Wacker Neuson DW100 Operator's Manual
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Wacker Neuson DW100 Operator's Manual

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Machine type
Edition
Order no
Language
Operator's Manual
Dumpers
DW60
DW90
DW100
D18-01/D18-02/D18-03
1.1
5100015363
us
5
1
0
0
0
1
5
3
6
3

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Summary of Contents for Wacker Neuson DW100

  • Page 1 Operator's Manual Dumpers DW60 DW90 DW100 D18-01/D18-02/D18-03 Machine type Edition Order no 5100015363 Language...
  • Page 2 – without prior permission in writing from the manufacturer. No reproduction or translation of this publication, in whole or part, without the written consent of Wacker Neuson Linz GmbH.

  • Page 3: Table Of Contents

    Table of contents Table of contents Table of contents 1 Foreword 1.1 Operator’s Manual ..........................1-1 1.2 Warranty and liability ..........................1-7 2 Safety 2.1 Safety symbols and signal words ......................2-1 2.2 Qualification of operating personnel ..................... 2-2 2.3 Conduct ..............................2-3 2.4 Operation ..............................
  • Page 4 Table of contents 7 Maintenance 7.1 Information on maintenance ......................... 7-1 7.2 Maintenance overview .......................... 7-2 7.3 Fluids and lubricants........................... 7-10 7.4 Maintenance accesses ........................7-13 7.5 Cleaning and maintenance ......................... 7-16 7.6 Lubrication work..........................7-19 7.7 Fuel system ............................7-19 7.8 Engine lubrication system........................
  • Page 5 Declaration of conformity Declaration of conformity EC Declaration of Conformity Manufacturer Wacker Neuson Linz GmbH, Flughafenstr. 7, 4063 Hörsching, Austria Product Machine designation Compact Dumper Model/version D18-01 Trade name DW60 Serial number Output in kW Measured sound power level dB(A)
  • Page 6 Declaration of conformity EC Declaration of Conformity Manufacturer Wacker Neuson Linz GmbH, Flughafenstr. 7, 4063 Hörsching, Austria Product Machine designation Compact Dumper Model/version D18-01 Trade name DW60 Serial number Output in kW Measured sound power level dB(A) Guaranteed sound power level dB(A)
  • Page 7 Declaration of conformity EC Declaration of Conformity Manufacturer Wacker Neuson Linz GmbH, Flughafenstr. 7, 4063 Hörsching, Austria Product Machine designation Compact Dumper Model/version D18-02 Trade name DW90 Serial number Output in kW Measured sound power level dB(A) Guaranteed sound power level dB(A)
  • Page 8 Declaration of conformity EC Declaration of Conformity Manufacturer Wacker Neuson Linz GmbH, Flughafenstr. 7, 4063 Hörsching, Austria Product Machine designation Compact Dumper Model/version D18-02 Trade name DW90 Serial number Output in kW Measured sound power level dB(A) Guaranteed sound power level dB(A)
  • Page 9 Declaration of conformity EC Declaration of Conformity Manufacturer Wacker Neuson Linz GmbH, Flughafenstr. 7, 4063 Hörsching, Austria Product Machine designation Compact Dumper Model/version D18-03 Trade name DW100 Serial number Output in kW Measured sound power level dB(A) Guaranteed sound power level dB(A)
  • Page 10 Declaration of conformity EC Declaration of Conformity Manufacturer Wacker Neuson Linz GmbH, Flughafenstr. 7, 4063 Hörsching, Austria Product Machine designation Compact Dumper Model/version D18-03 Trade name DW100 Serial number Output in kW Measured sound power level dB(A) Guaranteed sound power level dB(A)

  • Page 11: Foreword

    Foreword Table of contents Index Foreword 1 Foreword Operator’s Manual Information on this Operator’s Manual The Operator’s Manual is stored in the document box under the seat. This Operator’s Manual contains important information on how to work safely, correctly and economically with the machine. Therefore, it aims not only at new personnel, but it also serves as a reference for experienced personnel.
  • Page 12 1 Foreword Explanation of symbols and abbreviations Explanation of symbols • Identifies a list - Identifies a subdivision of a list Description of a result 1. Identifies an activity Follow the order of the activity! 2. Continuation of an activity Follow the order of the activity! A Identifies an alphabetical list B Continuation of an alphabetical list...
  • Page 13 Foreword 1 Abbreviations (in alphabetic order) Fig. Figure Operating hours approx. approximately particulate matter catalysts FGPS Front Guard Protective Structure FOPS Falling Objects Protective Structure if nec. if necessary max. maximum min. minimum Pos. Position ROPS Roll Over Protective Structure (without losing contact with the ground) TOPS Tip Over Protective Structure e.g.
  • Page 14 1 Foreword Definitions Towing The dumper tows another vehicle on public roads, or is towed itself. The dumper is towed out of an immediate danger zone (for example a railroad Towing crossing or job site). A company (or person) operating the machine. This can be a construction Operating company/person company, for example.
  • Page 15 Foreword 1 Target-group definition This Operator’s Manual is intended both for professional personnel on construction sites accustomed to handling construction machines, and also for private persons, for example, renting and operating a construction machine. The Operator’s Manual has been written in a way that allows machine operation by trained private persons without any special knowledge.
  • Page 16 1 Foreword Conversion table The rounded imperial values are indicated in brackets, for example 1060 cm³ (64.7 in³). Volume unit 1 cm³ (0.061 in³) 1 m³ (35.31 ft³) 1 ml (0.034 US fl.oz.) (0.26 gal) 1 l/min (0.26 gal/min) Unit of length 1 mm (0.039 in) (3.28 ft)

  • Page 17: Warranty And Liability

    • Wacker Neuson Linz GmbH shall not be liable for injury or damage to property that can caused by failure to observe the safety instructions and the Operator’s Manual, and by the negligence of the duty to...
  • Page 18 1 Foreword Notes: BA D18 us* 1.1 * D18v100.fm...

  • Page 19: Safety

    Safety Safety 2 Safety Safety symbols and signal words Explanation The following symbol identifies safety instructions. It is used for warning against potential personal risk or danger. DANGER DANGER identifies a situation causing death or serious injury if it is not avoided.

  • Page 20: Qualification Of Operating Personnel

    • Give the operator the authority to refuse instructions by other persons that are contrary to safety. • Have the machine serviced and repaired only by a Wacker Neuson service center. Required knowledge of operator • The operator is responsible for other persons.

  • Page 21: Conduct

    Do not put the machine into operation or operate it after an accident; have it inspected for damage by a Wacker Neuson service center. - Have the seat belt replaced by a Wacker Neuson service center after an accident, even if there is no visible damage.

  • Page 22: Operation

    2 Safety Operation Preparatory measures • Operation is only allowed with correctly installed and intact protective structures. • Keep the machine clean. This reduces injury, accident and fire hazards. • Safely store objects you carry with you in the places provided for this (for example in the storage compartment, drinks holder).
  • Page 23 Safety 2 Job site • The operator is responsible for other persons. • Before starting work, familiarize yourself with the job site. This applies to, for example: - Obstacles in the job site and machine travel area - Any barriers separating the job site from public roads - Soil weight-bearing capacity - Existing overhead and underground lines - Special operating conditions (for example dust, steam, smoke,...

  • Page 24: Machine Operation

    • Have all malfunctions jeopardizing the safety of the operator or other persons immediately repaired by a Wacker Neuson service center. Starting the engine of the machine • Start the engine only according to the Operator’s Manual.
  • Page 25 Safety 2 Machine travel on public roads/sites • The specific national driving license is required. • Observe the national regulations (for example the road traffic regula- tions) during machine travel on public roads/sites. • Ensure that the machine is in compliance with the national regulations. •...

  • Page 26: Lifting Gear Applications

    2 Safety Lifting gear applications Requirements • Have loads fastened and the operator guided by a qualified person having specific knowledge of lifting gear applications and the usual hand signals. • The person giving instructions to the operator must stay in visual contact with the operator when fastening, guiding or removing the load (maintain visual contact).
  • Page 27 Safety 2 Lifting gear applications • The machine must be certified for lifting gear applications. • Observe the national regulations for lifting gear applications. • Lifting gear applications are procedures involving raising, transporting and lowering loads with the help of lifting and fastening gear. •...

  • Page 28: Trailer Operation

    2 Safety Trailer operation Trailer operation • The machine must be certified for trailer operation. • Observe the national regulations for trailer operation. • The specific national driving license is required. • Carrying passengers on/in trailers is PROHIBITED. • Observe the maximum permissible vertical and trailer load. •...

  • Page 29: Towing, Loading And Transporting

    Safety 2 Removing and fitting attachments • Before uncoupling or coupling hydraulic connections: - Stop the engine - Releasing the pressure in the operating hydraulics • Picking up and lowering attachments to the ground requires special care: - Pick up and safely lock the attachment in accordance with the Operator’s Manual.
  • Page 30 2 Safety Crane-lifting • Seal off the danger zone. • The crane and the lifting gear must have suitable dimensions. • Observe the machine’s overall weight – see “Technical data”. • Wear protective clothing and equipment when fastening, guiding and removing the machine (for example a hard hat, safety glasses, safety boots).

  • Page 31: Maintenance

    Safety 2 Transportation • For the safe transportation of the machine: - The transport vehicle must have a sufficient load capacity and platform – see “Technical data” - The maximum weight rating of the transport vehicle must not be exceeded. •...
  • Page 32 2 Safety Personal safety measures • Avoid any operational mode that might be prejudicial to safety. • Wear protective clothing and equipment (for example a hard hat, protective gloves, safety boots). • Tie back long hair and remove all jewelry. •...
  • Page 33 Safety 2 Preparatory measures • Attach a warning label to the control elements (for example “Machine being serviced, do not start”). • Before performing assembly work on the machine, support the areas to be serviced and use suitable lifting and supporting equipment for the replacement of parts over 9 kg (20 lbs.).
  • Page 34 If damage or defects are detected, have them immediately checked and repaired by a Wacker Neuson service center. • Have retrofitting work only performed by a Wacker Neuson service center. • Replace self-locking fasteners (for example self-locking nuts) by new ones after removing them.

  • Page 35: Measures For Avoiding Risks

    • Leaking hydraulic and compressed-air lines can cause the full loss of the brake effect. • Have damage and leaks immediately repaired by a Wacker Neuson service center. • Have hydraulic hoses replaced by a Wacker Neuson service center within stipulated intervals even if no visual defects can be detected.
  • Page 36 2 Safety Battery CALIFORNIA Proposition 65 Warning Battery posts, terminals and related accessories contain lead and lead compounds, chemical known to the State of California to cause cancer and reproductive harm. Wash hands after handling. • Batteries contain caustic substances (for example sulfuric acid). When handling the battery observe the specific safety instructions and regulations relevant to accident prevention.
  • Page 37 Safety 2 Bleeding the fuel system and refueling • Do not bleed the fuel system or refuel near open flames. • Bleed the fuel system and refuel only in well-ventilated areas (for example due to vapors harmful to health, explosion hazard). •...
  • Page 38 2 Safety Working near non-electric supply lines • Before performing any work, the operator must check whether there are any non-electric supply lines in the job site. • If there are non-electric supply lines, the operator must take safety measures (for example switching off the supply line) in agreement with the operating company or owner of the supply lines.

  • Page 39: Introduction

    Introduction Introduction Introduction Machine overview Fig. 2 (symbolic representations) Designation Designation Rear chassis Rollbar Front chassis Control stand Tilt cylinder Skip Mudguard Steering cylinder Engine cover/ Articulated joint maintenance flap on left und right Operator seat BA D18 us* 1.1 * D18e300.fm...
  • Page 40 Introduction Fig. 3 (symbolic representations) Designation Designation Rear chassis Skip Front chassis Tilt cylinder Articulated joint Steering cylinder Operator seat Swivel centring Control stand Swiveling cylinder Mudguard Swiveling console Engine cover/ Cabin maintenance flap on left und right BA D18 us* 1.1 * D18e300.fm...

  • Page 41: Brief Description Of Machine

    DW60 D18-02 DW90 D18-03 DW100 The Wacker Neuson model D18 dumpers are self-propelled work machines. These powerful, highly flexible and efficient construction machines with minimum environmental impact are mainly used for moving earth, gravel and rubble on construction sites. Follow the relevant national and regional regulations.

  • Page 42: Information And Regulations On Use

    - Moving earth, gravel, coarse gravel or ballast and rubble. Every other use is regarded as not designated for the use of the machine. Wacker Neuson will not be liable for damage resulting from use other than mentioned above. The operator/machine owner alone will bear the risk.

  • Page 43: Labels

    Introduction Labels WARNING Injury hazard due to missing or damaged labels! Missing or incomplete warning and information labels can lead to situations with serious injury or death. ► Do not remove warning and information labels. ► Immediately replace damaged warning and information labels. Information Type, quantity and position of the labels depend on options, country and machine.
  • Page 44 Machine model Fig. 6 Unit Compact loader Dumper Excavator Internal model designation Check letter Production site Serial number Information Wacker Neuson components (for example Easy Lock, tilt bucket, rollbar) have numeric serial numbers only. BA D18 us* 1.1 * D18e300.fm...
  • Page 45 Introduction Rollbar type label The type label is located on the right on the rollbar. Fig. 7 (symbolic representation) Cabin type label (option) The type label is located on the B pillar on the left. Fig. 8 (symbolic representation) BA D18 us* 1.1 * D18e300.fm...
  • Page 46 Introduction Warning labels Fig. 9 BA D18 us* 1.1 * D18e300.fm...
  • Page 47 Introduction Meaning Explosion hazard due to wrong connection of battery jumper cables. Battery acid is caustic. Position Next to the battery. Fig. 10 Meaning Modifications to the structure (for example welding, driling), retrofitting and incorrect repairs affect the protective effect of the cabin or ROPS bar, and can cause serious injury and even death.
  • Page 48 Introduction Meaning Maintenance prop/center-pivot prop Secure the skip before performing maintenance/install the center-pivot prop before lifting the machine. Position Near the center-pivot prop and the maintenance prop of the skip. Fig. 14 Meaning Do not use starting-aid sprays. Position On the outside left of the engine cover. Fig.
  • Page 49 Introduction Meaning Raising/lowering and turning the skip (swivel skip option) Position On the right beside the operator seat. Fig. 18 Meaning Machine operation is only allowed if the rollbar is raised and locked, and if the seat belt is fastened. Position On the B pillar (cabin) or on the ROPS bar on the right.
  • Page 50 Introduction Information labels Fig. 20 3-12 BA D18 us* 1.1 * D18e300.fm...
  • Page 51 Introduction Meaning Fuses and relays Position Inside the fuse cover. Fig. 21 Meaning Main fuses and relays Position Inside the fuse cover. Fig. 22 Meaning Machine lifting points Position At the lifting eyes. Fig. 23 Meaning Machine tie-down points Position At the tie-down points.
  • Page 52 Introduction Meaning (option) The reservoir contains biodegradable hydraulic oil. This label is notched on the side depending on the biodegradable hydraulic oil used. Position Fig. 27 Next to the filler inlet of the hydraulic oil reservoir. Meaning Indication of sound power level produced by the machine. = sound power level.
  • Page 53 Introduction Meaning Trailer coupling Position On the rear part of the machine on right. Fig. 32 Meaning Tire pressure Position At the rear of the skip. Fig. 33 Meaning Thermal stability of coolant. Position On the radiator in the engine compartment. Fig.
  • Page 54 Introduction ANSI label (option) Fig. 36 3-16 BA D18 us* 1.1 * D18e300.fm...
  • Page 55 Introduction Position On the air filter in the engine compartment. Fig. 37 Position On the B pillar (cabin) or on the ROPS bar on the right. Fig. 38 Position On the air filter in the engine compartment. Fig. 39 Position At the rear of the skip.
  • Page 56 Introduction Position On the battery cover. Fig. 41 Position On the battery cover. Fig. 42 Position On the skip on the left and right. Fig. 43 3-18 BA D18 us* 1.1 * D18e300.fm...
  • Page 57 Introduction Position On the B pillar on the left. Fig. 44 Position On the B pillar on the left. Fig. 45 3-19 BA D18 us* 1.1 * D18e300.fm...
  • Page 58 Introduction Position On the B pillar on the left. Fig. 46 Position On the inside of the engine cover. Fig. 47 Position On the maintenance flap on the left and right. Fig. 48 3-20 BA D18 us* 1.1 * D18e300.fm...
  • Page 59 Introduction Position On the maintenance flap on the left. Fig. 49 Position On the B pillar (cabin) or on the ROPS bar on the right. Fig. 50 Position On the machine frame on the left and right. Fig. 51 Position On the ROPS bar.
  • Page 60 Introduction Notes: 3-22 BA D18 us* 1.1 * D18e300.fm...

  • Page 61: Putting Into Operation

    Putting into operation Putting into operation 4 Putting into operation Cabin/control stand CAUTION Injury hazard when entering or exiting! Entering or exiting incorrectly can cause injury. ► Keep the mandatory climbing aids A and handholds B clean and only use them for entering and exiting. ►...
  • Page 62 4 Putting into operation Unlocking and locking the door (option) Both cabin doors are equipped with locks. Unlocking Turn the starting key in door lock A anticlockwise (L). Lock Turn the starting key in door lock A clockwise (R). Fig. 55 Opening the door Outside Press door lock A and pull handle B.

  • Page 63: Emergency Exit

    Putting into operation 4 Closing the door Outside Release the door from the arrester by pressing ball handle A and closing it with handle B outside until it engages. Fig. 58 Inside Release the door from the arrester by pressing ball handle A and close it with handle C until it engages.
  • Page 64 4. Remove the weight off the operator seat for at least five seconds. 5. Carefully bring slide switch A to position 2 or 3. The machine must not start moving. Contact a Wacker Neuson service center immediately if the machine starts. Fig. 61 Fig.

  • Page 65: Operator Seat

    Putting into operation 4 Operator seat Adjusting the weight 1. Sit down on the operator seat. 2. Fold out and turn crank A until the red scale is in the middle of indicating instrument B (on the seat surface). Fig. 62 Adjusting the backrest 1.
  • Page 66 ► Keep the seat belt and buckle clean, and check them for damage. ► Have a damaged seat belt and buckle immediately replaced by a Wacker Neuson service center. ► Have the seat belt immediately replaced after every accident and the bearing capacity of the fastening points and seat fixtures checked by a Wacker Neuson service center.
  • Page 67 Putting into operation 4 Fastening the seat belt Insert buckle latch A into seat belt buckle B until it engages. Fig. 65 Unfastening the seat belt Press the red push button switch C on seat belt buckle B until the buckle latch comes out.
  • Page 68 4 Putting into operation WARNING Accident hazard due to incorrect adjustment of visual aids! Incorrectly adjusted visual aids can cause serious injury or death. ► Before starting work, ensure that all visual aids are clean, functional and adjusted in accordance with the instructions in this Operator’s Manual. ►...
  • Page 69 6. Press the menu button to exit the settings menu. Setup menu – adjusting the camera The camera is preset at the factory. For additional details contact a Wacker Neuson service center. Visual range The camera has a vertical visual range of 66°.
  • Page 70 4 Putting into operation Fire extinguisher A fire extinguisher is not available from Wacker Neuson. Contact a Wacker Neuson service center for the installation of a fire extinguisher (NFPA). Information Ensure that the fire extinguisher is firmly fastened during machine operation.
  • Page 71 ► Replace the complete protective structure if it is damaged, deformed or cracked. ► Contact a Wacker Neuson service center in case of doubt. ► Retrofit, assembly and repair work may only be performed by a Wacker Neuson service center.
  • Page 72 4 Putting into operation FOPS level II cabin (option) DANGER Crushing hazard due to falling objects! Causes serious injury or death. ► Install a protective FOPS structure in areas with danger of falling objects. Information The cabin complies with the FOPS level II requirements according to EN ISO 3449:2008 ►...
  • Page 73 Putting into operation 4 Rollbar Rollbar A is included in the machine’s standard equipment. DANGER Accident hazard due to falling objects! Causes serious injury or death. ► Machine operation is only allowed if the rollbar is raised and locked, and if the seat belt is fastened. ►...
  • Page 74 4 Putting into operation Lowering the rollbar 1. Park the machine on level ground. 2. Raise ring D. 3. Remove split pin C from lock pin B. 4. Remove lock pin B. 5. Slowly lower rollbar A with the help of a second qualified person from the side of the machine.
  • Page 75 Putting into operation 4 Protection (on left and right of rollbar). Fig. 76 Assembly: Install the sunshield with at least two qualified persons. 1. Remove the rotating beacon. 2. Route the cable for the rotating beacon through the opening in the roof. Fig.
  • Page 76 4 Putting into operation Skip grid (option) Skip grid A protects the cabin and the operator’s compartment against falling material or against an excavator bucket penetrating the cabin during loading. Fig. 79 Symbolic representation Assembly: Skips delivered from quarter 4/2015 have a threaded fitting for fastening the skip grid with screws.

  • Page 77: Overview Of Control Elements

    Putting into operation 4 Function Position Raise Insert and secure the pin in hole 1 Lower Insert and secure the pin in hole 2 Fig. 83 Document box The Operator’s Manual is stored in the document box under the seat. 12 V connection A 12 V power outlet A is located beside the starter.
  • Page 78 4 Putting into operation Control stand Fig. 85 Overview of control elements 4-18 BA D18 us* 1.1 * D18i400.fm...
  • Page 79 Putting into operation 4 Designation See page 4-4; 1 Operator seat and seat belt 2 Service brake 3 Steering-column lever (option for Austrian road traffic regulations StVZO) 4-22 4 Display element 4-24 5 Switch panel 4-22 6 Accelerator pedal 7 12 V connection 4-17 8 Document box 4-17...
  • Page 80 4 Putting into operation Cabin (option) Fig. 86 Overview of control elements 4-20 BA D18 us* 1.1 * D18i400.fm...
  • Page 81 Putting into operation 4 Designation See page 4-4; 1 Operator seat and seat belt 2 Rear left switch panel (option) 4-22 3 Drinks holder 4 Switch panel on left (option) 4-22 5 Service brake 6 Steering-column lever (option for Austrian road traffic regulations StVZO) 4-22 7 Display element 4-24...
  • Page 82 4 Putting into operation Control elements and switches Front side of control lever Switch panel Rear side of control lever Switch panel on left (option) Steering-column lever (option) Rear left switch panel (option) Fig. 87 4-22 BA D18 us* 1.1 * D18i400.fm...
  • Page 83 Putting into operation 4 Designation See page 5-19 Hazard warning system (option) 5-18 Rotating beacon (option) 5-16 Working lights (option) Particulate matter catalyst (Tier IV engine only) 7-42 5-22 Operating hydraulics 5-11 Selection of travel direction Eco push button Speed changeover (no function for DW 60) 5-18 Horn 5-21...

  • Page 84: Indicator Lights And Warning Lights (Overview)

    4 Putting into operation Indicator lights and warning lights (overview) Display element The display element and the multifunctional display informs the operator of the operating states, required maintenance or possible machine malfunctions. Information After switching on the starter, the indicator lights are checked during the first 2 seconds and the current reading of the maintenance meter is displayed.
  • Page 85 Putting into operation 4 Symbol Color Designation Turn indicators Green 5-19 Flashes when the steering-colum lever is actuated Yellow PCM regeneration disabled/interrupted 7-42 Yellow High exhaust-gas temperatures 7-42 8-1, 8-2, Engine stop 7-48 8-1, 8-2, Yellow Engine warning 7-48 Yellow PCM regeneration 7-42 Engine oil pressure Yellow Preheating...
  • Page 86 4 Putting into operation Meaning of displays and symbols Symbol Designation Page Speed range 1 Speed range 2 (DW90/100 only) 450.2 Hour meter 4-28 49.8 Operating hours to next maintenance 12:10 Time 800 rpm Engine speed Fuel tank capacity 4-28 100°...
  • Page 87 Putting into operation 4 Symbol Designation Page n/min Detailed engine oil pressure 0 kPa Engine number Setting of display brightness Setting of display contrast Setting of time/date Pilot control pressure Replace the hydraulic oil filter Dirty air filter Dirty hydraulic oil radiator Charge indicator light PCM: low load PCM: medium load...
  • Page 88 4 Putting into operation Hour meter Counts the engine operating hours with the engine running. Fig. 88 Maintenance meter Counts the engine operating hours until the next maintenance. The maintenance meter starts at 500.0 hours. It counts down to 0.0 hours. The wrench symbol then starts to flash.

  • Page 89: Preparatory Work

    Only operate the machine from the seat with the seat belt fastened. Before using the machine in work operation for the first time, Wacker Neuson recommends trying out the machine on open ground without any obstacles.
  • Page 90 4 Putting into operation Requirements and information for the operating personnel Read, understand and follow this Operator’s Manual and all other Operator’s Manuals supplied with the machine. The machine may only be put into operation by authorized personnel that has been instructed –...
  • Page 91 The checklists below assist you in checking and monitoring the machine before, during and after operation. Wacker Neuson does not claim those lists to be exhaustive. If the answer to one of the following questions is No, first rectify the cause of the error (or have it rectified) before starting or continuing work.
  • Page 92 4 Putting into operation Operation checklist Check/observe the following before beginning operation or after starting the engine: Question Page Are there any persons or objects in the danger zone of 5-24 the machine? Indicator light for engine oil pressure and alternator charge function gone out after a few seconds? Has a brake test been performed? Coolant temperature of engine in normal range?
  • Page 93 Putting into operation 4 Putting into operation for the first time and running-in period Before putting the machine into operation for the first time, check whether the equipment supplied with the machine is complete. • Check the fluid levels according to chapter “Maintenance”. Each machine is correctly adjusted and checked before it is delivered.

  • Page 94: Starting And Stopping The Engine

    4 Putting into operation Machine travel on public roads 1. Ensure that all legal requirements for machine travel on public roads are fulfilled. This applies both to the machine and to the operator (for example a corresponding driving license). 2. Lower the skip completely. If the machine is equipped with a swivel skip, ensure in addition that the skip is in the middle position.

  • Page 95: Starting The Engine

    All indicator lights go out. If the engine does not start after 30 seconds: Interrupt the start procedure and repeat it after two minutes. If the engine still does not start after a few tries, contact a Wacker Neuson service center. Warm-up phase After starting the engine, let it warm up at slightly increased idling speed until it reaches its operating temperature.
  • Page 96 4 Putting into operation Starting the engine at low ambient temperatures Start the engine as described in chapter Starting the engine. Warm-up phase at low ambient temperatures • Let the engine run below 1800 rpm until the coolant reaches its operating temperature.
  • Page 97 Putting into operation 4 Starting aid WARNING Explosion hazard in case of incorrect handling of battery! Incorrect battery handling can cause serious injury or death. ► Wear protective equipment. ► Fire, open flames and smoking is prohibited. ► Do not jump start the engine if the battery is malfunctioning or frozen, or if the acid level is too low.
  • Page 98 4 Putting into operation NOTICE Damage to battery jumper cables when placing them near rotating parts. Information Use only authorized battery jumper cables which conform to national and regional safety requirements. Designations/symbols Meaning Machine with empty battery Vehicle with full battery Positive/machine X Positive/vehicle Y Negative/vehicle Y...
  • Page 99 Putting into operation 4 6. Open the engine cover. 7. Connect the battery jumper cables in the following order: C-D-E-F. 8. Wait five minutes for the empty battery to be charged a little. WARNING Injury hazard due to open base cover! Can cause serious injury and death.

  • Page 100: Stopping The Engine

    4 Putting into operation Low-load operation NOTICE Possible damage to the engine due to low-load operation. ► Run the engine at idling speed or at high engine speed at over 20 % engine load. Possible consequences of low-load operation are: •...

  • Page 101: Operation

    Operation Operation 5 Operation Instrument panel cover Before putting the machine into operation, open lock A with the starting key and slide back instrument panel cover B until it locks into place. Fig. 100 Leave instrument panel cover B open during operation. To lock instrument panel cover B, disengage it from the lock, close it and lock it with ball handle C.

  • Page 102: Steering System

    5 Operation Steering system The machine is steered with a steering wheel. The mechanical actuation is transmitted to a travel cylinder. Steering is therefore not performed by means of a steering axle, but with the steering joint. Function Machine movement Steering wheel turned to Machine is steered to the left and turns left the left...

  • Page 103: Accelerator Actuation

    Fig. 103 Speed changeover Models DW90 and DW100 have two speed ranges that can be selected with push button A on the control lever. The Eco mode is selected with push button B. Fuel-saving operation is selected with this mode, and maximum speed is reduced –...

  • Page 104: Brakes

    Pull the parking brake backward only to the notch for this. Do not operate the lock lever under any circumstances. Contact a Wacker Neuson service center. Information The parking brake responds with a certain delay, but then with a strong braking effect.
  • Page 105 Do not put the machine into operation if a brake test gives a negative result or if there are doubts as to the correct brake function. Contact a Wacker Neuson service center and have the malfunction rectified. The following tests help check the brake function. If possible, always park the machine without any load and on level ground, and secure it with suitable means (for example chocks).
  • Page 106 5 Operation Multifunctional display Display element buttons A: selection button B: to next menu page/set Fig. 109 Menu structure of display setting Information The software version number is displayed from version 3.3. BA D18 us* 1.1 * D18b500.fm...
  • Page 107 Operation 5 Time/engine speed changeover 100° Change over between engine speed and time with push button A. 80° 450.2 60° 12:10 800 rpm Fig. 110 800 rpm Display adjustment menu The selected menu level is marked with an arrow. Press push button A 1 x: brightness Press push button A 2 x: contrast Brightness Press push button A 3 x: time/date...
  • Page 108 5 Operation Adjusting contrast Press push button B to access the adjustment mode. Press push button A to adjust the contrast. Fig. 113 Setting the time or date Adjustment sequence: year/month/day/hours/minutes Press push button B to access the adjustment mode. Press push button A to set or to access the next setting (month, day, etc.).

  • Page 109: Machine Travel

    Operation 5 Machine travel WARNING Accident hazard due to incorrect adjustment of travel direction! Can cause serious injury and 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 own weight! Can cause serious injury and death.
  • Page 110 5 Operation Road-travel position Lower the skip and secure it against unintentional operation with lock lever Fig. 115 If the machine is equipped with a swivel skip, ensure that it is in the middle position. Fig. 116 Enabling/disabling the operating hydraulics Function Position Disables the operating hydraulics...
  • Page 111 Operation 5 Starting machine travel and stopping Starting machine travel • Start the engine. Indicator lights A (charge indicator light) and B (engine oil pressure) go out. • Press the service brake. Fig. 118 Selecting a travel direction After starting the engine, position 1 has to be selected otherwise the machine cannot be moved forward for safety reasons.
  • Page 112 5 Operation Machine travel on slopes WARNING Crushing hazard due to tipping over of machine! A tipping machine can cause serious injury or death. ► Set the machine to travel position. ► Perform machine travel on slopes only on firm ground. ►...
  • Page 113 Operation 5 Machine travel on slopes with a loaded skip When performing machine travel on slopes with a loaded skip, the front side of the machine must always face the uphill side of the slope whichever the travel direction. Do not perform machine travel on slopes steeper than 25 %.
  • Page 114 5 Operation Machine travel across slopes Do not perform machine travel on slopes with a lateral angle of inclination over 25 %. < 25 % Fig. 122 Change position on level ground and then perform straight-ahead machine travel onto the slope. Fig.

  • Page 115: Differential Lock

    Operation 5 Parking the machine WARNING Crushing hazard due to machine rolling away under its own weight after parking it! Serious injury or death can be caused by not securing the machine. ► Lower the skip. At near-freezing temperatures, park the machine with the skip tilted to prevent material from freezing or ice from forming in the skip.

  • Page 116: Lights/Signaling System

    5 Operation Lights/signaling system Working lights (option) The switch is located on the right of the steering wheel. WARNING Motorists can be blinded by bright lights on the job site! Working lights can blind motorists. This can cause serious injury or death. ►...
  • Page 117 Operation 5 Road travel lights (option) The steering-column lever is located on left of the steering wheel. Ring A is located on the steering column lever. Function Position Switch off the lights Turn ring A to position 0 Switch on clearance lights (B) and Turn ring A to position 1 rear lights (C) Switch on headlights (D)
  • Page 118 5 Operation Horn Press push button A on the rear side of the control lever. Fig. 131 Fig. 131 Press push button B on the steering column lever (option for Austrian road traffic regulations StVZO). Fig. 132 Fig. 132 Rotating beacon (option) Switch A is located on the right of the steering wheel.
  • Page 119 Operation 5 Information Follow the national and regional regulations concerning rotating beacon operation. Fig. 134 Turn indicators (option) The steering-column lever is located on left of the steering wheel. Operating the turn indicators on the steering column lever. Function Position Turn indicators on the left flash Press steering column lever A down Turn indicators on the right Press steering column lever A up...

  • Page 120: Wiper/Wash System (Option)

    ► Do not allow anyone to stay in the danger zone. ► Do not rely on the reversing signal under any circumstances. ► If the reversing signal does not sound, stop machine operation immediately and contact a Wacker Neuson service center. Follow the national and regional regulations. Wiper/wash system (option) The switch is located on the rear left beside the operator seat.

  • Page 121: Heating, Ventilation And Air Conditioning System

    Operation 5 Heating, ventilation and air conditioning system Heating/ventilation (option) Switch A is located on the left beside the operator seat. Function Position Switch off the fan Press switch A all the way up Fan in 1st speed Press switch A to the first position Fan in 2nd speed Press switch A to the second position Fig.

  • Page 122: Operating Hydraulics

    Operation 5 Operation Operating hydraulics Skip operation Operate the skip with the control lever. WARNING Accident hazard during machine travel with a tilted-out skip! Can cause serious injury or death. ► Machine travel with a tilted-out skip is prohibited. ► Tilt out material that sticks in the skip only to the front in the straight position of the machine.
  • Page 123 Operation 5 Front skip operation During skip operation, always put forward-reverse control B for the travel direction in neutral position 1. Function Operation Tilt out the skip Press control lever A forward Lower the skip Pull control lever A backward Fig.

  • Page 124: Attachments

    5 Operation 5.10 Attachments Not available. 5.11 Work operation Danger zone • The danger zone is the area in which persons are in danger due to the movements of the machine or load. • The danger zone also includes the area that is affected by falling material, equipment or by debris that is thrown out.
  • Page 125 Operation 5 • Do not travel up to the edge of an unsecured pit – danger of cave-in. • Do not perform machine travel and operation under projecting earth. Stones or the projecting earth can fall onto the machine. • Before working on roofs or similar structures, check the resistance and the structure itself before starting work.
  • Page 126 5 Operation Loading WARNING Injury hazard when loading the machine Can cause serious injury or death. Leave the machine before loading it, and get onto it again only after it is completely loaded. Information Incorrect loading causes serious damage to the machine. ►...
  • Page 127 Speed range 2 The DW90 and DW100 machines are equipped with an additional 2nd speed range. This speed range makes it possible to perform machine travel at higher speeds depending on the ground and the surroundings.
  • Page 128 5 Operation Operation in water Do not immerse the machine in water any farther than to the middle of the axles. Fig. 150 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 exhaust system.

  • Page 129: Emergency Lowering

    Operation 5 5.12 Emergency lowering DANGER Crushing hazard when lowering the skip! Causes serious crushing or injury resulting in death. ► Do not allow anyone to stay in the danger zone. ► Stop all work movements immediately if someone enters the danger zone.
  • Page 130 5 Operation Immobilizer (option) A = starting key (blue) For starting the machine. 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.
  • Page 131 Operation 5 Maneuvering operation (option) The machine is equipped with a towing gear A. However, it is not a tractor vehicle and may not be used as such in difficult terrain. • If the machine is used on construction sites for towing trailers, weight the skip with 25 % of the payload.

  • Page 132: Putting Out Of Operation/Back Into Operation

    5 Operation 5.14 Putting out of operation/back into operation The specified measures refer to putting the machine out of operation and back into operation after more than 30 days. Putting out of operation temporarily Store the machine indoors if possible. Park the machine only on firm ground (for example concrete) outdoors.
  • Page 133 12.Have the hydraulic oil filters (return and breather filters) replaced by a Wacker Neuson service center if the machine was out of operation for over six months. 13.Switch on the starter and check whether there are any malfunctions –...

  • Page 134: Permanently Putting Out Of Operation

    All fluids, lubricants, material, etc., used on the machine are subject to specific regulations. Dispose of different materials and consumables separately and in an environmentally friendly manner. Have only a Wacker Neuson service center ensure machine disposal. Observe the national guidelines regarding disposal. Environment...

  • Page 135: Transportation

    Transportation Transportation 6 Transportation Towing the machine WARNING Accident hazard due to incorrect towing! Incorrect towing can cause accidents and serious injury or death. ► Tow the machine away only from the immediate danger zone until it can be loaded. ►...
  • Page 136 6 Transportation WARNING Crushing hazard due to machine rolling away under its own weight after parking it! Serious injury or death can be caused by not securing the machine. ► The machine may only be towed on level ground or uphill. ►...
  • Page 137 Transportation 6 Disabling the pressure limiting valves Clean the area around the pressure limiting valves. Fig. 157 Loosen screws A with exactly 3 revolutions. Fig. 158 BA D18 us* 1.1 * D18t600.fm...
  • Page 138 6 Transportation Disabling the hydraulic parking brake WARNING Burn hazard due to hot surfaces! Can cause serious burns or death. ► Stop the engine and let it cool down. ► Wear protective equipment. NOTICE Higher towing speeds and longer towing distances may cause severe damage to the machine.

  • Page 139: Loading The Machine

    Transportation 6 Loading the machine WARNING Accident hazard due to incorrect loading! Incorrect loading can cause accidents and serious injury or death. ► Do not 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.
  • Page 140 6 Transportation 6. Start the engine. 7. Lower the skip. 8. Carefully travel the machine backward onto the middle of the transport vehicle. 9. Move the machine to transport position. 10.Apply the parking brake. 11.Stop the engine. 12.Remove the starting key and carry it with you. 13.Leave the control stand.
  • Page 141 Transportation 6 Lifting WARNING Accident hazard due to incorrect loading! Incorrect loading can cause accidents and serious injury or death. ► Do not 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.
  • Page 142 6 Transportation 1. Empty the skip and lower it to middle position. 2. Remove all dirt from the machine. 3. Park the machine on firm, level and horizontal ground. 4. Lock the control lever – see chapter “ Enabling/disabling the operating hydraulics”...

  • Page 143: Transporting The Machine

    Transportation 6 Transporting the machine 1. Install the center-pivot prop. 2. Firmly fasten the machine on the loading area with tie-down points A with slings of appropriate size. Observe the legal regulations. 3. Before transporting the machine through wet weather: Close the exhaust pipe.
  • Page 144 6 Transportation Notes: 6-10 BA D18 us* 1.1 * D18t600.fm...

  • Page 145: Maintenance

    7-8. • In order to avoid damage to electronic components, do not perform welding work on the machine. Contact a Wacker Neuson service center. • High engine load or a manual regeneration of the particulate matter catalyst can lead to shorter engine oil maintenance intervals. Output is reduced if the machine is used beyond the maintenance interval.

  • Page 146: Maintenance Overview

    7 Maintenance Maintenance overview Maintenance label Maintenance that has to be performed by the operator is indicated on the maintenance label. DW60 62.5 kW (83.8 hp) Fig. 168 I Checking functions and levels, filling up and draining II Checking wear parts, seals, hoses and threaded fittings III Checking for damage, corrosion and dirt IV Lubricate daily after the work shift Superscript numbers, for example...
  • Page 147 Maintenance 7 Maintenance that has to be performed by the operator is indicated on the maintenance label. DW60, DW90, DW100 55 kW (73.8 hp) Fig. 169 I Checking functions and levels, filling up and draining II Checking wear parts, seals, hoses and threaded fittings...
  • Page 148 7 Maintenance Maintenance that has to be performed by the operator is indicated on the maintenance label. DW60, DW90, DW100 86 kW (115.3 hp) Fig. 170 I Checking functions and levels, filling up and draining II Checking wear parts, seals, hoses and threaded fittings...
  • Page 149 Maintenance 7 Maintenance plan Daily maintenance (operator) Inspection work Symbol (Check the following engine/machine fluids. Check the oil levels after a test Page run and add oil if necessary.) Check the engine/machine fluids (engine oil, engine coolant, hydraulic oil, 7-26, 7-29, brake fluid) 7-34 Check the radiator for dirt, clean it if necessary...
  • Page 150 7 Maintenance Daily maintenance (operator) Check the condenser for dirt, clean it if necessary 7-30 Leakage check Check for tightness, leaks and chafing: pipes, flexible lines and threaded fittings of the follow- ing assemblies and components. Have them repaired if necessary. Engine and hydraulic system Traveling drive, axles and transfer gearbox Braking system...
  • Page 151 Contact a Wacker Neuson service center.) Only once after the first 50 operating hours (Wacker Neuson service center) Page...
  • Page 152 7 Maintenance Preparing lubrication 1. Stop the machine on firm, level and horizontal ground. 2. Lower the skip. Check the middle position if the machine is equipped with a swivel skip see page 5-27 “Middle position of swivel skip.” 3. Stop the engine. 4.
  • Page 153 Maintenance 7 Lubrication plan Lubricate the specified lubrication points once a day. Before starting maintenance, lower the red maintenance prop when the skip is raised and secure the skip with it. Fig. 172 Position Lubrication point Quantity Articulated joint on left and right Articulated joint (left side of joint, right side of machine) Front and rear of steering cylinder Top and bottom of steering cylinder...

  • Page 154: Fluids And Lubricants

    7 Maintenance Fluids and lubricants Season/tempera- Application Fluid/lubricant Specification Capacities ture ASTM D975 grade 2D S15 (USA) Summer or winter 83 l EN 590 (EU) diesel depending Diesel fuel (21.9 gal) on outside tem- Engine (Tier III/Tier peratures BS 2869:2010 class A2 (GB) Distilled water and anti- 16 l...
  • Page 155 Maintenance 7 Engine oil types Tier III engine Viscosity grade Ambient temperature EMA LRG-1; API CH-4 min. °C min. °F max. °C max. °F SAE 0W20 SAE 0W30 SAE 0W40 SAE 5W30 SAE 5W40 SAE 10W30 SAE 15W40 Tier IV engine Viscosity grade Ambient temperature API CJ-4;...
  • Page 156 • Always have the condensation water in the hydraulic oil reservoir drained by a Wacker Neuson service center before the cold season. The water content may not exceed 0.1 % by weight. •...

  • Page 157: Maintenance Accesses

    Maintenance 7 Maintenance accesses WARNING Burn hazard due to hot surfaces! Can cause serious burns or death. ► Stop 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. ►...
  • Page 158 7 Maintenance Maintenance flaps Unlocking and locking Function Operation Turn the starting key in lock A Open the maintenance flap toward the rear of the machine Turn the starting key in lock A Lock the maintenance flap toward the skip Open Unlock the maintenance flap and open it completely until lock B engages.
  • Page 159 Maintenance 7 Fuse box The fuse box is located at the front right of the chassis. Function Operation Opening the fuse box Remove screws A and cover B Install cover B and Close the fuse box tighten screws A Description of fuses –...

  • Page 160: Cleaning And Maintenance

    7 Maintenance Cleaning and maintenance WARNING Injury hazard due to rotating parts! Rotating parts can cause serious injury or death. ► Open the maintenance flap only at engine standstill. WARNING Burn hazard due to hot surfaces! Hot surfaces can cause serious burns or death. ►...
  • Page 161 Maintenance 7 Cleaning the machine is divided into three separate areas: • Inside the cabin • Exterior of the machine • Engine compartment Washing solvents • Ensure sufficient room ventilation. • Wear suitable protective clothing. • Do not use flammable liquids, such as gasoline or diesel. Compressed air •...

  • Page 162: Seat Belt

    5. Allow the machine to dry and check it again for salt deposits. Loose threaded fittings and attachments Retighten loose connections immediately, and have them immediately replaced by a Wacker Neuson service center if necessary. 7-18 BA D18 us* 1.1 * D18w700.fm...

  • Page 163: Lubrication Work

    Maintenance 7 Lubrication work – see chapter “ Preparing lubrication” on page 7-8. Fuel system Important information regarding the fuel system NOTICE Damage to injection pump due to air in the 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.
  • Page 164 7 Maintenance Refueling WARNING Explosion hazard due to flammable fuel/air mixtures! Fuels develop explosive and flammable mixtures with air that can cause serious burns or death. ► Fire, open flames and smoking is prohibited. ► Open tank lock carefully to release the pressure in the fuel tank. ►...
  • Page 165 Maintenance 7 Filler inlet A of the fuel tank is located behnd the maintenance flap on the right. 1. Stop and park the machine. Stop the engine – see “Preparing lubrication” on page 7-8. 2. Open the maintenance flap on the right. 3.
  • Page 166 2. Remove the starting key and carry it with you. 3. Bleed the fuel system again as described above. 4. Check for leaks after starting the engine. 5. Have a Wacker Neuson service center perform a check if necessary. 7-22 BA D18 us* 1.1 * D18w700.fm...
  • Page 167 3. Bleed the fuel system again as described above. 4. Check for leaks after starting the engine. 5. Have a Wacker Neuson service center perform a check if necessary. Information The fuel system can also be bled if the engine is warm.
  • Page 168 7 Maintenance Emptying the water separator Information Empty the water separator, if error message SPN 97 (only Tier IV) appears in the multifunctional display. Drain the water/fuel mixture (A) until the sight glass contains only fuel (B). 1. Stop the machine, stop the engine –...

  • Page 169: Engine Lubrication System

    Damage due to wrong engine oil. ► Use engine oil according to the Fluids and lubricants list. ► Have the oil changed only by a Wacker Neuson service center. NOTICE Possible engine damage due to adding engine oil too quickly.
  • Page 170 7 Maintenance Checking the engine oil level 1. Stop and park the machine. Stop the engine – see “Preparing lubrication” on page 7-8. 2. Open the maintenance flap on the right. 3. Clean the area around the oil dipstick with a lint-free cloth. 4.
  • Page 171 Maintenance 7 Adding engine oil 1. Stop and park the machine. Stop the engine – see “Preparing lubrication” on page 7-8. 2. Open the maintenance flap on the right. 3. Clean the area around the oil filler cap with a lint-free cloth. 4.

  • Page 172: Cooling System

    7 Maintenance Cooling system Important information regarding the cooling system WARNING Poisoning hazard due to hazardous substances! Contact with hazardous substances can cause serious injury or death. ► Wear protective equipment. ► Do not inhale or swallow coolant. ► Avoid contact of the coolant or antifreeze with the skin and eyes. WARNING Burn hazard due to coolant or antifreeze! The coolant and antifreeze are easily flammable fluids that can cause...
  • Page 173 Maintenance 7 Checking the coolant level 1. Stop and park the machine. Stop the engine – see “Preparing lubrication” on page 7-8. 2. Let the engine and the coolant cool down. 3. Open the maintenance flap on the left. 4. Check the coolant level on sight glass A. If the coolant level is below the FULL mark: Add coolant.
  • Page 174 7 Maintenance Cleaning the radiator WARNING Burn hazard due to hot surfaces! Can cause serious burns or death. ► Stop the engine and let hot surfaces cool down. ► Wear protective equipment. NOTICE Possible damage to diesel engine and hydraulic system due to dirt on the radiator fins.
  • Page 175 Maintenance 7 Water/hydraulic oil radiator, fuel cooler, charge-air cooler The water/hydraulic oil radiator, the fuel cooler and the charge-air cooler (option) are located behind fan grid A. 1. Stop and park the machine. Stop the engine – see “Preparing lubrication” on page 7-8.

  • Page 176: Air Filter

    5. Close and lock the maintenance flap on the left. Fig. 193 NOTICE Even the smallest dirt particles penetrating into the air intake can cause machine damage. ► Have air filter B changed only by a Wacker Neuson service center. Fig. 194 7-32 BA D18 us* 1.1 * D18w710.fm...

  • Page 177: V-Belt

    Search for hydraulic leaks with a piece of cardboard. NOTICE Damage due to wrong hydraulic oil. ► Only use hydraulic oil according to Fluids and lubricants. ► Have the hydraulic oil only changed by a Wacker Neuson service center. 7-33 BA D18 us* 1.1 * D18w710.fm...
  • Page 178 ► Cloudy hydraulic oil in the sight glass is a sign of water or air in the hydraulic system. Contact a Wacker Neuson service center. ► Contact a Wacker Neuson service center if the filter of the hydraulic system is dirty.
  • Page 179 Maintenance 7 Adding hydraulic oil The filler opening of the hydraulic oil reservoir is located behind the maintenance flap on the left. 1. Stop and park the machine. Stop the engine – see “Preparing lubrication” on page 7-8. 2. Release the pressure in the hydraulic system. 3.
  • Page 180 NOTICE Leaks and damaged pressure lines must immediately be repaired or replaced by a Wacker Neuson service center. This not only increases the operating safety of the machine but also helps to protect the environment. ► Have damaged or leaky pressure lines immediately repaired or replaced by a Wacker Neuson service center.

  • Page 181: Electrical System

    7.13 Electrical system Important information regarding the electrical system Maintenance and repair work on the electrical system may only be performed by a Wacker Neuson service center. • Have malfunctioning components of the electrical system replaced by a Wacker Neuson service center.
  • Page 182 Only use fuses with the specified amperage. – see chapter “ Fuse box” on page 9-6. Battery state of charge Have this checked only by a Wacker Neuson service center. Charging the battery Have this performed only by a Wacker Neuson service center.

  • Page 183: Heating, Ventilation And Air Conditioning System

    Have maintenance performed only by a Wacker Neuson service center. Checking the brake-fluid level Brake fluid reservoir A (DW90 and DW100 have two reservoirs) is located behind the maintenance flap on the left. The fluid level must reach the mark indicated. Check the fluid level once a day, add fluid if necessary –...

  • Page 184: Tires

    7 Maintenance 7.18 Tires Information Use only tires and rims released for the machine. – see chapter “9.5 Tires” on page 9-4 WARNING Accident hazard due to incorrect maintenance! Can cause serious injury or death. Fig. 201 ► Have repair work on wheels, tires, etc. performed only by a Wacker Neuson service center.

  • Page 185: Maintenance Of Attachments

    Maintenance 7 Wheel change 1. Park the machine on firm, level and horizontal ground. 2. Apply the parking brake. 3. Use wheel chocks to prevent the machine from rolling away. 4. Loosen the wheel nuts of the wheel you want to remove. 5.

  • Page 186: Exhaust Gas Treatment

    7 Maintenance 7.21 Exhaust gas treatment The machine is equipped with a particulate matter catalyst for cleaning the exhaust gas (only Tier IV). The soot produced by burning diesel fuel is collected and burned in the particulate matter catalyst at regular intervals. This process is called regeneration.
  • Page 187 ► High engine load = low load. ► Low engine load = high load. Information Wacker Neuson recommends not to influence the automatic regeneration if possible. Should it be necessary to disable or interrupt regeneration, perform it again as soon as possible.
  • Page 188 7 Maintenance Indication of load Symbol Description Effect Full engine power Low load Automatic regeneration possible Full engine power Medium load Automatic or manual regeneration is possible Reduced engine power Highest load Only manual regeneration is possible Symbol flashes: PCM regeneration required Symbol illuminates: PCM regeneration active The symbols are displayed from software version 3.3.
  • Page 189 Maintenance 7 Regeneration push button Push button A is located on the right of the steering wheel. Push button A is in the middle position and can be pressed either upward or downward, but does not engage. The automatic regeneration mode is preset if the engine is stopped for at least 30 seconds.
  • Page 190 7 Maintenance Indication E in the multifunctional display changes depending on the contamination level (from software version 3.2). Fig. 205 Fig. 205 Position Effect Indication Automatic regeneration, no functional limitations. Lowest load Indicator light D must not illuminate – see “Automatic regeneration mode”...
  • Page 191 Maintenance 7 Automatic regeneration mode The automatic regeneration mode is preset if the engine is stopped for at least 30 seconds. NOTICE Fire hazard at the exhaust system. ► There must be no easily flammable material in the direct vicinity of the muffler, in particular near the end pipe.

  • Page 192: Machine Preservation

    Regeneration not performed – stopping the machine Engine power is reduced if indicator lights B and F illuminate and if indicator light E flashes. Stop the engine immediately and contact a Wacker Neuson service center. 7.22 Machine preservation Machines are partly preserved at the factory (for example in the engine compartment).

  • Page 193: Malfunctions

    Malfunctions Malfunctions 8 Malfunctions NOTICE Contact a Wacker Neuson service center in case of malfunctions or signs that are not listed in the following tables or that persist after maintenance has been performed correctly. Engine warning lights Engine Engine Description...

  • Page 194: Engine And Engine Oil Indicator Lights

    1. If the engine stop or oil pressure light does not illuminate, stop machine oper- ation immediately and contact a Wacker Neuson service center. No malfunction. Low oil pressure (if the oil pressure indicator light illuminates during opera- tion).
  • Page 195 The battery is no longer charged Coolant temperature too high. Alternator or V-belt malfunction. Stop the engine immediately. Contact a Wacker Neuson service center. Buzzer sounds. Coolant temperature too high. Let the engine run at idling speed without any load. 100°...

  • Page 196: General Malfunctions

    7-15 Engine does not start or is not easy to Malfunctioning fuse Check the fuse start Electronic feed pump is not Contact a Wacker Neuson running service center Parking brake applied Release the parking brake No travel direction selected Select a travel direction...
  • Page 197 Malfunction Possible cause Remedy Mechanical lock enabled Release the lock lever 5-10 None of the hydraulic functions can be Contact a Wacker Neuson operated Control valve error service center Electrical components do not work Malfunctioning fuse Check the fuse Malfunctioning fuse...
  • Page 198 The traveling drive is disabled. • Stop and park the machine. • Contact a Wacker Neuson service center and have the malfunction rectified. Machine travel and operation is possible in case of minor errors. • Engine performance is not reduced.
  • Page 199 Malfunctions 8 Symbol SPN XXXXXX SPN XXXXXX Engine error SPN XXXXXX Indicates engine errors. SPN XXXXXX SPN XXXXXX SPN XXXXXX Machine error SPN XXXXXX SPN XXXXXX Indicates machine errors. SPN XXXXXX SPN XXXXXX SPN XXXXXX SPN XXXXXX Particulate matter catalyst data SPN XXXXXX Indicates particulate matter catalyst data.
  • Page 200 8 Malfunctions Notes: BA D18 us* 1.1 * D18b800.fm...

  • Page 201: Technical Data

    Model designations and trade names Machine model Trade name D18-01 DW60 D18-02 DW90 D18-03 DW100 Engine DW60, DW90, DW100 DW60, DW90, DW100 Engine DW60 62.5 kW (83.8 hp) 55 kW (73.8 hp) 86 kW (115.3 hp) Manufacturer Perkins Type 1104D-44T...

  • Page 202: Traveling Drive/Axles

    9 Technical data Traveling drive/axles DW60 62.5 kW (83.8 hp)/ DW60, DW90, DW100 Traveling drive DW60, DW90, DW100 86 kW (115.3 hp) 55 kW (73.8 hp) Design Infinitely variable axial piston pump with electric control 152 l/min 171 l/min Flow rate...

  • Page 203: Brakes

    Front wheels Direct Effect Direct Rear wheels Via cardan shaft Parking brake DW60, DW90, DW100 Design Hydraulic parking brake Location Front axle center housing Effect Via cardan shaft on all 4 wheels, hydromechanical actuation BA D18 us* 1.1 * D18t900.fm...

  • Page 204: Tires

    Swivel skip 5998 mm (19'-8'') 6546 mm (21'-6'') Operating hydraulics DW60 62.5 kW (83.8 hp)/ DW60 86 kW (115.3 hp)/ Operating hydraulics DW60, DW90, DW100 DW90, DW100 55 kW (73.8 hp) Hydraulic pump 69.2 cm (4.22 in 78.1 cm (4.77 in...

  • Page 205: Electrical System

    Technical data 9 Steering system DW60, DW90, DW100 Flow rate at 2200 rpm 68 l/min (18 gal/min) Max. operating pressure 180 bar +15 bar/−5 bar (2,611 psi +218 psi/−73 psi Secondary pressure protection 235 bar +15 bar/−5 bar (3,408 psi +218 psi/−73 psi...
  • Page 206 9 Technical data Fuse box Fuse box A is located at the front right of the chassis. Fig. 210 Main fuses B are located on the right. Fig. 211 Schematic fuse box assignment for all models Fig. 212 BA D18 us* 1.1 * D18t900.fm...
  • Page 207 Technical data 9 Fuses/ Rated cur- Protected circuits Tier III Protected circuits Tier IV relays rent Fuel pump Engine control unit Starter, machine control unit 12 V 30 and 12 V 15, F901 lights, multifunctional display, radio, wiper , air conditioning, clearance lights , hazard warning system Diagnosis connector Starter plus 12 V 15, preheating, cutoff solenoid, drive control unit,...
  • Page 208 9 Technical data Fuses/ Rated cur- Protected circuits Tier III Protected circuits Tier IV relays rent Fuel pump, additional start quantity, Relay Engine control unit, horn horn Relay Starter Relay Turn indicators Relay Air conditioning Relay Brake lights Relay Low beam Relay High beam Relay...

  • Page 209: Tightening Torques

    Technical data 9 Tightening torques General tightening torques Property class 10.9 12.9 10.9 Screws according to DIN 912, DIN 931, DIN 933, etc. Screws according to DIN 7984 Screw dimen- sions Nm (ft.lbs.) Nm (ft.lbs.) Nm (ft.lbs.) Nm (ft.lbs.) Nm (ft.lbs.) 5.5 (4) 8 (6) 10 (7)

  • Page 210: Coolant

    9 Technical data 9.10 Coolant Compound table Outside temperature Distilled water Coolant up to −37 °C (−34.6 °F) 50 % by volume 50 % by volume Use the 1:1 concentration for warm outside temperatures, too, to ensure protection against corrosion, cavitation and deposits. Do not mix the coolant with other coolants.

  • Page 211: Vibration

    Technical data 9 9.12 Vibration Vibration Effective acceleration value for the upper extremi- < Trigger value ties of the body (hand-arm vibration) < 2.5 m/s Effective acceleration value for the body (whole- < 0.5 m/s body vibration) Vibration values indicated in m/s². Directive 2002/44/EC of European Parliament and Council on minimum health and safety requirements regarding exposure of workers to risks arising from physical agents (vibration).
  • Page 212 9 Technical data Directives on reduction of vibration values in earth moving machines: • Perform correct adjustments and maintenance on the machine. • Avoid jerky movements during machine operation. • Keep slopes in a perfect condition. Whole-body vibration can be reduced with the following guidelines: •...
  • Page 213 European Parliament and Council on minimum health and safety requirements regarding exposure of workers to risks arising from physical agents (vibration). Your Wacker Neuson dealer provides information on other machine functions reducing vibration and on safe operation. 9-13 BA D18 us* 1.1 * D18t900.fm...

  • Page 214: Weight

    9 Technical data 9.13 Weight Machine weights Front skip ROPS DW60 kg/lbs DW90 kg/lbs DW100 kg/lbs Transport weight 4532 (9,991) 5232 (11,534) 5277 (11,634) Operating weight 4614 (10,172) 5314 (11,715) 5359 (11,815) Front skip cabin DW60 kg/lbs DW90 kg/lbs DW100 kg/lbs...

  • Page 215: Payload

    Skip capacity (heaped) 3200 l (845 gal) 4400 l (1162 gal) 3050 l (845 gal) DW60 DW90 DW100 Payload 6000 kg (13,228 lb) 9000 kg (19,842 lb) 10000 kg (22,046 lb) NOTICE Possible damage to property due to tipping over of machine. Do not exceed the weights indicated in the table.

  • Page 216: Dimensions

    9 Technical data 9.15 Dimensions Front skip (overview) 9-16 BA D18 us* 1.1 * D18t900.fm...
  • Page 217 Technical data 9 DW60 standard DW90 DW100 Values mm (in) mm (in) mm (in) Rollbar 3350 (10'-12'') 3405 (11'-2'') 3595 (11'-10'') A1 Height including rotating beacon Cabin 3215 (10'-7'') 3270 (10'-9'') 3460 (11'-4'') Rollbar 3110 (10'-2'') 3165 (10'-5'') 3355 (11'-0'')
  • Page 218 9 Technical data Swivel skip with rollbar (overview) 9-18 BA D18 us* 1.1 * D18t900.fm...
  • Page 219 Technical data 9 DW60 standard DW60 3 m skip DW90 Values mm (in) mm (in) mm (in) A1 Height including rotating beacon 3350 (10'-12'') 3595 (11'-10'') A2 Height without rotating beacon 3110 (10'-2'') 3355 (10'-10'') A3 Height with lowered rollbar 2300 (91) 2545 (8'-4'') A4 Height of lowered rollbar...
  • Page 220 9 Technical data Swivel skip with cabin (overview) 9-20 BA D18 us* 1.1 * D18t900.fm...
  • Page 221 Technical data 9 DW60 DW60 3 m skip DW90 Values mm (in) mm (in) mm (in) A1 Height including rotating beacon 3215 (10'-7'') 3460 (11'-4'') A2 Height without rotating beacon 2998 (9'-10'') 3245 (10'-8'') A3 Height without cabin 2300 (91) 2545 (8'-4'') B1 Length without maneuvering coupling 4835 (15'-10'')
  • Page 222 9 Technical data 9-22 BA D18 us* 1.1 * D18t900.fm...

  • Page 223: Index Index

    Index Index Index Index Information before putting into operation ....4-29 Abbreviations ............1-3 Information on this Operator’s Manual ....1-1 Adding coolant ............. 7-29 Air filter Checking the air intake ........7-32 Labels Information labels ..........3-12 Warning labels ........... 3-8 Battery ..............
  • Page 224 Index Tarp (option) ............5-1 Technical data Brakes ............... 9-3 Bulbs ..............9-8 Coolant compound table ......... 9-10 Electrical system ..........9-5 Engine ............... 9-1 Front skip dimensions ........9-16 Fuses/relays ............9-6 Ground clearance/ground pressure ....9-14 Machine weights ..........9-14 Maximum speed ..........
  • Page 225 Wacker Neuson Linz GmbH keep abreast of the latest technical developments and constantly improve their products. For this reason, we may from time to time need to make changes to figures and descriptions in this documentation which do not reflect products that have already been delivered and that will not be implemented on these machines.
  • Page 228 Wacker Neuson Production Americas LLC, N92W15000 Anthony Ave., Menomonee Falls, WI. 53051 Tel.: (262) 255-0500 Fax: (262) 255-0550 Tel.: (800) 770-0957 Wacker Neuson Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong. Tel: (852) 3605 5360, Fax: (852) 2758 0032...

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