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Wacker Neuson DV60, Operator'S Manual

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4-32

BA D24 en/us* 1.0 * D24_1_0_400.fm

4 Putting into operation

Status indicators

Symbol

Starter/engine start

starting key in position

1

Engine operating mode

Coolant temperature

If the coolant temperature is too high the symbol shown on the left appears and
the buzzer sounds.
• Let the engine run at high idling speed without any load.
• Wait until the temperature drops and the indicator light goes out.
• Stop the engine.
• Check the coolant level.

Fuel tank capacity

Refuel if the symbol shown on the left appears.

Time

Operating hours

Maintenance meter

Counts the remaining engine operating hours down to the next maintenance
work due.

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Summary of Contents for DV60

Page 1: ...ne models D24 01 D24 02 D24 03 Edition 1 0 Document order no 1000409070 Language en us Series number DV60 WNCD2401CPAL00160 DV90 WNCD2402CPAL00160 DV100 WNCD2403EPAL00160 Operator s manual Dual View T...

Page 2: ...n delivered and that will not be implemented on these vehicles Technical data dimensions and weights are only given as an indication Non metric values are rounded off Responsibility for errors or omis...

Page 3: ...1 Cab control console 4 1 4 2 Overview of control elements 4 19 4 3 Control and warning lights overview 4 24 4 4 Preparatory work 4 33 4 5 Starting and stopping the engine 4 35 5 Operation 5 1 Steeri...

Page 4: ...ir conditioning system 7 33 7 15 Washer system 7 33 7 16 Axles 7 33 7 17 Braking system 7 33 7 18 Tyres 7 34 7 19 Maintenance of attachments 7 35 7 20 Maintenance of options 7 35 8 Malfunctions 8 1 En...

Page 5: ...ch Germany Distinguishing EU number 0515 For 2000 14 EG notified body involved in procedure T V S D Industrie Service GmbH Westendstr 199 D 80686 Munich Directives and standards We hereby declare that...

Page 6: ...09 80687 Munich Germany Distinguishing EU number 0515 For 2000 14 EG notified body involved in procedure T V S D Industrie Service GmbH Westendstr 199 D 80686 Munich Directives and standards We hereby...

Page 7: ...9 80687 Munich Germany Distinguishing EU number 0515 For 2000 14 EG notified body involved in procedure T V S D Industrie Service GmbH Westendstr 199 D 80686 Munich Directives and standards We hereby...

Page 8: ...EG 4 BA D24 en us 1 0 D24_1_0_konf fm Declaration of conformity...

Page 9: ...operator s manual is aimed at new professional operating personnel or those yet to be trained Operator qualification and requirements for safe operation Among other things safe reliable vehicle operat...

Page 10: ...y maintenance work is carried out according to the maintenance plan The maintenance work and the handover inspection are carried out by an authorized service center and entered in the service log Exem...

Page 11: ...ontinuation of an alphabetical list Cross references see page 1 1 page Cross references 7 pos no or table no Cross references Fig 3 Fig no 1 Cross references see chapter 5 Operation on page 5 1 see ch...

Page 12: ...imately DPF Diesel particulate filter etc et cetera FGPS Front Guard Protective Structure FOPS Falling Objects Protective Structure if nec if necessary max maximum min minimum Item Position ROPS Roll...

Page 13: ...eration does not include maintenance work that only an authorized service center is allowed to perform Cab Closed safety component for the operator The term cab is used in this opera tor s manual for...

Page 14: ...left front rear The terms refer to the main travel direction 1 Left 2 Right 3 Front 4 Rear Main travel direction seat position facing the drive unit A Side travel direction seat position facing the l...

Page 15: ...n Volume unit 1 cm 0 061 in 1 m 35 31 ft 1 ml 0 034 US fl oz 1 l 0 26 gal 1 l min 0 26 gal min Unit of length 1 mm 0 039 in 1 m 3 28 ft Weight 1 kg 2 2 lbs 1 g 0 035 oz Pressure 1 bar 14 5 psi 1 kg cm...

Page 16: ...1 8 BA D24 en us 1 0 D24_1_0_100 fm 1 Foreword...

Page 17: ...ded Consequences in case of non observance Avoidance of injury or death WARNING WARNING identifies a situation that can cause death or serious injury if it is not avoided Consequences in case of non o...

Page 18: ...e operator the authority to refuse safety instructions from third parties Have the vehicle serviced and repaired only by an authorized service center Required knowledge of the operator The operator is...

Page 19: ...ed use and the instructions set forth in this Operator s Manual The operator and owner are obligated not to put a damaged or malfunctioning vehicle into operation or operate it If a damage or malfunct...

Page 20: ...and operate the vehicle only with the seat belt fastened and only from the place provided for this Check the condition and the fastening of the seat belt Have malfunc tioning seat belts and mounting h...

Page 21: ...k of carbon monoxide poisoning Use existing visual aids to stay aware of the danger zone In conditions of darkness and poor visibility switch on existing work lights and ensure that motorists are not...

Page 22: ...example protective structures such as a cabin or rollbar removable safety devices is installed and functional Check the vehicle for visible damage and defects In case of damage and or unusual behavio...

Page 23: ...direction Never get on a moving vehicle and never jump off the vehicle Machine travel on public roads sites The specific national driving license is required Observe the national regulations for examp...

Page 24: ...rake suitable wheel chocks Remove the starting key and secure the vehicle against unauthorized operation 2 5 Lifting gear applications Requirements Have loads fastened and the operator guided by a qua...

Page 25: ...oads must be fastened so as to prevent them from slipping or falling Move loads only on horizontal level and firm ground Move loads close to the ground In order to avoid oscillating movements of loads...

Page 26: ...er the load Stop the vehicle immediately and stop the engine if persons enter the danger zone Use the machine for lifting gear applications ONLY if the mandatory lifting gear for example a joint rod a...

Page 27: ...rning circle Before hitching unhitching the trailer secure it to prevent it from rolling away for example with the parking brake suitable wheel chocks There must be nobody between the vehicle and the...

Page 28: ...ving the seat Removing and fitting attachments Before uncoupling or coupling hydraulic connections Stop the engine Release the pressure in the operating hydraulics Picking up and lowering attachments...

Page 29: ...ble speed and itinerary A tractor vehicle of the same weight category must be used as a minimum Furthermore the tractor vehicle must be equipped with a safe braking system and sufficient tractive powe...

Page 30: ...within sight or sound of him Observe all movements of the vehicle and lifting gear Secure the vehicle against unintentional movement Raise the vehicle only after it is safely attached and the person...

Page 31: ...hines of the German employers liability insurance association for construction engineering Bear in mind the weather conditions for example ice snow Ensure the minimum load on the steering axle s of th...

Page 32: ...f two Both persons must be authorized and trained for the operation of the vehicle One person must be seated on the seat and stay in contact with the second person Keep a safe distance from rotating p...

Page 33: ...med under a raised machine attachment support the machine attachment for example with a lift platform trestles ensuring safety and stability Hydraulic cylinders or jacks alone do not sufficiently secu...

Page 34: ...d by an authorized service center Have retrofitting work only performed by an authorized service center Replace self locking fasteners for example self locking nuts by new ones after removing them 2 1...

Page 35: ...rvals even if no visual defects can be detected Electrical system Use only fuses with the specified current rating In case of damage or malfunction in the electrical system Put the vehicle out of oper...

Page 36: ...ic substances for example sulfuric acid When handling the battery observe the specific safety instructions and regulations relevant to accident prevention A volatile oxyhydrogen mixture forms in batte...

Page 37: ...fuel lines Don t start or let the engine run in case of leaks Breathing the exhaust fumes causes death very quickly Engine exhaust contains gases you cannot see or smell for example carbon monoxide an...

Page 38: ...nt for example with a breathing mask Do not operate the vehicle in radioactively biologically or chemically contaminated areas Fire hazard Fuel lubricants and coolants are flammable Do not put the veh...

Page 39: ...ured accordingly If live supply lines are touched nevertheless Do not leave touch the cab Faraday cage If possible drive the vehicle out of the danger zone Warn others against approaching and touching...

Page 40: ...ctors Do not wear ear protectors during machine travel on public roads sites Cleaning Risk of injury from compressed air and high pressure cleaners Wear appropriate protective clothes Do not use any d...

Page 41: ...ion 3 3 Introduction 3 1 Machine overview Fig 2 symbolic representations 1 6 3 4 2 5 7 nr Designation nr Designation 1 Drive unit 5 Seat console 2 Loader unit 6 Tilt cylinder 3 Engine cover maintenanc...

Page 42: ...0 fm 3 Introduction Fig 3 symbolic representations 5 7 8 9 3 1 4 2 6 nr Designation nr Designation 1 Drive unit 6 Tilt cylinder 2 Loader unit 7 Skip 3 Articulation 8 Swiveling console 4 Steering cylin...

Page 43: ...ith minimum environmental impact The application area is mainly moving soil gravel and debris Overview of models and trade names Information The machine can be equipped with the Telematic option for t...

Page 44: ...missing or damaged labels An insufficient warning of dangers can cause serious injury or death Do not remove warning and information labels Immediately replace damaged warning and information labels...

Page 45: ...Fahrzeug Modell model mod le Machine designation Leistung performance Engine power Typ version Machine model Betriebsgewicht operating weight poids en charge Operating weight Transportgewicht transpo...

Page 46: ...components for example Easy Lock tilt bucket rollbar have numeric serial numbers only Rollbar type label The type label is located on the right on the rollbar Cabin type label option The type label is...

Page 47: ...BA D24 en us 1 0 D24_1_0_300 fm 3 7 Introduction 3 Warning labels Fig 9...

Page 48: ...ROPS bar on the left Meaning Read the Operator s Manual before starting the vehicle Remove the starting key and carry it with you Injury hazard due to rotating parts Open the maintenance flap only at...

Page 49: ...ter pivot prop before crane lifting the machine Position Near the center pivot prop and the maintenance prop of the skip Meaning Distance articulation range Keep a safe distance from the machine durin...

Page 50: ...rear on the left Meaning This label shows the following information regulations Maximum payload of machine Tilt out only in straight machine position Maximum permissible angle of inclination during m...

Page 51: ...BA D24 en us 1 0 D24_1_0_300 fm 3 11 Introduction 3 Information labels Fig 21...

Page 52: ...on At the lifting eyes Meaning Machine tie down points Position At the tie down points Meaning Only refuel with diesel fuel with a sulfur content of less than 15 mg kg 0 0015 Position Next to the fuel...

Page 53: ...s on the vehicle Position At the drive unit on the left Meaning This label explains the raising process of the vehicle Position At the rear of the skip Meaning Indication of maintenance intervals Posi...

Page 54: ...at Meaning Tire pressure Position At the rear of the skip Meaning Thermal stability of coolant Position On the radiator in the engine compartment Meaning Battery master switch Position At battery mast...

Page 55: ...1 0 D24_1_0_300 fm 3 15 Introduction 3 Meaning Indication of lubrication intervals Position At the rear of the skip Information Type quantity and position of the labels depend on options country and v...

Page 56: ...3 16 BA D24 en us 1 0 D24_1_0_300 fm 3 Introduction ANSI label option Fig 38...

Page 57: ...roduction 3 Position On the air filter in the engine compartment Position On the B pillar cab or on the ROPS bar on the right Position On the air filter in the engine compartment Position At the rear...

Page 58: ...3 18 BA D24 en us 1 0 D24_1_0_300 fm 3 Introduction Position On the battery cover Position On the battery cover Position On the skip on the left and right Fig 43 Fig 44 Fig 45...

Page 59: ...BA D24 en us 1 0 D24_1_0_300 fm 3 19 Introduction 3 Position On the B pillar on the left Position On the B pillar on the left Fig 46 Fig 47...

Page 60: ...BA D24 en us 1 0 D24_1_0_300 fm 3 Introduction Position On the B pillar on the left Position On the inside of the engine cover Position On the maintenance flap on the left and right Fig 48 Fig 49 Fig...

Page 61: ...ntenance flap on the left Position On the B pillar cab or on the ROPS bar on the right Position On the vehicle frame on the left and right Position On the ROPS bar Position At the parking brake switch...

Page 62: ...3 22 BA D24 en us 1 0 D24_1_0_300 fm 3 Introduction...

Page 63: ...he vehicle when getting on and off Face the vehicle as you enter and leave it Immediately have damaged stages and handholds replaced Do not operate the vehicle CAUTION Risk of injury due to incorrectl...

Page 64: ...the door Open Pull on door handle B Close Close the door applying firm pressure Securing an open door Press bracket C firmly against arrester D Releasing the door arrester Pull button E Opening the do...

Page 65: ...only possible on one side Main travel direction emergency exit left Side travel direction emergency exit right WARNING Injury hazard when leaving the cabin in an emergency An emergency exit can cause...

Page 66: ...bited for operators weighing less than 50 kg 110 lbs or more than 140 kg 309 lbs Information The seat can be fitted with an optional operator presence switch The traveling drive shifts to neutral as s...

Page 67: ...ment Adjusting the backrest 1 Sit down on the operator seat 2 Actuate handle A and move the backrest to the required position at the same time 3 Release handle A Adjusting the weight 1 Sit down on the...

Page 68: ...0 fm 4 Putting into operation Set in lengthwise direction 1 Sit down on the operator seat 2 Pull lever C upward and at the same time lock the seat in the required position 3 Release the lever C Fig 67...

Page 69: ...ce it over hard edged or fragile items in your clothes Ensure that the buckle is inserted pull test Do not use seat belt extensions WARNING Injury hazard due to damaged or dirty seat belt A damaged or...

Page 70: ...nto operation Insert buckle latch A into seat belt buckle B until it engages Release seat belt Press the red push button switch C on seat belt buckle B until the buckle latch comes out Seat belt D is...

Page 71: ...e seat console 1 Sit down on the operator seat 2 Place your feet on the seat console 3 Apply the parking brake 4 Set the forward reverse control A to position N 5 Ensure that no objects are in the rad...

Page 72: ...4 10 BA D24 en us 1 0 D24_1_0_400 fm 4 Putting into operation Fig 72 Fig 72 Holding positions of the control console B C...

Page 73: ...if necessary for example a camera mirrors bystander Additional equipment must not be installed if it impairs visibility WARNING Accident hazard due to incorrect adjustment of visual aids Incorrectly a...

Page 74: ...rs on left and right Ensure sufficient visibility from the seat of the work areasite Ensure maximum visibility to the loader unit Ensure visibility of the rear left edge of the vehicle in the mirror o...

Page 75: ...sion is restricted if the skip is tilted Fire extinguisher A fire extinguisher is not available from Wacker Neuson Contact a Wacker Neuson service center for the installation of a fire extinguisher DI...

Page 76: ...ifications for example drilling weaken the structure and causes serious injury or death No drilling cutting or grinding Do not install any brackets No welding straightening or bending Replace the comp...

Page 77: ...ional regulations and must inform the operator on the protective structure to be used in a specific work situation Cabin FOPS category II Information The cabin complies with the FOPS category level II...

Page 78: ...passage DANGER Accident hazard during machine operation with a lowered rollbar Can cause serious injury or death Only drive on flat and load bearing subsurfaces Do not fasten the seat belt in order t...

Page 79: ...safety pin B Raising the rollbar 1 Park the machine on level ground 2 Remove safety pin B 3 Remove safety bolt C 4 Raise the rollbar A 5 Affix the lock pin C in the desired position 6 Secure with safe...

Page 80: ...the engine see Preparing lubrication on page 7 6 2 Put the skip grid on the assembly points with at least two persons Use suitable external climbing aids 3 Tighten the four screws B to 410 Nm 302 ft...

Page 81: ...the seat 12 V connection option A 12 V connection A is located beside the storage compartment of the cab 4 2 Overview of control elements This chapter describes the controls and contains information...

Page 82: ...verview of control elements 8 10 7 1 3 9 4 2 5 6 Designation See page 1 Seat with seat belt 4 4 2 Document box 4 19 3 Seat console 4 9 4 Steering column lever 5 13 5 Service brake 5 3 6 Seat console l...

Page 83: ...8 9 11 10 Designation See page 1 Seat with seat belt 4 4 2 Document box 4 19 3 Seat console 4 9 4 Steering column lever 5 13 5 Service brake 5 3 6 Seat console lever 4 9 7 Accelerator pedal 5 2 8 Dis...

Page 84: ...Horn 4 Horn option 5 Road travel lights option 6 Turn indicators option 7 Front window wiper wash system option 8 Rear window wiper wash system option 9 Test parking brake 10 Auto stop option Steering...

Page 85: ...D24_1_0_400 fm 4 23 Putting into operation 4 11 Parking brake 12 Road working mode 13 Hazard warning system option 14 Rotating beacon option 15 Working lights option 16 Air conditioning option 17 Ven...

Page 86: ...ning lights overview Display element multifunctional display The display element and the multifunctional display informs the operator of the operating states required maintenance or possible machine m...

Page 87: ...operation 4 Information The indicator lights are tested when the starter is engaged and are illuminated for a few seconds Information The indicator lights shown are only selected examples All possible...

Page 88: ...ndicator light 4 Red Parking brake 5 3 5 Red Fault at exhaust after treatment Yellow High exhaust gas temperatures 6 Red Drive combined fault Red ECU error indicator light Yellow ECU warning light 7 Y...

Page 89: ..._400 fm 4 27 Putting into operation 4 13 Blue Speed range 1 5 2 Blue Speed range 2 14 Blue Engine operating mode Green Blue Red Work hydraulics deactivated 5 7 Green Work hydraulics activated nr Symbo...

Page 90: ...4 28 BA D24 en us 1 0 D24_1_0_400 fm 4 Putting into operation 15 Blue Travel direction 5 6 16 Green Road travel mode 5 7 Green Operating mode 5 7 Red Skip tipped nr Symbol Color Designation See...

Page 91: ...24 en us 1 0 D24_1_0_400 fm 4 29 Putting into operation 4 17 Green Main travel direction 1 5 Green Side travel direction Red Seat not engaged 4 9 Red Seat not occupied 4 4 nr Symbol Color Designation...

Page 92: ...the following symbols are displayed for a few seconds in the multi functional display Error symbols are listed according to priority Symbol Designation Symbol Designation Air filter Overspeed Hydraul...

Page 93: ...ving direction Seat not engaged Reverse travel direction Seat not occupied Speed range 1 Overspeed Speed range 2 Cold drive lockout Engine start interruption Speed increase Overspeed Engine auto stop...

Page 94: ...igh the symbol shown on the left appears and the buzzer sounds Let the engine run at high idling speed without any load Wait until the temperature drops and the indicator light goes out Stop the engin...

Page 95: ...BA D24 en us 1 0 D24_1_0_400 fm 4 33 Putting into operation 4 Machine status multifunctional display Abb 87 H H G F D C A E B...

Page 96: ...A Engine error B Controlling error C Engine data D Machine data E Diesel particulate filter data Option F Dispaly data G Adjustment of multi functional display H No error Adjusting the multi functiona...

Page 97: ...BA D24 en us 1 0 D24_1_0_400 fm 4 35 Putting into operation 4 Enlarge camera image Abb 89...

Page 98: ...djusted in accordance with the instructions in this operator s manual The operator must follow the national and regional regulations Follow the safety instructions in the safety chapter see chapter Op...

Page 99: ...ine at high speed for extended periods Observe the maintenance plans see chapter 7 2 Maintenance overview on page 7 2 Road traffic regulation accessories Information Observe the national and regional...

Page 100: ...starter cannot be actuated if the engine is already running start repeat interlock Do not run the starter for more than 30 seconds Wait two minutes so the battery can recover and the starter does not...

Page 101: ...l pressure illuminates 10 Turn and hold the starting key in position 2 until the engine starts Release the starting key All indicator lights go out If the engine does not start after 30 seconds Interr...

Page 102: ...phase After reaching the operating temperature the engine can be operated under full load The engine reaches its operating temperature more quickly at low engine speed and under load This is more effi...

Page 103: ...ar protective equipment WARNING Injury hazard due to rotating parts Rotating parts can cause serious injury or death Open the maintenance flap only at engine standstill NOTICE Damage to machine due to...

Page 104: ...lace the battery jumper cables near rotating parts Information Use only authorized battery jumper cables which conform to national and regional safety requirements Designations symbols Meaning X Machi...

Page 105: ...e of vehicle Y run 3 Unlock cover E and open 4 Remove cover from positive terminal A 5 Connect the battery jumper cables in the following order A B C D 6 Wait five minutes for the empty battery to be...

Page 106: ...ilter regeneration cycles only in case of Tier IV Reduced engine oil replacement intervals Stopping the engine NOTICE Possible damage to the engine when it is stopped after running under high load Let...

Page 107: ...battery master switch no sooner than two minutes after shutting down the engine Actuate the battery isolator switch If the vehicle is parked for longer periods of time e g over the weekend If the veh...

Page 108: ...4 46 BA D24 en us 1 0 D24_1_0_400 fm 4 Putting into operation...

Page 109: ...n 5 1 Steering system The vehicle is equipped with articulated steering The steering wheel actuates a hydraulic cylinder which pivots the drive unit A Emergency steering features If the engine or the...

Page 110: ...e button A on the joystick Keep the service brake pressed to change over The machine must be at a standstill Accelerator pedal Accelerator pedal C is located on the right in the leg room Speed is cont...

Page 111: ...l speed with service brake A Parking brake The parking brake A is located in the switch panel to the right on the control stand WARNING Accident hazard Do not operate the unlocking device during machi...

Page 112: ...there are doubts as to the correct brake function Contact a Wacker Neuson service center and have the malfunction rectified Requirements The test track must be horizontal even and have a high load be...

Page 113: ...The selected travel direction appears in the display 5 Press the accelerator pedal and increase the engine speed to 1400 rpm The machine must not move 6 Release accelerator pedal 7 Release button D 8...

Page 114: ...death Ensure that the surrounding area is clear Set the forward reverse control to the required position before starting machine travel WARNING Accident hazard due to machine rolling away under its ow...

Page 115: ...e 1 Start the engine see chapter Starting the engine on page 4 39 2 Lower the skip 3 If the machine is equipped with a swivel skip ensure that it is in the middle position 4 Press the service brake 5...

Page 116: ...side the vehicle Do not exceed the permissible payloads Do not turn or dump out a full skip during uphill or downhill machine travel Dump out the skip on slopes only on the uphill side of the machine...

Page 117: ...phill or downhill vehicle travel in a straight line When changing position do not exceed a maximum gradient angle of 14 25 and a maximum lateral angle of inclination of 14 25 Change position on level...

Page 118: ...ded skip When using the machine to travel on slopes with an unloaded skip the loader unit of the machine must always face the downhill side of the slope whichever the direction of travel Do not perfor...

Page 119: ...the machine accordingly for example with chocks 1 Park the vehicle on firm level and horizontal ground The machine may be parked on a slope only if it cannot be avoided Park the machine only transver...

Page 120: ...ite can be ensured without blinding other motorists Information Switch on the working lights in conditions of poor visibility If illumination still is not sufficient use external lights If this still...

Page 121: ...Position Switch off the lights Turn ring A to position 0 Switch on the side marker lights Turn ring A to position 1 Switch on low beam Turn ring A to position 2 Switch on the high beam Pull the steer...

Page 122: ...tton B on the steering column lever option for Austrian road traffic regulations StVZO Rotating beacon option Switch A is located on the switch panel on the right Fig 118 Fig 118 A Fig 119 Fig 119 B F...

Page 123: ...ng beacon C lights up when the operator s seat belt is fastened Turn indicators The steering column lever is located on left of the steering wheel Operating the turn indicators on the steering column...

Page 124: ...m 5 Operation Hazard warning system The switch is located on the switch panel on the right Fig 124 A Function Position Switch off the hazard warning sys tem Press switch A upward Switch on the hazard...

Page 125: ...llow the national and regional regulations 5 7 Wiper wash system option The switch is located on the switch panel on the right Switch A front window wiper Switch B rear window wiper Reservoir C for th...

Page 126: ...itch on the air conditioning system once a month for at least 10 15 minutes to ensure its full function and efficiency Abb 127 A Function Position Switch off the fan Press switch A all the way up Fan...

Page 127: ...ator is supported by a bystander Do not tilt out the skip if material is stuck in the skip Remove the material from the skip with a suitable tool Keep a safe distance for example from buildings edges...

Page 128: ...n N Lower the skip only in the straight position to avoid damage to the lock Fig 130 Fig 130 A B N Function Operation Tilt out the skip Press control lever A forward Lower the skip Pull control lever...

Page 129: ...s different from the one on a level surface secure the load Stop vehicle operation immediately as soon as someone enters the danger area see chapter Vehicle travel on slopes on page 5 8 Seal off the d...

Page 130: ...and damage The hydraulic system of the machine is still pressurized even when the engine is not running Release the pressure in the hydraulic system before starting repair work Before tilting out the...

Page 131: ...es of the Dual View Truck sufficiently dimensioned for the excavator that is loading the Dual View Truck Observe the national and regional regulations Preparations 1 Lower the skip 2 Move the control...

Page 132: ...position Lower the skip completely If the machine is equipped with a swivel skip ensure in addition that the skip is in the middle position Middle position of swivel skip General information regarding...

Page 133: ...han to the middle of the axles Information Operation in salt water is prohibited When leaving the water take special care not to immerse the rear end of the machine in the water in particular the exha...

Page 134: ...the vehicle Scope of delivery includes 2 keys B master key red Information Store the master key in a safe place It can only be used for coding new starting keys A new immobilizer must be installed if...

Page 135: ...quiring coding is detected by the system within 15 seconds Deleting coded keys Deleting all coded keys is necessary whenever a coded key is lost The master key code is not deleted during deletion 1 In...

Page 136: ...s Ensure that all lights and associated indicator lights are functional The plug receptacle D for the power supply of auxiliary units is located at the rear of the vehicle NOTICE Only attach the hitch...

Page 137: ...n a suitable place see chapter 7 5 Cleaning and maintenance on page 7 14 3 Check the machine for leaks and loose nuts screws and connections 4 Carefully clean and dry the entire vehicle 5 Spray an ant...

Page 138: ...uel system on page 7 20 8 Check the vehicle for leaks 9 Lubricate the vehicle according to the lubrication plan 10 Check all engine machine fluids in the units or reservoirs and add fluids if necessar...

Page 139: ...center ensure machine disposal Observe the national guidelines regarding disposal Environment Do not allow environmentally damaging wastes to get into the ground or stretches of water and dispose of t...

Page 140: ...5 32 BA D24 en us 1 0 D24_1_0_510 fm 5 Operation Notes...

Page 141: ...equal to 1 5 times the length of the towing equipment Do not tow the vehicle if it is stuck or on a slope Load the vehicle The machine cannot be steered when the hydraulic oil reservoir is empty Allo...

Page 142: ...the machine away only from the immediate danger zone until it can be loaded Do not tow the vehicle if it is stuck or on a slope Load the vehicle Only tow the machine using suitable towing equipment i...

Page 143: ...en us 1 0 D24_1_0_600 fm 6 3 Transportation 6 Disabling the pressure limiting valves Clean the area around the pressure limiting valves Loosen screws A with exactly 3 revolutions Fig 145 Fig 145 Fig...

Page 144: ...hine farther than 20 meters 66 ft Wear protective equipment 1 Secure the machine with chocks to prevent it from rolling 2 Secure the machine at the tie down points with slings of sufficient dimensions...

Page 145: ...f subsequently installed equipment to the weight of the machine Get off a transport vehicle only with the help of a bystander Tie down points Preparations 1 see chapter Transportation on page 2 15 2 P...

Page 146: ...ave the control stand If the machine is equipped with a cabin option close and lock the door windows and all covers Center pivot prop WARNING Crushing hazard due to machine steered via the articulatio...

Page 147: ...allow anyone to stay in the danger zone Read the transport weight off the type label Add the weight of subsequently installed equipment to the weight of the machine The vehicle may only be raised wit...

Page 148: ...prop in place see Center pivot prop on page 6 6 10 Use suitable lifting gear chain etc 11 Put the lifting gear through bracket A on the edge of the skip and fasten it on lifting eyes B on the left and...

Page 149: ...efore transporting the machine through wet weather Close the exhaust pipe 4 The driver of the transport vehicle must observe the following before departure Permitted overall height width and weight of...

Page 150: ...6 10 BA D24 en us 1 0 D24_1_0_600 fm 6 Transportation Notes...

Page 151: ...ions Important safety instructions on maintenance Follow all safety instructions given in this Operator s Manual Follow the instructions given in chapter Safety safety instructions on maintenance and...

Page 152: ...med by the operator is indicated on the maintenance label I Checking functions and levels filling up and draining II Checking wear parts seals hoses and screw connections III Checking for damage corro...

Page 153: ...the engine air intake 7 27 Check the pin locks Check line fixtures Check the indicator lights and acoustic warning devices 4 24 Check the service and parking brake function 5 4 Check the screw connect...

Page 154: ...engine compartment for damage Check the cabin and protective structures for damage for example the rollbar Check the piston rods of the cylinders for damage Check the seat belt for damage 7 16 Check...

Page 155: ...rding to the indicator light every 1000 o h or once a year at the latest Replace after 50 o h when in extensive use in environments with acidic air such as acid production facilities steel and aluminu...

Page 156: ...el skip 3 Stop the engine 4 Remove the starting key and carry it with you 5 Safely store all loose objects 6 Close the windows and doors cab option 7 Close and lock all covers 8 Attach a warning label...

Page 157: ...Before starting maintenance lower the red maintenance prop when the skip is raised and secure the skip with it Fig 158 3 6 1 5 1 4 2 7 3 4 Position Lubrication point Quantity 1 Articulation 3 2 Steeri...

Page 158: ...oil reservoir Hydraulic oil Eurolub HVLP 464 4 According to DIN 51524 section 3 ISO VG 46 Year round5 5 Depending on local conditions see Engine oil types on page 7 9 60 liters 15 9 gal Biodegradable...

Page 159: ...0W30 35 31 30 86 SAE 0W40 35 31 40 104 SAE 5W30 30 22 30 86 SAE 5W40 30 22 40 104 SAE 10W30 15 5 30 86 SAE 10W40 15 5 40 104 SAE 15W40 15 5 40 104 SAE 20W50 5 23 40 104 Hydraulic oil types Viscosity...

Page 160: ...ional and regional regulations as you replace it Observe the manufacturer s indications Do not add mineral oil the content of mineral oil should not exceed 2 of the system fill in order to avoid foami...

Page 161: ...the engine and let hot surfaces cool down Wear protective equipment WARNING Injury hazard due to rotating parts Rotating parts can cause serious injury or death Open the maintenance flap only at engi...

Page 162: ...intenance accesses Fig 159 Maintenance accesses 1 3 6 4 5 2 Item Designation Item Designation 1 Reservoir filler inlet 4 Battery circuit breaker jump start equipment 2 Hydraulic oil filler inlet 5 Eng...

Page 163: ...er is supported by a gas strut Closing the engine cover 1 Firmly pull engine cover downwards by handle B until the engine cover locks into place 2 Turn the starting key in lock A clockwise Fan grid Th...

Page 164: ...leaning agents can be harmful to health Use only suitable cleaning agents Ensure sufficient ventilation NOTICE Damage to rubber and electrical parts when cleaning with solvents Do not use solvents ben...

Page 165: ...e cleaner Cover electric parts Do not point the water jet directly at electric parts and damping material Cover the breather filter on the hydraulic oil reservoir and the covers of the fuel tank and t...

Page 166: ...n destroy the fabric Cleaning in a saline environment 1 Park the vehicle in a wash bay or place see Preparing lubrication on page 7 6 2 Check the vehicle for salt deposits or corrosion Have corrosion...

Page 167: ...he fuel system Do not run the fuel tank completely dry Information In order to prevent the formation of condensation water fully fill up the fuel tank at the end of each working day Diesel fuel specif...

Page 168: ...not refuel in closed rooms Do not add gasoline to diesel fuel Let the engine cool down CAUTION Health hazard due to diesel fuel Diesel fuel and fuel vapors are harmful to health Avoid contact with the...

Page 169: ...smallest particles of dirt can cause increased engine wear malfunctions in the fuel system and reduced effectiveness of the fuel filters Refueling from barrels If refueling from barrels cannot be avo...

Page 170: ...ommissioned for more than 30 days Bleeding 1 Stop and park the vehicle Stop the engine see Preparing lubrication on page 7 6 2 Fill up and close the fuel tank 3 Turn the starting key to the first posi...

Page 171: ...onnect a suitable hose to the drain device A 5 Disconnect electrical connection C 6 Remove the vent screw D 7 Open drain valve B 8 Drain the fuel water mixture into a receptacle 9 Close drain valve B...

Page 172: ...ne oil according to the Fluids and lubricants list Have the oil changed only by a Wacker Neuson service center Add the engine oil slowly so it can go down without entering the intake system The oil le...

Page 173: ...he engine cover Adding engine oil 1 Stop and park the vehicle Stop the engine see Preparing lubrication on page 7 6 2 Open the engine cover 3 Wipe the area around the sealing push in cap with a lint f...

Page 174: ...mmable fluids that can cause serious burns or death if they are brought into contact with fire or open flames Wear protective equipment Only perform maintenance on an engine that has cooled down Fire...

Page 175: ...ngine cover Adding coolant 1 Stop and park the vehicle Stop the engine see Preparing lubrication on page 7 6 2 Open the engine cover 3 Carefully unscrew filler cap B and release the pressure 4 Open fi...

Page 176: ...ance from the radiator during cleaning Use oil free compressed air 2 bar 29 psi max to clean Water hydraulic oil radiator The water hydraulic oil radiators are located behind the fan grid A 1 Stop and...

Page 177: ...a day before putting the vehicle into operation 1 Stop and park the vehicle Stop the engine see Preparing lubrication on page 7 6 2 Remove the starting key and carry it with you 3 Check and if necessa...

Page 178: ...vehicle with leaking or damaged hydraulic system components Open the breather filter carefully to slowly release the pressure inside the reservoir Wear protective equipment If hydraulic oil contacts t...

Page 179: ...ed at the rear left 6 Check the oil level on sight glass A If the engine is warm the oil level must be approximately at the middle of sight glass A Add hydraulic oil if the oil level is below this mar...

Page 180: ...and hose connections only when the system is not under pressure Release the pressure before working on pressure lines Do not weld or solder damaged or leaking pressure lines and screw connections but...

Page 181: ...nnect the grounding strap of the battery before starting repair work on the electrical system Do not place conductive articles on the battery risk of short circuit NOTICE Possible damage to electrical...

Page 182: ...he battery Have this performed only by a Wacker Neuson service center Replacing the battery The battery is maintenance free However have the battery checked at regular intervals to ensure that the ele...

Page 183: ...r mat 1 Stop and park the vehicle Stop the engine see Preparing lubrication on page 7 6 2 Check the fill level in the reservoir A and add a cleaning solution glass cleaner if necessary 7 16 Axles Have...

Page 184: ...ation Depending on load work and ground conditions the extent of wear of the tires can be different Therefore interchange the tires regularly to ensure identical rolling properties Information If a da...

Page 185: ...000 kg 11 023 lbs under the axle mounting ensuring stability 6 Raise the machine on the side where you want to change a wheel 7 Check the machine is standing firmly 8 Secure the machine with trestles...

Page 186: ...7 36 BA D24 en us 1 0 D24_1_0_710 fm 7 Maintenance...

Page 187: ...gine power Contact a Wacker Neuson service center Flashes On Engine is about to be shut down or is already shut down Stop the engine immediately and contact a Wacker Neuson service center Engine warn...

Page 188: ...arking brake applied Release the parking brake 5 3 No travel direction selected Select a travel direction 5 6 Engine speed too low Press the accelerator pedal 5 2 Operator is not sitting on the seat a...

Page 189: ...achine pulls to the right or left Damaged steering cylinder Contact a Wacker Neuson service center Uneven wear of the tires Contact a Wacker Neuson service center Uneven tire pressure Check the tire p...

Page 190: ...ted in case of major errors Engine power is reduced The traveling drive is disabled Stop and park the vehicle Contact a Wacker Neuson service center and have the malfunction rectified Machine travel a...

Page 191: ...ine management Electronic Displacement 2925 cm3 178 in3 Nominal bore and stroke 92 x 110 mm 3 6 x 4 3 in Rated output at rated speed 55 4 kW at 2200 rpm 74 3 hp at 2200 rpm Engine power at preset maxi...

Page 192: ...rpm 50 Oscillation angle 11 Boost pump DV60 DV90 DV100 Design Gear pump Flow rate 11 6 cm3 rev 0 71 in3 rev Min charging boost pressure 25 bar 363 psi Max charging boost pressure 29 bar 421 psi Hydrau...

Page 193: ...k brake on loader unit axle Location loader unit axle Effect Wheels of drive unit Indirectly via cardan shaft Direct Wheels of drive unit Direct Parking brake DV60 DV90 DV100 Design Wet multidisk brak...

Page 194: ...Priority valve Steering angle design 29 28 3 Turning radius DV60 DV90 DV100 Front skip Drive unit 5894 mm 19 4 6585 mm 21 7 Loader unit 5911 mm 19 5 6547 mm 21 6 Swivel skip Drive unit 5894 mm 19 4 6...

Page 195: ...6 1 gal min Max operating pressure 185 bar 5 bar 2683 psi 73 psi Secondary pressure protection 250 bar 10 bar 3625 psi 145 psi DV60 Main travel direction Side travel direction Speed range 1 Forward 15...

Page 196: ...4_1_0_900 fm 9 Technical data 9 8 Electrical system Electrical components DV60 DV90 DV100 Alternator 12 V 120 A Starter 12 V 3 2 kW Battery1 1 According to DIN EN 50342 DIN IEC 60095 2 12 V 100 Ah 12...

Page 197: ...BA D24 en us 1 0 D24_1_0_900 fm 9 7 Technical data 9 Fuse box Fuse box A is located at the front left in the control console Loosen screws B Fig 180 A B Fig 181...

Page 198: ...tating beacon hazard warning light F015 10A Telematics drive interlock position light rear lights license plate lighting trailer F016 10A Radio interior lighting F017 15A Window wiper washer pump F018...

Page 199: ...elay 20 35A Rotating beacon K130 Relay 20 35A Horn K131 Relay 20 35A 12 V 15 K146 Relay 20 35A Green rotating beacon Fuses relays Rated current Protected circuits DV 60 90 100 Working lights roof ligh...

Page 200: ...1040 767 1480 1092 1770 1305 870 642 1250 922 M30 1420 1047 2010 1482 2400 1770 1200 885 1700 1254 Tightening torques fine pitch thread Property class 8 8 10 9 12 9 8 8 10 9 Screw dimen sions Screws a...

Page 201: ...1 concentration for warm outside temperatures too to ensure protection against corrosion cavitation and deposits Distilled water Coolant2 2 Do not mix the coolant with other coolants up to 37 C 34 6...

Page 202: ...and load Job site organization preparation surroundings weather conditions and material Machine version seat quality quality of suspension system attach ments and condition of attachments Precise indi...

Page 203: ...ation values in earth moving vehi cles Perform correct adjustments and maintenance on the vehicle Avoid jerky movements during vehicle operation Keep slopes in a perfect condition Whole body vibration...

Page 204: ...up and raising loads repeatedly must be limited to a minimum Reference The vibration values and calculations are based on the indications made in ISO TR 25398 Mechanical Vibrations Guidelines for ass...

Page 205: ...p canopy DV60 kg lbs DV90 kg lbs DV100 kg lbs Transport weight1 4225 9315 4725 10 417 4755 10 483 Operating weight2 4343 9575 4844 10 679 4874 10 745 Front skip cabin DV60 kg lbs DV90 kg lbs DV100 kg...

Page 206: ...00 liters 634 gal 2550 liters 674 gal Skip capacity struck 2700 liters 713 gal 3750 liters 991 gal 4150 liters 1096 gal Skip capacity heaped 3600 liters 951 gal 4600 liters 1215 gal 5000 liters 1321 g...

Page 207: ...BA D24 en us 1 0 D24_1_0_900 fm 9 17 Technical data 9 9 15 Dimensions...

Page 208: ...5 7 B4 4476 14 8 4650 15 3 4688 15 5 C1 2440 96 2440 96 2420 95 C2 2533 100 2533 100 2533 100 C3 1221 48 1221 48 1221 48 C4 2218 87 2453 97 C5 2328 92 2524 99 2524 99 D 1790 70 1920 76 1920 76 E 2485...

Page 209: ...I Ignition lock 4 35 Information before putting into operation 4 33 Information on this Operator s Manual 1 1 L Label Warning labels 3 7 Lateral angle of inclination 5 10 Letting the engine warm up 4...

Page 210: ...m 9 6 Engine 9 1 Fuses relays 9 7 Ground clearance ground pressure 9 15 Machine weights 9 15 Maximum speed 9 5 Noise emissions 9 11 Tightening torques 9 10 Traveling drive axles 9 2 Work hydraulics 9...

Page 211: ...have already been delivered and that will not be implemented on these vehicles Technical data dimensions and weights are only given as an indication Responsibility for errors or omissions not accepted...

Page 212: ...Wacker Neuson Linz GmbH Flughafenstr 7 A 4063 H rsching Phone 43 0 7221 63000 Fax 43 0 7221 63000 2200 E mail office linz wackerneuson com www wackerneuson com Order no 1000409070 Language en us...

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