Wacker Neuson DV60 Operator's Manual
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Wacker Neuson DV60 Operator's Manual

Dual view truck
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Operator's manual
Dual View Truck
Machine models
Edition
Document order no.
Language
Series number
D24-01/D24-02/D24-03
1.0
1000409070
en/us
DV60: WNCD2401CPAL00160
DV90: WNCD2402CPAL00160
DV100: WNCD2403EPAL00160

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Summary of Contents for Wacker Neuson DV60

  • Page 1 Operator’s manual Dual View Truck Machine models D24-01/D24-02/D24-03 Edition Document order no. 1000409070 Language en/us Series number DV60: WNCD2401CPAL00160 DV90: WNCD2402CPAL00160 DV100: WNCD2403EPAL00160...
  • Page 2 Violations of legal regulations, in particular of the copyright protection, will be subject to civil and criminal prosecution. 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 that do not reflect products that have already been delivered and that will not be implemented on these vehicles.

  • 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 ..........................1-2 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..........................7-8 7.4 Maintenance accesses ........................7-11 7.5 Cleaning and maintenance ......................... 7-14 7.6 Lubrication work..........................7-17 7.7 Fuel system ............................7-17 7.8 Engine lubrication system........................
  • Page 5 Declaration of conformity Declaration of conformity EC Compliance Statement Manufacturer Wacker Neuson Linz GmbH, Flughafenstr. 7, 4063 Hörsching, Austria Product Machine designation Compact Dumper Machine model D24-01 Trade name DV60 Serial number Engine/output kW TD 2.9 L4 DOC/55.4 Measured sound power level dB (A)
  • Page 6 Declaration of conformity EC Compliance Statement Manufacturer Wacker Neuson Linz GmbH, Flughafenstr. 7, 4063 Hörsching, Austria Product Machine designation Compact Dumper Machine model D24-02 Trade name DV90 Serial number Engine/output kW TD 2.9 L4 DOC/55.4 Measured sound power level dB (A)
  • Page 7 Declaration of conformity EC Compliance Statement Manufacturer Wacker Neuson Linz GmbH, Flughafenstr. 7, 4063 Hörsching, Austria Product Machine designation Compact Dumper Machine model D24-03 Trade name DV100 Serial number Engine/output kW TD 2.9 L4 DOC/55.4 Measured sound power level dB (A)
  • Page 8 Declaration of conformity EG-4 BA D24 en/us* 1.0 * D24_1_0_konf.fm...

  • Page 9: Foreword

    This will help avoid personal injury and physical damage and the vehicle can be safely and economically operated. Wacker Neuson recommends distributors or vehicle lessors to instruct operators accordingly. Please contact your dealer if you require more information on the vehicle or the Operator’s Manual.

  • Page 10: Warranty And Liability

    • Performing vehicle modifications without proper authority and using spare parts, accessories, attachments and optional equipment that have not been checked and released by Wacker Neuson Linz GmbH. The vehicle does not meet the requirements for conformity and regis- tration.
  • Page 11 Foreword 1 Symbol • 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 Cross references: see page (page)
  • Page 12 1 Foreword Abbreviations Fig. Figure Width Operating hours approx. approximately 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 Over Protective Structure (without losing contact with the ground) TOPS Tip Over Protective Structure e.
  • Page 13 (for example regarding operation) The actual weight of the vehicle at the beginning of Loading weight transportation. This weight refers to vehicles which are equipped exclusively with options approved by Wacker Neuson BA D24 en/us* 1.0 * D24_1_0_100.fm...
  • Page 14 1 Foreword • Main travel direction: seat position facing the drive unit (A). • Side travel direction: seat position facing the loader unit (B). Right/left/front/rear The terms refer to the main travel direction. • 1: Left • 2: Right • 3: Front •...
  • Page 15 Foreword 1 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 16 1 Foreword BA D24 en/us* 1.0 * D24_1_0_100.fm...

  • Page 17: 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 18: Qualification Of Operating Personnel

    2 Safety Qualification of operating personnel Owner’s duties • Only allow specifically authorized, trained and experienced persons to operate, drive and perform maintenance on the vehicle. • Do not allow persons to be trained or instructed by anyone other than an authorized and experienced person.

  • Page 19: Conduct

    Safety 2 Preparatory measures for the operator • Before starting, check the vehicle whether it can be driven and operated safely. • Tie back long hair and remove all jewelry. • Wear close-fitting work clothes that do not hinder movement. Conduct Prerequisites for operation •...

  • Page 20: Operation

    2 Safety Operation Preparatory measures • Operation is only allowed with correctly installed and intact protective structures. • Keep the vehicle 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 21 Safety 2 Job site • The operator is responsible for third parties. • Before starting work, familiarize yourself with the job site. This applies to, for example: - Obstacles in the job site and vehicle 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 22 2 Safety Carrying passengers • Carrying passengers with the vehicle is PROHIBITED. • Carrying passengers on/in attachments/tools is PROHIBITED. • Carrying passengers on/in trailers is PROHIBITED. Mechanical integrity • The operator and owner are obligated to operate the vehicle only in a safe and working condition.
  • Page 23 Safety 2 Machine operation • Start and operate the vehicle only with the seat belt fastened and only from the place provided for this. • Put the vehicle into operation only if visibility is sufficient (have another person guide you if necessary). •...

  • Page 24: Lifting Gear Applications

    2 Safety Stopping the engine of the vehicle • Stop the engine only according to the Operator’s Manual. • Before stopping the engine, lower the work equipment/attachment to the ground. Stopping and securing the vehicle • Unbuckle the seat belt only after stopping the engine. •...
  • Page 25 Safety 2 Fastening, guiding and removing loads • Follow the applicable specific regulations for fastening, guiding and removing a load. • Wear protective clothing and equipment when fastening, guiding and removing loads (for example a hard hat, safety glasses, protective gloves, safety boots).
  • Page 26 2 Safety Lifting gear applications • The vehicle 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 27: Trailer Operation

    Safety 2 Trailer operation Trailer operation • The vehicle 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 28 2 Safety Operation • Carrying persons on/in an attachment is prohibited. • Installing a work platform is prohibited. - Exception: The vehicle is certified and equipped with the necessary safety equipment. • Attachments and counterweights modify handling, as well as the steering and brake capability of the vehicle.

  • Page 29: Towing, Loading And Transporting

    Safety 2 Towing, loading and transporting Towing • Seal off the danger zone. • Ensure that no one is near the towing bar or cable. The safety distance is equal to 1.5 times the length of the towing equipment. Use a towing cable for vehicles with a total weight of up to 4.0 tons. Use a towing bar for vehicles with a total weight of over 4.0 tons.
  • Page 30 2 Safety Crane-lifting • Seal off the danger zone. • The crane and the lifting gear must have suitable dimensions. • Observe the vehicle’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 vehicle: - 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 vehicle, 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: Measures For Avoiding Risks

    2 Safety Modifications and spare parts • Do not modify the machine and the work equipment/attachment (for example the safety equipment, lights, tires, straightening and welding work). • Modifications must be approved by the manufacturer and performed by an authorized service center. •...
  • Page 35 Safety 2 Hydraulic and compressed-air system • Check all lines, hoses and screw connections regularly for leaks and visible damage. • Splashed oil can cause injury and fire. • Leaking hydraulic and compressed-air lines can cause the full loss of the brake effect.
  • Page 36 2 Safety Battery California proposal 65 WARNING Batteries, battery poles, terminals and corresponding accessory parts contain lead and its compounds and other chemicals that, according to the state of knowledge of the state of California, cause cancer, birth defects or reproductive harm.
  • Page 37 Safety 2 Safety instructions regarding internal combustion engines California proposal 65 WARNING The engine exhaust fumes of this product contain chemicals that, according to the state of knowledge of the state of California, cause cancer, birth defects or reproductive harm. WARNING Diesel engine exhaust fumes and some of its components cause, according to the state of knowledge of the state of California, cancer, birth...
  • Page 38 2 Safety Handling oil, grease and other substances • When handling oil, grease and other chemical substances (for example the battery acid, coolant), observe the safety data sheets. • Wear appropriate protective equipment (for example protective gloves, safety glasses). • Be careful when handling hot consumables –...
  • Page 39 Safety 2 Working near electric supply lines • Before performing any work, the operator must check whether there are any electrical supply lines in the designated working area. • If there are electrical supply lines, only a vehicle with cab may be used (Faraday cage).
  • Page 40 2 Safety Behavior during thunderstorm • Stop machine operation if a thunderstorm is gathering, stop the machine, secure and leave it, and avoid being near it. Noise • Observe the noise regulations (for example, during applications in enclosed premises). • Bear in mind external sources of noise (compressed-air hammer, concrete saw).

  • Page 41: Introduction

    Introduction Introduction Introduction Machine overview Fig. 2 (symbolic representations) Designation Designation Drive unit Seat console Loader unit Tilt cylinder Engine cover/maintenance access Skip Control stand BA D24 en/us* 1.0 * D24_1_0_300.fm...
  • Page 42 Introduction Fig. 3 (symbolic representations) Designation Designation Drive unit Tilt cylinder Loader unit Skip Articulation Swiveling console Steering cylinder Swiveling cylinder BA D24 en/us* 1.0 * D24_1_0_300.fm...

  • Page 43: Brief Description Of The Vehicle

    Introduction Brief description of the vehicle Wacker Neuson Dual View Trucks are powerful, highly flexible and efficient construction machines with minimum environmental impact. The application area is mainly moving soil, gravel and debris. Overview of models and trade names Machine model...

  • Page 44: Labels

    Introduction Labels WARNING Injury hazard due to 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. Information Type, quantity, and position of the labels depend on options, country and vehicle.
  • Page 45 Introduction Type labels Serial number The serial number is stamped on the machine chassis. It is also located on the type label. Fig. 4 Machine type label Type label The type label is located at the front on the vehicle chassis. Designation Designation Vehicle serial no.
  • Page 46 Check letter Production site Serial number Information Wacker Neuson 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. Fig. 7 (symbolic representation) Cabin type label (option) The type label is located on the B pillar on the left.
  • Page 47 Introduction Warning labels Fig. 9 BA D24 en/us* 1.0 * D24_1_0_300.fm...
  • Page 48 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 49 Introduction Meaning Maintenance prop/center-pivot prop Secure the skip before performing maintenance/install the center-pivot prop before crane-lifting the machine. Position Near the center-pivot prop and the maintenance prop of the skip. Fig. 14 Meaning Distance/articulation range Keep a safe distance from the machine during operation. Position On either side of the loader unit.
  • Page 50 Introduction Meaning Vehicle 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. Fig. 17 Meaning Trailer coupling Position On the vehicle rear on the left.
  • Page 51 Introduction Information labels Fig. 21 3-11 BA D24 en/us* 1.0 * D24_1_0_300.fm...
  • Page 52 Introduction Meaning Fuses and relays Position On the exterior of 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 Fig. 24 Meaning Only refuel with diesel fuel with a sulfur content of less than 15 mg/kg (=0.0015%) Position Next to the fuel tank filler inlet...
  • Page 53 Introduction Meaning (option) The reservoir contains biodegradable hydraulic oil Depending on the biodegradable hydraulic oil used, the triangle is cut out at the side Position Fig. 27 Next to the filler neck of the hydraulic oil tank Meaning Indication of sound power level produced by the vehicle = sound power level The sound power level depends on the vehicle Position...
  • Page 54 Introduction Meaning Raising/lowering and turning the skip (swivel skip option) Position On the right beside the seat 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 55 Introduction Meaning Indication of lubrication intervals Position Fig. 37 At the rear of the skip Information Type, quantity, and position of the labels depend on options, country and vehicle. 3-15 BA D24 en/us* 1.0 * D24_1_0_300.fm...
  • Page 56 Introduction ANSI label (option) Fig. 38 3-16 BA D24 en/us* 1.0 * D24_1_0_300.fm...
  • Page 57 Introduction Position On the air filter in the engine compartment Fig. 39 Position On the B pillar (cab) or on the ROPS bar on the right Fig. 40 Position On the air filter in the engine compartment Fig. 41 Position At the rear of the skip Fig.
  • Page 58 Introduction Position On the battery cover Fig. 43 Position On the battery cover Fig. 44 Position On the skip on the left and right Fig. 45 3-18 BA D24 en/us* 1.0 * D24_1_0_300.fm...
  • Page 59 Introduction Position On the B pillar on the left Fig. 46 Position On the B pillar on the left Fig. 47 3-19 BA D24 en/us* 1.0 * D24_1_0_300.fm...
  • Page 60 Introduction Position On the B pillar on the left Fig. 48 Position On the inside of the engine cover Fig. 49 Position On the maintenance flap on the left and right Fig. 50 3-20 BA D24 en/us* 1.0 * D24_1_0_300.fm...
  • Page 61 Introduction Position On the maintenance flap on the left Fig. 51 Position On the B pillar (cab) or on the ROPS bar on the right Fig. 52 Position On the vehicle frame on the left and right Fig. 53 Position On the ROPS bar Fig.
  • Page 62 Introduction 3-22 BA D24 en/us* 1.0 * D24_1_0_300.fm...

  • Page 63: Putting Into Operation

    Putting into operation Putting into operation 4 Putting into operation Cab/control console CAUTION Risk of injury when getting on and off! Entering or exiting incorrectly can cause injury. ► Keep the mandatory stages and handhold clean and only use them for entering and exiting.
  • Page 64 4 Putting into operation Unlocking and locking the door Unlocking Turn the starting key in door lock A anticlockwise. Lock Turn the starting key in door lock A clockwise. Fig. 59 Unlocking and locking the door Opening and closing the door Open Pull on door handle B.
  • Page 65 Putting into operation 4 Emergency exit Emergency exit is 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 serious injury or death. ►...
  • Page 66 6. Remove the weight off the seat for at least five seconds. 7. Carefully bring forward-reverse control A to position 1. The machine must not start moving. Fig. 63 Fig. 63 Contact a Wacker Neuson service center immediately if the machine starts. BA D24 en/us* 1.0 * D24_1_0_400.fm...
  • Page 67 Putting into operation 4 The seat can be adjusted as follows: A Backrest B Adjusting the weight C Horizontal seat adjustment Fig. 64 Symbolic representation 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.
  • Page 68 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 Set in lengthwise direction BA D24 en/us* 1.0 * D24_1_0_400.fm...
  • Page 69 ► Have a damaged seat belt and buckle immediately replaced by an authorized service center. ► Have the seat belt immediately replaced after every accident and the load-bearing capacity of the fastening points and seat fixtures checked by a Wacker Neuson service center. BA D24 en/us* 1.0 * D24_1_0_400.fm...
  • Page 70 4 Putting into operation Insert buckle latch A into seat belt buckle B until it engages. Fig. 68 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 automatically retracted. Fig.
  • Page 71 Putting into operation 4 Seat console WARNING Danger of crushing when rotating the seat console! Foot injuries may occur when rotating the seat console. ► Place your feet on the seat console. ► Rotate the seat console according to the instructions. Information If the forward-reverse control A is in position 1 or 2, the seat console will pivot a maximum of 7°.
  • Page 72 4 Putting into operation Fig. 72 Holding positions of the control console Fig. 72 4-10 BA D24 en/us* 1.0 * D24_1_0_400.fm...
  • Page 73 Putting into operation 4 Visual aids WARNING Risk of injury to persons in the danger zone! Persons in the danger area are possibly not seen when reversing the vehicle and this can cause accidents with serious injuries or death. ► Adjust the existing visual aids (for example the rearview mirrors) correctly.
  • Page 74 4 Putting into operation Adjusting the outside rearview mirrors 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 on the left.
  • Page 75 The camera’s field of vision is restricted if the skip is tilted. Fig. 75 Fire extinguisher A fire extinguisher is not available from Wacker Neuson. Contact a Wacker Neuson service center for the installation of a fire extinguisher (DIN-EN 3). Information Ensure that the fire extinguisher is firmly fastened during machine operation.
  • Page 76 ► 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 77 Putting into operation 4 Responsibility for vehicle equipped with protective structures The decision regarding the necessary protective structures (type and category I or II) must be made by the company/person operating the machine and depends on the specific work situation. The vehicle operator must observe the national regulations and must inform the operator on the protective structure to be used in a specific work situation.
  • Page 78 4 Putting into operation Rollbar Rollbar A is included in the machine’s standard equipment. DANGER Accident hazard due to falling objects! Causes serious injury or death. ► Vehicle operation is only allowed if the rollbar is raised and locked, and if the seat belt is fastened.
  • Page 79 Putting into operation 4 Lowering the rollbar 1. Park the machine on level ground. 2. Remove safety pin B. 3. Remove lock pin C. 4. Slowly fold down the rollbar A. 5. Affix the safety bolt C in the desired position. 6.
  • Page 80 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: 1. Stop and park the vehicle. Stop the engine –...

  • Page 81: Overview Of Control Elements

    Putting into operation 4 Document box The operator’s manual is stored in the document box to the left next to the seat. 12 V connection (option) A 12 V connection A is located beside the storage compartment of the cab. Fig.
  • Page 82 4 Putting into operation Control stand Fig. 84 Overview of control elements Designation See page 1 Seat with seat belt 2 Document box 4-19 3 Seat console 4 Steering-column lever 5-13 5 Service brake 6 Seat console lever 7 Accelerator pedal 8 Display 4-24 9 Joystick...
  • Page 83 Putting into operation 4 Cabin (option) Designation See page 1 Seat with seat belt 2 Document box 4-19 3 Seat console 4 Steering-column lever 5-13 5 Service brake 6 Seat console lever 7 Accelerator pedal Display 4-24 Joystick 4-22 10 12 V connection 4-19 11 Switch panel 4-22...
  • Page 84 4 Putting into operation Control elements and switches Front side of control lever Front side of control lever Rear side of control lever Steering-column lever (option) Switch panels Fig. 86 Designation See page Selection of travel direction Speed changeover Horn Horn (option) Road travel lights (option) Turn indicators (option)
  • Page 85 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 Ventilation (option) 4-23 BA D24 en/us* 1.0 * D24_1_0_400.fm...

  • Page 86: Control And Warning Lights Overview

    4 Putting into operation Control and warning 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 malfunctions. 4-24 BA D24 en/us* 1.0 * D24_1_0_400.fm...
  • Page 87 Putting into 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 display variants are shown on the following pages. 4-25 BA D24 en/us* 1.0 * D24_1_0_400.fm...
  • Page 88 4 Putting into operation Symbol Color Designation Green Turn indicators 5-15 Blue High beam Green Low beam 5-13 Green Parking light Charge indicator light Parking brake Fault at exhaust after-treatment Yellow High exhaust-gas temperatures Drive combined fault ECU error indicator light Yellow ECU warning light Yellow Preheating 4-36...
  • Page 89 Putting into operation 4 Symbol Color Designation Blue Speed range 1 Blue Speed range 2 Blue Green Engine operating mode Blue Work hydraulics deactivated Green Work hydraulics activated 4-27 BA D24 en/us* 1.0 * D24_1_0_400.fm...
  • Page 90 4 Putting into operation Symbol Color Designation Blue Travel direction Green Road-travel mode Green Operating mode Skip tipped 4-28 BA D24 en/us* 1.0 * D24_1_0_400.fm...
  • Page 91 Putting into operation 4 Symbol Color Designation Green Main travel direction Green Side travel direction Seat not engaged Seat not occupied 4-29 BA D24 en/us* 1.0 * D24_1_0_400.fm...
  • Page 92 4 Putting into operation Error symbols If an error occurs, 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 Hydraulic pump / Traveling drive Oil pressure Hydraulic oil temperature Charge indicator light...
  • Page 93 Putting into operation 4 Symbol Designation Symbol Designation Main travel direction Side travel direction Charge condition Forward travel direction Parking brake Neutral driving 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...
  • Page 94 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. •...
  • Page 95 Putting into operation 4 Machine status multifunctional display Abb. 87 4-33 BA D24 en/us* 1.0 * D24_1_0_400.fm...
  • Page 96 4 Putting into operation 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-functional display Abb. 88 A: Brightness B: Time C: Date D: 12h/24h...
  • Page 97 Putting into operation 4 Enlarge camera image Abb. 89 4-35 BA D24 en/us* 1.0 * D24_1_0_400.fm...

  • Page 98: Preparatory Work

    4 Putting into operation Preparatory work Important information before putting the vehicle into operation Perform a visual check before starting work: - There must be no leaks. - There must be no damaged or loose parts. - Do not allow anyone to stay in the danger zone. Only operate the vehicle from the seat with the seat belt fastened.
  • Page 99 Putting into operation 4 Putting into operation for the first time and running-in period Before putting the vehicle into operation for the first time, check whether the equipment supplied with the vehicle is complete. • Check the fluid levels according to chapter “Maintenance”. Each vehicle is correctly adjusted and checked before it is delivered.

  • Page 100: Starting And Stopping The Engine

    4 Putting into operation Starting and stopping the engine Preparations for starting the engine WARNING Accident hazard due to unintentional operation of the vehicle! Unintentional operation can cause serious injury or death. ► Only operate the vehicle from the seat with the seat belt fastened. The starter cannot be actuated if the engine is already running (start repeat interlock).
  • Page 101 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 102 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 103 ► The vehicles must not touch each other during the starting aid. ► If the engine still does not start despite a starting aid, contact a Wacker Neuson service center. NOTICE Possible damage due to wrong battery voltage.
  • Page 104 4 Putting into operation NOTICE Damage to battery jumper cables when placing them near rotating parts. ► Do not place 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 Machine with empty battery...
  • Page 105 Putting into operation 4 Connections 1. Move vehicle Y close to machine X so that the length of the battery jumper cables is sufficient. 2. Let the engine of vehicle Y run. 3. Unlock cover E and open. 4. Remove cover from positive terminal A. Fig.
  • Page 106 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: • Increased engine oil consumption •...
  • Page 107 Putting into operation 4 Battery circuit breaker NOTICE Possible damage to the electronics due to improper actuation of the battery master switch! ► Do not operate the battery master switch with a running engine. ► Operate the battery master switch no sooner than two minutes after shutting down the engine.
  • Page 108 4 Putting into operation 4-46 BA D24 en/us* 1.0 * D24_1_0_400.fm...

  • Page 109: Operation

    Operation Operation 5 Operation Screen protector 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. 96 Leave instrument panel cover B open during operation. Fig.

  • Page 110: Accelerator Actuation

    5 Operation Accelerator actuation Speed changeover The vehicle has two speeds that are selected with the button A on the joystick. Speed range selection Indication Speed range 1 Speed range 2 Fig. 99 Keep the service brake pressed to change over. The machine must be at a standstill.

  • Page 111: Brakes

    Operation 5 Brakes Service brake The service brake is located on the left in the leg room of the seat console. The travel speed is progressively reduced with the service brake A. The machine slows down when the accelerator pedal is released. Information Reduce the travel speed with service brake A.
  • Page 112 Information 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. Requirements •...
  • Page 113 Operation 5 Parking brake test Information If the parking brake is activated, the vehicle automatically deactivates the drive system. 1. Start the vehicle. 2. Apply the parking brake. 3. Set the forward-reverse control A to position 1. 4. Press and hold down the button D. - The selected travel direction appears in the display.

  • Page 114: Machine Travel

    5 Operation Machine travel There are two different operating modes: • Work mode Includes all work, such as for moving earth, gravel, coarse gravel and rubble. • Road-travel mode Designates machine travel on public roads. No work may be performed in road-travel mode.
  • Page 115 Operation 5 Activate road mode Switch A is located on the switch panel on the right. Function Position Activate road mode Set switch A to position 1 Enable work mode Press switch A into position 2 Fig. 106 Symbolic photo Fig.
  • Page 116 5 Operation Operating temperature range Operate the machine only at ambient temperatures between −15°C (5°F) and +45°C (+113°F). Vehicle travel on slopes WARNING Crushing hazard due to tipping over of vehicle! A tipping vehicle can cause serious injury or death. ►...
  • Page 117 Operation 5 Preparations for performing vehicle travel on slopes Always perform uphill 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%). <...
  • Page 118 5 Operation Machine travel on slopes with a loaded skip When using the machine to travel on slopes with a loaded skip, the loader unit of the machine must always face the uphill side of the slope, whichever the direction of travel. Do not perform vehicle travel on slopes steeper than 14°...

  • Page 119: Differential Lock

    Operation 5 Parking the machine WARNING Crushing hazard due to vehicle rolling away under its own weight after parking it! Serious injury or death can be caused by not securing the vehicle. ► 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 120: Lighting/Signaling System

    5 Operation Lighting/signaling system Working lights (option) The switch is located on the switch panel on the right. WARNING Accident hazard due to blinded motorists! Working lights can blind motorists. This can cause serious injury or death. ► Stop vehicle operation if motorists are blinded. ►...
  • Page 121 Operation 5 Road travel lights Ring A is located on the steering column lever. Function 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 steering-column control lever...
  • Page 122 5 Operation Horn Press push button A on the rear side of the control lever. Fig. 118 Fig. 118 Press push button B on the steering column lever (option for Austrian road traffic regulations StVZO). Fig. 119 Fig. 119 Rotating beacon (option) Switch A is located on the switch panel on the right.
  • Page 123 Operation 5 Information Follow the national and regional regulations concerning rotating beacon operation. Fig. 121 Rotating beacon, green (option) The green rotating beacon C lights up when the operator’s seat belt is fastened. Fig. 122 Turn indicators The steering-column lever is located on left of the steering wheel. Operating the turn indicators on the steering column lever.
  • Page 124 5 Operation Hazard warning system The switch is located on the switch panel on the right. Function Position Switch off the hazard warning sys- Press switch A upward Switch on the hazard warning sys- Press switch A down Fig. 124 5-16 BA D24 en/us* 1.0 * D24_1_0_500.fm...

  • Page 125: 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 switch panel on the right.

  • Page 126: Heating, Ventilation And Air Conditioning System

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

  • Page 127: Operating Hydraulics

    Operation Operation 5 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. ► Driving with a tipped skip is prohibited on public roads. ►...
  • Page 128 5 Operation Front skip operation Bring slide switch B into neutral position N. Function Operation Tilt out the skip Press control lever A forward Lower the skip Pull control lever A backward Fig. 130 Fig. 130 Swivel skip operation In order to turn the skip, raise it with control lever A until lock C is raised from guide D.

  • Page 129: Attachments

    Operation 5 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 130 5 Operation • Do not drive 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 131 Operation 5 Load (ROPS bar) The operator must leave the Dual View Truck and the danger area before loading. Observe the national and regional regulations. Load (cab) If the Dual View Truck is equipped with cab and skip grid, the operator can conduct a risk assessment and decide whether the operator must leave the cab while loading the Dual View Truck.
  • Page 132 5 Operation Transporting with a full skip WARNING Accident hazard when transporting with a full skip! Can cause serious injury or death. ► Put a full skip to transport position before performing machine travel. ► Observe the national and regional regulations when transporting with a full skip.
  • Page 133 When leaving the water, take special care not to immerse the rear end of the machine in the water, in particular the exhaust system. After using the machine in water, have the axles checked by a Wacker Neuson service center. Fig. 138 5-25...

  • Page 134: Emergency Lowering

    5 Operation 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 135 Operation 5 Information The procedure is automatically cancelled if no key requiring 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.
  • Page 136 5 Operation Maneuvering operation (option) For pulling trailers in the construction site area, the vehicle has a maneuvering coupling A. Pulling trailers is prohibited on public roads. • The vehicle skip must be 25% filled in maneuvering operation. The gross weight rating of the trailer and the contents of the skip may not exceed the vehicle’s payload.

  • Page 137: Putting Out Of Operation/Back Into Operation

    Operation 5 5.14 Putting out of operation/back into operation The specified measures refer to putting the vehicle 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 138 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 ignition and check whether there are any malfunctions .

  • Page 139: 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 140 5 Operation Notes: 5-32 BA D24 en/us* 1.0 * D24_1_0_510.fm...

  • Page 141: Transportation

    Transportation Transportation 6 Transportation Towing the vehicle 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 142 6 Transportation WARNING Crushing hazard due to vehicle rolling away under its own weight after parking it! Serious injury or death can be caused by not securing the vehicle. ► The machine may only be towed on level ground or uphill. ►...
  • Page 143 Transportation 6 Disabling the pressure limiting valves Clean the area around the pressure limiting valves. Fig. 145 Fig. 145 Loosen screws A with exactly 3 revolutions. Fig. 146 BA D24 en/us* 1.0 * D24_1_0_600.fm...
  • Page 144 6 Transportation Disabling the electronic 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 145: Loading The Vehicle

    Transportation 6 Loading the vehicle 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 146 6 Transportation 4. Start the engine. 5. Lower the skip. 6. Carefully drive the machine backward onto the middle of the transport vehicle. 7. Move the machine to transport position. 8. Apply the parking brake. 9. Stop the engine. 10.Remove the starting key and carry it with you. 11.Place the rollbar in the middle position –...
  • Page 147 Transportation 6 Crane-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 148 6 Transportation 1. Empty the skip and lower it to middle position. 2. Remove all dirt from the vehicle. 3. Park the vehicle on firm, level, and horizontal ground. 4. Activate road mode. 5. Stop the engine. 6. Remove the starting key and carry it with you. 7.

  • Page 149: Transporting The Vehicle

    Transportation 6 Transporting the vehicle 1. Install the center-pivot prop. 2. Firmly fasten the vehicle 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 150 6 Transportation Notes: 6-10 BA D24 en/us* 1.0 * D24_1_0_600.fm...

  • Page 151: Maintenance

    7-6. • In order to avoid damage to electronic components, do not perform welding work on the machine. Contact a Wacker Neuson service center. • Increased engine load can cause shorter engine oil maintenance intervals. Output is reduced if the machine is used beyond the mainte- nance interval.

  • Page 152: Maintenance Overview

    7 Maintenance Maintenance overview Maintenance label Maintenance that has to be performed by the operator is indicated on the maintenance label. Fig. 156 Maintenance label (symbolic representation) I Checking functions and levels, filling up and draining II Checking wear parts, seals, hoses and screw connections III Checking for damage, corrosion and dirt Superscript numbers, for example : number of lubrication points...
  • Page 153 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, 7-23, 7-25, brake fluid) 7-29, 7-33...
  • Page 154 7 Maintenance Daily maintenance (operator) Engine and hydraulic system Traveling drive , axles and transfer gearbox Braking system Cooling systems, heating, and hoses (visual check) Visual check Check for correct function, deformations, damage, surface cracks, wear and corrosion. Page Check the exhaust system for damage Check the insulating mats in the 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...
  • Page 155 Only once after the first 50 operating hours (Wacker Neuson service center) Page...
  • Page 156 7 Maintenance Preparing lubrication 1. Stop the vehicle on firm, level, and horizontal ground. 2. Lower the skip. Check the middle position if the machine is equipped with a swivel skip. 3. Stop the engine. 4. Remove the starting key and carry it with you. 5.
  • Page 157 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. 158 Position Lubrication point Quantity Articulation Steering cylinder Tilt cylinder Skip Seat console...

  • Page 158: Fluids And Lubricants

    7 Maintenance Fluids and lubricants Season/tempera- Application Fluid/lubricant Specification Capacities ture ASTM D975 grade 2D Summer or winter S15 (USA) diesel depending 80 liters Diesel fuel EN 590 (EU) on outside tem- (21.13 gal) peratures BS 2869 class A2 (GB) Engine Distilled water and anti- freeze ASTM D3306,...
  • Page 159 Maintenance 7 Engine oil types Tier IV engine Viscosity grade Ambient temperature min. °C min. °F max. °C max. °F SAE 0W30 SAE 0W40 SAE 5W30 SAE 5W40 SAE 10W30 SAE 10W40 SAE 15W40 SAE 20W50 >40 >104 Hydraulic oil types Hydraulic oil types Viscosity grade Ambient temperature...
  • Page 160 • 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 161: 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 162 7 Maintenance Maintenance accesses Fig. 159: Maintenance accesses Item Designation Item Designation Reservoir filler inlet Battery circuit breaker/jump-start equipment Hydraulic oil filler inlet Engine cover Fuse box Air conditioning - relays/filter 7-12 BA D24 en/us* 1.0 * D24_1_0_700.fm...
  • Page 163 Maintenance 7 Opening the engine cover 1. Stop and park the vehicle. Stop the engine. 2. Turn the starting key in lock A anticlockwise. 3. Press lock A and pull handle B. The engine cover is supported by a gas strut. Fig.

  • Page 164: 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 165 Maintenance 7 Cleaning the vehicle is divided into three separate areas: • Inside the cabin • Exterior of the vehicle • 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 166 7-6. 2. Check the vehicle for salt deposits or corrosion. Have corrosion removed by a Wacker Neuson service center. 3. Clean the vehicle with a high-pressure cleaner. Clean the vehicle ensuring that there are no salt deposits in places that are difficult to access.

  • Page 167: Lubrication Work

    Maintenance 7 Lubrication work – see chapter “ Preparing lubrication” on page 7-6. 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 168 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 169 Maintenance 7 Filler inlet A for the fuel tank is located in the drive unit, on the rear left. 1. Stop and park the vehicle. Stop the engine – see "Preparing lubrication" on page 7-6. 2. Unlock tank lock A with the starting key. 3.
  • Page 170 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. 7-20 BA D24 en/us* 1.0 * D24_1_0_700.fm...
  • Page 171 Maintenance 7 Emptying the water separator Information Empty the water separator, if error message SPN 97 appears in the multifunctional display. 1. Stop the vehicle, stop the engine – see "Preparing lubrication" on page 7-6. 2. Place a suitable container under the water separator. 3.

  • Page 172: Engine Lubrication System

    Possible engine damage from improper handling of engine oil. ► Use engine 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.
  • Page 173 Maintenance 7 Checking the engine oil level 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 oil-level dipstick with a lint-free cloth. 4. Pull out oil-level dipstick A and wipe it with a lint-free cloth. 5.

  • Page 174: 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 175 Maintenance 7 Information Check the coolant level once a day before starting the engine. Observe the coolant compound table Checking the coolant level 1. Stop and park the vehicle. Stop the engine – see "Preparing lubrication" on page 7-6. 2. Open the engine cover. 3.
  • Page 176 7 Maintenance Cleaning the radiator WARNING Burn hazard due to hot surfaces! Hot radiators can cause burns. ► Stop the engine and let it cool down. ► Wear protective equipment. NOTICE Possible engine damage or damage to the hydraulic system from dirty radiator fins.

  • Page 177: Air Filter

    Maintenance Maintenance 7 7.10 Air filter Have maintenance performed only by a Wacker Neuson service center. Checking the air intake NOTICE Possible engine damage due to intake of dirty air. ► Check once a day before putting the vehicle into operation.

  • Page 178: V-Belt

    ► Wear protective equipment. If hydraulic oil contacts the eye flush immediately with clean water and seek medical treatment. ► Have damaged or leaky screw connections, hoses and pressure lines immediately repaired or replaced by a Wacker Neuson service center. Search for hydraulic leaks with a piece of cardboard. NOTICE Damage due to wrong hydraulic oil.
  • Page 179 ► Always add hydraulic oil using the filling screen. ► 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 an authorized service center if the filter of the hydraulic system is dirty.
  • 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 vehicle 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 Wacker Neuson service center. • Only use fuses with the specified amperage. 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. Replacing the battery The battery is maintenance-free.

  • Page 183: Heating, Ventilation And Air Conditioning System

    Maintenance 7 7.14 Heating, ventilation and air conditioning system Checking/changing the cabin air filter Have this performed only by a Wacker Neuson service center. 7.15 Washer system Only use glass cleaner (with antifreeze if necessary) for refilling. Checking the fluid level and adding fluid Reservoir A for the cleaning solution of the washer system is located on the left under the floor mat.

  • Page 184: Tyres

    Accident hazard due to incorrect maintenance! Can cause serious injury or death. ► Have repair work on wheels, tires, etc. performed only by a Wacker Neuson service center. ► Use suitable assembly tools, for example covering sleeves for the studs, a jack.

  • Page 185: Maintenance Of Attachments

    Maintenance 7 Wheel change NOTICE Support the vehicle and raise it so that it is not damaged. Information Note the direction of travel of the tires. 1. Park the vehicle on firm, level, and horizontal ground. 2. Apply the parking brake. 3.
  • Page 186 7 Maintenance 7-36 BA D24 en/us* 1.0 * D24_1_0_710.fm...

  • Page 187: 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 warning Engine stop...

  • Page 188: General Malfunctions

    Replace the battery 7-32 tery Malfunctioning fuse Check the fuse Electric feed pump is not run- Contact a Wacker Neuson Engine does not start or is not easy to ning service center start Do not select a travel direc- Travel direction selected...
  • Page 189 Engine starts, but does not run Air in fuel system Bleeding the fuel system 7-20 smoothly or dies Black engine smoke or Contact a Wacker Neuson Dirty air filter Output loss service center Contact a Wacker Neuson Blue engine smoke...
  • Page 190 The traveling drive is disabled. • Stop and park the vehicle. • Contact a Wacker Neuson service center and have the malfunction rectified. Machine travel and operation is possible in case of minor errors. • Engine power is not reduced.

  • Page 191: Technical Data

    Technical data Technical data 9 Technical data Model designations and trade names Machine model Trade name D24-01 DV60 D24-02 DV90 D24-03 DV100 Engine Engine DV60/DV90/DV100 Manufacturer Deutz Type TD 2.9 L4 DOC Design Water-cooled 4-cylinder diesel engine Intake system Turbo-charging...

  • Page 192: Drive/Axles

    9 Technical data Drive/axles Travel drive DV60/DV90/DV100 Design Infinitely variable axial piston pump with electric control Flow rate 123.2 l/min (32.55 gal/min) Max. operating pres- 260 bar (3771 psi) sure Starting speed 1300 rpm +/- 50 Oscillation angle 11° Boost pump...

  • Page 193: Brakes

    Technical data 9 Brakes Service brake DV60 DV90/DV100 Dual-circuit brake Design Wet multidisk brake on loader unit axle Location loader unit axle Wheels of Indirectly via cardan shaft drive unit Effect Direct Wheels of Direct drive unit Parking brake DV60/DV90/DV100...

  • Page 194: Tires

    9 Technical data Tires Tire type/size DV60 DV90 DV100 Tire size 405/70-20 (16/70-20) 41x18LL-22.5 500/60-22.5 Model MPT01 MPT03 Lawn Drive unit 2 bar (29 psi) 2.5 bar (36 psi) 2.8 bar (41 psi) Tire pressure Loader unit 3.5 bar (51 psi)
  • Page 195 Technical data 9 Steering system DV60/DV90/DV100 Flow rate at 1900 rpm 60,6 l/min (16.1 gal/min) Max. operating pressure 185 bar +/-5 bar (2683 psi +/-73 psi) Secondary pressure protection 250 bar +/-10 bar (3625 psi +/-145 psi) Maximum speed Information Follow the national and regional legal regulations regarding maximum speed.

  • Page 196: Electrical System

    9 Technical data Electrical system Electrical components DV60/DV90/DV100 Alternator 12 V/120 A Starter 12 V/3.2 kW Battery 12 V/100 Ah 12 V power outlet 15 A max. According to DIN EN 50342, DIN IEC 60095-2 BA D24 en/us* 1.0 * D24_1_0_900.fm...
  • Page 197 Technical data 9 Fuse box Fuse box A is located at the front left in the control console. Loosen screws B. Fig. 180 Fig. 181 BA D24 en/us* 1.0 * D24_1_0_900.fm...
  • Page 198 9 Technical data Fuses/ Rated current Protected circuits relays F001 Switched power consumers F002 Preheating F003 12 V 30 F004 12V15, 12V15_1, 12V30 F005 7.5A Clearance light (left) F006 7.5A Clearance light (right) F007 Engine ECU 12 V 30 F008 Drive ECU 12 V 30 F009 CPU drive ECU 12 V 30...
  • Page 199 Technical data 9 Fuses/ Rated current Protected circuits relays K030 Relay 20/35A Brake lights K062 Relay 20/35A Low beam K063 Relay 20/35A High beam Time lag relay K087 Start time lag relay 0.75s K088 Relay 20/35A Fuel pump K114 Relay 20/35A Rotating beacon K130 Relay 20/35A...

  • Page 200: Tightening Torques

    9 Technical data 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 201: Coolant

    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. 9.11 Noise emissions DV60/DV90/DV100 Measured sound power level 101 dB(A) Guaranteed sound power...

  • Page 202: Vibrations

    9 Technical data 9.12 Vibrations 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 203 Technical data 9 Note: For further vibration indications, refer to the indications in ISO/TR 25398 Mechanical Vibrations – Directive on Estimation of whole-body vibration during operation of earth moving vehicles. This publication uses measuring values of international institutes, organizations and manufacturers.
  • Page 204 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. 9-14 BA D24 en/us* 1.0 * D24_1_0_900.fm...

  • Page 205: Weight

    Technical data 9 9.13 Weight Machine weights Front skip ROPS DV60 kg/lbs DV90 kg/lbs DV100 kg/lbs Transport weight 4114 (9070) 4614 (10,172) 4644 (10,238) Operating weight 4232 (9330) 4733 (10,434) 4763 (10,501) Front skip canopy DV60 kg/lbs DV90 kg/lbs DV100 kg/lbs...

  • Page 206: Payload

    9 Technical data 9.14 Payload Front skip DV60 DV90 DV100 Liquid capacity 1900 liters (502 gal) 2400 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)

  • Page 207: Dimensions

    Technical data 9 9.15 Dimensions 9-17 BA D24 en/us* 1.0 * D24_1_0_900.fm...
  • Page 208 9 Technical data DV60 DV90 DV100 mm (in) mm (in) mm (in) 3078 (10'-1'') 3083 (10'-1'') 3083 (10'-1'') 2938 (9'-8'') 2944 (9'-8'') 2945 (9'-8'') 3617 (11'-10'') 3620 (11'-11'') 3620 (11'-1'') 3302 (10'-10'') 3307 (10'-10'') 3307 (10'-10'') 2400 (95) 2405 (95)

  • Page 209: Index

    Index Index Index Abbreviations ............1-4 Label Adding coolant ............. 7-25 Warning labels ........... 3-7 Air filter Lateral angle of inclination ........5-10 Checking the air intake ........7-27 Letting the engine warm up ......4-36, 4-37 Loading the vehicle ..........6-5 Low-load operation ..........
  • Page 210 Index Tarp (option) ............5-1 Technical data Brakes ............... 9-3 Bulbs ..............9-9 Coolant compound table ......... 9-11 Dimensions ............. 9-17 Electrical system ..........9-6 Engine ............... 9-1 Fuses/relays ............9-7 Ground clearance/ground pressure ....9-15 Machine weights ..........9-15 Maximum speed ..........
  • Page 211 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 that do not reflect products that have already been delivered and that will not be implemented on these vehicles.
  • Page 212 Wacker Neuson Linz GmbH Flughafenstr. 7 A-4063 Hörsching 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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