Position cover C ensure that it...

Page 72: ...er cartridge A Ensure that all dirt dust inside the cover C has been removed Position cover C ensure that it is properly seated Tighten wing nut B again on cover C Environment Dispose of filter cartri...

Page 73: ...one of the following problems is detected Damaged or leaky hydraulic seals Worn or torn shell or bare reinforcement Expanded shells in several positions Entangled or crushed movable parts Foreign bod...

Page 74: ...il Refill hydraulic oil only with the engine stopped otherwise hydraulic oil will overflow at the filler opening on the hydraulic oil tank Fill up as follows Park the machine on level ground Raise the...

Page 75: ...l hydraulic fluid in the hydraulic system does not exceed 8 when changing biodegradable oil manufacturer indications Do not fill up with mineral oil the content of mineral oil should not exceed 2 in o...

Page 76: ...search for leaks with your bare hands but wear protective gloves Use paper or wood to check for minor leaks Never use an unprotected light or naked flame Have damaged flexible lines replaced by works...

Page 77: ...d not sag more than 15 mm when tight Notice If possible the distance from the rollers should be the same for both tracks Increasing track tension Proceed as follows Park the dumper on firm and level g...

Page 78: ...table means Tracks should be raised off the ground Stop the engine Use additional supports for the dumper and ensure that it cannot overturn Unscrew set screw D with a suitable tool The fork E is retr...

Page 79: ...he battery can burst or explode Replace the battery immediately There must be no naked flame near open battery cells Avoid sparks No smoking The gas that forms during normal battery operation can igni...

Page 80: ...hen carrying out maintenance work on the electrical system pay particular attention to ensuring good contact in leads Alternator Always observe the following instructions Only test run the engine with...

Page 81: ...p start the machine if the battery is frozen or if the acid level is low The battery can rupture or explode Replace the battery immediately Always disconnect the negative terminal from the battery bef...

Page 82: ...not use flammable liquids such as petrol or diesel Cleaning with compressed air Work carefully Wear goggles and protective clothing Do not aim the compressed air at the skin or at other people Do not...

Page 83: ...nt the jet directly at electric sensors such as the oil pressure switch The humidity penetrating any such sensors causes them to fail and leads to engine damage Screw connections and attachments All s...

Page 84: ...l based on saturated synthetic esters with an iodine value of 10 according to DIN 51524 section 3 HVLP HEES PANOLIN HLP Synth 46 FINA BIOHYDRAN SE 46 Hydraulic oil tank model DT08 D Hydraulic oil AGIP...

Page 85: ...insert Hydraulic oil Replace the air filter element Hydraulic oil tank breather Replace the spark plug Inspection work Check the following material Refill if necessary Check the fuel level fill up fu...

Page 86: ...aks and chafing pipes flexible lines and screw connections of the following assemblies and components Rectify if necessary Visual check Engine and hydraulic system Oil cooling circuit Travelling drive...

Page 87: ...c oil tank breather Inspection work Check the following material Refill if necessary Check injection setting Check and adjust injection time 4 Clean and adjust the fuel injection pump 5 Check and adju...

Page 88: ...ts Rectify if necessary Visual check Engine and hydraulic system Oil cooling circuit Travelling drive 1 Drain engine oil the first time after 50 s h then every 200 s h 2 Replace the engine oil filter...

Page 89: ...BA DT08 SL EN Edition 1 0 dt08b560 fm 5 29 5 12 Lubrication plan DT08 with skip Explanation Symbol Lubrication point...

Page 90: ...5 30 BA DT08 SL EN Edition 1 0 dt08b560 fm 5 13 Lubrication plan DT08 with high tip skip option Explanation Symbol Lubrication point...

Page 91: ...BA DT08 SL EN Edition 1 0 dt08b560 fm 5 31 Maintenance opening Maintenance opening for cleaning the chassis Unscrew 4 screws to remove housing A Fig 88 Maintenance opening A...

Page 92: ...5 32 BA DT08 SL EN Edition 1 0 dt08b560 fm...

Page 93: ...dling speed 1200 30 rpm 1400 150 rpm Fuel injection system Mechanical governor Electronic ignition Starting aid Reverse starter Battery 12 V 44 Ah 12 V 30 Ah Max inclined position engine no longer sup...

Page 94: ...on 2 sections Max operating pressure 150 5 bar Filter Return filter Hydraulic oil tank 22 3 l 22 3 l Skip Model DT08 D Model DT08 P Struck 334 l Heaped 387 l Liquid capacity 166 l Skip length 1135 mm...

Page 95: ...ective acceleration value for the upper extremities of the body1 1 Measurements as per 2002 44 EC ISO EN 20643 and ISO TR 25398 measurement under the following conditions exca vating driving Machine a...

Page 96: ...achine dimensions model DT08 D with skip Main data Model DT08 D Payload 500 kg Dead weight incl skip and loader unit 560 kg Length 1660 mm Width 790 mm Height 1313 mm Foothold projection 387 mm Track...

Page 97: ...12 442 Fig 90 Machine dimensions model DT08 D with high tip skip Main data Model DT08 D Payload 500 kg Dead weight incl skip and loader unit 625 kg Length 1545 mm Width 790 mm Height 1240 mm Foothold...

Page 98: ...Machine dimensions model DT08 P with skip Main data Model DT08 P Payload 500 kg Dead weight incl skip and loader unit 515 kg Length 1660 mm Width 790 mm Height 1313 mm Foothold projection 388 mm Trac...

Page 99: ...92 Machine dimensions model DT08 P with high tip skip Main data Model DT08 P Payload 500 kg Dead weight incl skip and loader unit 580 kg Length 1540 mm Width 790 mm Height 1180 mm Foothold projection...

Page 100: ...15 Fuses Loader unit option Electrical system Model DT08 D Model DT08 P Dynamo 12 V 15 A 12 V 1 A Starter 12 V 12 V Battery 12 V 44 Ah 12 V 30 Ah Fig 93 Diesel engine fuse Fig 93 Petrol engine fuse F...

Page 101: ...h have already been delivered and which will not be implemented on these machines Technical data dimensions and weights are given as an indication only Responsibility for errors or omissions not accep...

Page 102: ...cker Neuson Linz GmbH Haidfeldstr 37 A 4060 Linz Leonding Austria Tel 43 0 732 90 5 90 0 Fax 43 0 732 90 5 90 200 E mail office linz wackerneuson com www wackerneuson com Order no 1000268368 Language...

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