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Operator`s Manual

1. eit 1000168250 Fig 11 Keep a safe distance 97050146 Fig 12 Diesel Fig 14 Read the Operator s Manual l k l T 9705421 Fig 15 Dumping out the skip BA 3001 En Edition 4 0 345001b110 fm Introduction Meaning Indicates that persons other than the driver must keep a safe distance from the machine during operation Location On left and right of front chassis Meaning Fill in diesel fuel only Location On the fuel filler inlet Meaning Hydraulic oil filler inlet see chapter Filling up hydraulic oil on page 5 20 Location On the filler inlet of the hydraulic oil tank Meaning Fold down the maintenance strut before carrying out work underneath the skip Location On the swivelling console at the front Meaning Shows how the skip can be dumped out Location On the engine cover 1 7 Introduction Fig 16 Swivelling the skip SS Fig 17 Caution Fig 18 Lap belt 1 8 Meaning Shows how the skip can be swivelled Location On the engine cover Meaning Caution rotating or hot parts Read the Operator s Manual Location On the engine cover Meaning Al
2. 1085 H 1960 i A Fig 49 Machine dimensions model 3001 S 2 2 metres high with skip dumped out option Main data Model 3001S Dead weight 2400 kg Overall height 2670 mm Overall height with rollbar folded down 1850 mm Overall height without rollbar 1850 mm Overall width 1750 mm Ground clearance 230 mm Wheelbase 1960 mm Outside turning radius 3950 mm Hill climbing ability 50 theoretically Safe authorised inclination 25 in all drive positions BA 3001 En Edition 4 0 345001b610 fm 6 7 Specifications 6 8 WACKER NEUSON BA 3001 En Edition 4 0 345001b610 fm WACKER NEUSON Safety instructions for operation of earth moving machines Safety instructions for operation of earth moving machines 7 1 7 2 7 2 1 7 2 2 7 2 3 7 2 4 Preliminary remark Designated use BA 3001 En Edition 4 0 345001b710 fm The following machines are designated as earth moving machines e Excavators e Loaders e Backhoe loaders e Dozers e Dumpers e Scrapers e Graders e Pipe laying machines e Trench cutting machines e Compactors and Other special earthmoving machines Instructions for the safe operation of earth moving machines are given in the following Also comply with the national safety standards such as regulations for accident preven tion or safety guidelines for machine maintenance during
3. Fig 21 Front skip maintenance strut BA 3001 En Edition 4 0 345001b510 fm 5 1 WACKER Maintenance NEUSON Swivel skip maintenance strut AN Danger Mount the red maintenance strut before you carry out maintenance work with the skip raised Mount the maintenance strut as follows t Raise the skip t Remove safety pin B from pin C t Lower the skip until maintenance strut A rests on swivelling console D Mount the maintenance strut back onto the skip in the reverse order if it is no longer needed Fig 22 Swivel skip maintenance strut 5 2 BA 3001 En Edition 4 0 345001b510 fm WACKER NEUSON 5 2 Fuel system Specific safety instructions Refuelling Fig 23 Fuel filler inlet BA 3001 En Edition 4 0 345001b510 fm Maintenance e Extreme caution is essential when handling fuel high risk of fire e Never carry out work on the fuel system in the vicinity of naked flames or sparks e Do not smoke when working on the fuel system or when refuelling e Before refuelling stop the engine and remove the ignition key Do not refuel in closed rooms e Wipe away fuel spills immediately Keep the machine clean to reduce the risk of fire Filler inlet A for the fuel tank is located under the engine cover on the right in driving direc tion AN Danger All work involving fuel carries an increased Danger of fire and poisoning t Do not refuel in closed rooms t Never
4. ss snsnsnsnsnnsnsnsnrsnsnrsrsnnnnsrnnnnsrnnrnrsrsennens 3 17 Driving on slopes with an empty skip ssnsnsnssnsnsnsnnsnsnsrisrsnnnrsnrsnsrsnisrsrnnrsrsrsrnna 3 17 Driving Across SIOpES scecsdtesosnnenteisncstnuinstntannniiwatnetwedsancdailastiubannenntaauseiesddonen 3 17 Parking n MAGI IR 3 18 Loading the machine cccescssssscssssssessessessseeseeseessesersesseesaesersaesersseseesaseas 3 19 SEAU NON aa enn E E 3 20 Weight adjustment E 3 20 Horizontal adjustment EEN 3 20 Backrest adjustment sinssscnsvcsnnsaaionnncoasweviatnconssanncaonnisddoesnonsvaneudesealhdetvuenautoentees 3 20 See E 3 21 ENN OVO E 3 22 Working Kohn 3 23 General safety instructions EEN 3 23 Dumper 3001 front skip operation c cc cccccseceesssssssssessssseseseesssssseesesseseeseesatees 3 24 Dumper 3001 swivel skip operation ou ccccccsscsscssessssssescessessessessessesaseeseeseesatees 3 25 ROND tee ae eae tet cen nC acai dl edi dba meade ete 3 26 TOWING E 3 27 Opening the high pressure circuit EEN 3 27 Conte ele 3 28 Beie duebel ite WC 3 28 Crane handling the machine cccccsesssecsccecsessscscssesssesessesaecssseseesessesesansates 3 29 Machine 300 TOF surasa nn en cee er 3 29 Machine 3001 S 2 2 metres high with skip dumped Out c cece 3 30 Loading and transporting the machine 3 31 Tying down the machine cccccssssssesssssseeseeseseseeserssessesesrssessessesersaess 3 32 Battery Master SWIM EE 3 32 Troubleshooting
5. 7 6 6 5 BA 3001 En Edition 4 0 345001b710 fm WACKER NEUSON Safety instructions for operation of earth moving machines When driving on slopes select a route that will enable you to brake the earth mov ing machine safely Avoid reversing over longer distances Earth moving machines may be driven on public roads only if the operating and driving licences as defined by national traffic regulations have been obtained for them When not driving on public roads e g construction sites apply the road traffic rules accordingly This also applies to driving permits Load and unloading The machine operator may move the work equipment across persons in driver seats or work stations of other machines only if they are protected by canopies FOPS lf not protected accordingly the driver of this vehicle must leave the operator s place if moving the work equipment across his place cannot be avoided When loading vehicles make sure they are not overloaded and that they will not loose any material when driving Load them from the lowest possible height If possible the places where material is unloaded should enable the driver to avoid reversing over longer distances At places where material is dumped operate earth moving machines only after hav ing taken appropriate measures to prevent the machines from falling down or rolling away under their own weight Persons giving instructions Persons giving instructions must be eas
6. Clean the machine especially connections and threaded unions of any traces of oil fuel or preservatives before carrying out maintenance repair work Do not use aggressive detergents Use lint free cleaning rags Before cleaning the machine with water steam jet high pressure cleaner or deter gents cover or tape up all openings which for safety and functional reasons must be protected against water steam or detergent penetration Special care must be taken with the electrical system After cleaning remove all covers and tapes applied for that purpose After cleaning examine all fuel lubricant and hydraulic oil lines for leaks chafe marks and damage Rectify all defects without delay Always tighten any screw connections that have been loosened during maintenance and repair Any safety devices removed for set up maintenance or repair purposes must be refitted and checked immediately upon completion of the maintenance and repair work Make sure all consumables and replaced parts are disposed of safely and with minimum environmental impact Before taking up work on machine parts dangerous for life and limb bruising cutting always ensure safe blocking support of these areas Carry out maintenance and repair work beneath a raised machine work equipment attachments or additional equipment only if a safe and secure support has been provided for the sole use of hydraulic rams jacks etc does not sufficiently secur
7. Prevents the machine from rolling away Lock the control levers see chapter 3 18 Locking the control levers on page 3 28 e The rollbar can be lowered to reduce the transport height Put the centre pivot strut in place see chapter 3 17 Centre pivot strut on page 3 28 e Remove the four screws B on the rollbar e Mount two shackles A on either side e Mount four screws B and tighten them to 210 Nm e Fasten eye hooks 2 and 3 on either side Use suitable lifting gear chains etc 1 and position them vertically over the steering wheel as shown in the drawing Ensure a length of 1650 mm e Slowly raise the machine Fig 46 Craning operation 3 30 BA 3001 En Edition 4 0 345001b330 fm WACKER e NEUSON Operation Loading and transporting the machine Safety instructions e The transport vehicle must be of adequate size refer to Chapter 6 Specifications for the machine s dimensions and weights e Remove any mud snow or ice from the tyres so that the machine can be safely driven onto the ramps e Secure the machine against unintentional movement see Parking the machine on page 3 18 AN Danger The machine must be loaded and transported properly Danger of accidents ts t is essential that you read the safety instructions at the beginning of this chapter and follow any other safety instructions relevant in your country t Load as follows e Secure the transport vehicle with chocks
8. Mode iit Model year ante nnn Cas 4 4242 itt Output an SefialhOs ence Max payload etn nnn GR niece Operating weight nen nn LE Front GAWR enn Transport weight een nnn Rear GAWR atten enn ferent TK Verse ita e Other information see chapter 6 Specifications on page 6 1 1000191013 Made in Austria Fig 1 Type label location Nee acker Neuson Linz GmbH jaidfeldstraRe 37 4060 Linz Leonding Austria el 43 0 732 90590 0 Fax 43 0 732 90590 200 office wackerneuson com kg PTAC Zul Achslast vorn Front GAWR kg PNBE AV Zul Achslast hinten Uad U D p DD sas css ISL S55 PLO FSS aa Paes RRR S ad Fig 2 Type label Engine number The type label arrow is located on the valve cover of the engine Example Yanmar 46557 Fig 3 Yanmar diesel engine number Hydraulic pump number The type label arrow is located on the hydraulic pump housing Fig 4 Number of variable displacement pump 1 4 BA 3001 En Edition 4 0 345001b110 fm WACKER NEUSON Introduction Rollbar number The type label is located on the left on the rollbar Axle number The type label arrow is located on the upper side of the axle housing Fig 6 Axle type label BA 3001 En Edition 4 0 345001b110 fm 1 5 Introduction WACKE
9. 18470 Agang SNP Ja eM y ULAJI US 000 Aae ue us 00G Jee out IS Y 10 OIINeupPAY y open Us 000 AJen8 ue Us OG Jaye SUH ei au P SUL Jo Ip Nep y y open Jeak e 80U0 JO U S 000 Alan u y U S OG 14e SWI SJ y IO au Boe dey Jeak e 80U0 JO U S 000 Agang UAL U S OG 194e SWI SJ y IO au Boe dey Jeak e 80U0 JO U S 000 H r USL U S OG 194e SWI SJ y IO au Boe dey Us 00G Aland Uy Us OG Jaye oun et OU Jo any y soe day US 009 Aloo Udy us OG JOYE au IS OY Je 10 auf ay ode U S 00G Ald UBL U S 0G Jaye oun zs a 10 aufua ueq CH e SE NA FO ON OD SAWP BulljaAed zen nouo Bulo a w s s onespAy pue dulbuz sn Y29342 JENSI AJESS809U JI ANDY szjuauodwos pue Sal quasse HUIMO O y zo suooauuoo m s pue Soul q X s d d Huyey pue sye j ssauzyfy Jo yoouD K K Le E had lt e OO lt lt e _ o o SKS 2 o 2 oC o may Gei co gt ei ss D D D Se gt gt gt gt LLI c o LLI LLI a Be c O y S Sinoy adIAJas uejd a2upuauueN 177 yoayo aBeyeay uonouny Duugee uonouny eyeig BuIed Lage Bulusem osnooe uerge Buljeubis s y6r7 Alessaoeu J Ate S uUaUOdWOD Sal quasse Huimojjo y JO UOOUNJ y Y29049 lt gt Jeun jeuoyjoun4 9JOSUOD Bul aAIMS e Julol paye noiy Wed SHO Wed III we Duugoe T Se JoINjoBsNUeW IWUSUUDEUE
10. ENJING POUDIE EE 4 1 Maintenance UC N aro E E E EE E E EO 5 1 Front skip maintenance strut oo ccesccccsecsecsscsseesssssessessesssesseesesesesreateass 5 1 Swivel skip maintenance strut oo ee eseeteeeeeseeseesseessesseseeceeseteeseseeseeseesaesatees 5 2 WISEN 5 3 Specific safety instructions 5 3 Eege csensdtecenesvereraneseeeswacuerusentdeeuosepseetaessodesteooseesaseuesutet 5 3 SCHMITT el ul 5 4 Diesel fuel specification oo cece cceescsessssssscsececssesssesesseseeseesescasseseesseseesaesateateas 5 4 Bleeding the fuel system ue 5 4 Fuel prefilter with water separator cc ccccccecseceessssssssesssessessesrsssesseesersateass 5 5 Replacing the fuel filter c ccccscsssssssssssssssssscssceesersessseseesassesseseeserseesansansasees 5 6 Engine lubrication system cccccccccscsssssesssscsesessscssseseessesseseesetsaseasseseeseesaesateates 5 7 Checking the oil level cccecceccssssssssssscsscsessessessessessesesseseeseeseesaesasseseesansasees 5 7 Slllelfietldet Tel 5 8 Engine and hydraulics cooling system ccccccssessessesssssesssecsecsssssseseesseseseesatsaees 5 9 Specific safety instructions 5 9 Checking filling up coolant cece cccccssceesssssssssecsecssceseesessessesaesasseseesesateass 5 10 POAC mounting 3U EE 9 12 Srel 5 12 KIELEN 5 13 PAM TMNT E 5 14 Replacing the filter EE 5 15 BA 3001 En Ausgabe 4 0 Ba345001en4_0IVZ fm WACKER NEUSON MOE E A A E E E AE NA 5 16 Checki
11. Edition 4 0 345001b610 fm 30 in all directions 97 68 EC tier 2 EPA tier 2 Variable displacement pump 97 68 EC tier 3 EPA tier 3 Model 3001 Design Axial piston pump Displacement 45 cm rev Flow rate 126 l min Max operating pressure 360 bar Boost pump integrated in variable displacement pump Design Gear pump Displacement 8 4 cm Charging boost pressure 25 bar Service brake parking brake Model 3001 Design Wet multidisc brakes Location Front axle Hydraulic service brake SR mechanical parking brake 6 1 Specifications 6 5 Steering system 6 6 Work hydraulics 6 7 Skip 6 8 Drive specifications 6 9 Electrical system 6 2 Steering system WACKER NEUSON Model 3001 Design Hydrostatic Steering mode Chassis articulation steering Work hydraulics Model 3001 Hydraulic pump displacement 16 2 cm rev Hydraulic pump flow rate 45 l min Max operating pressure 200 bar a pressure limiting for offset 160 bar Hydraulic tank capacity 48 Steering system 150 bar Model 3001S Skip Model 3001 F Model 3001S Ba berated th i out 1500 I struck 1300 I struck 1020 struck Skip capacity 1850 heaped 1750 heaped 1300 heaped 1160 liquid capacity 900 liquid capacity 820 liquid capacity Payload 3000 kg 2600 kg Swivel angle 180 217 180 217 Steering system Mode
12. To avoid this t Clean the outside of the radiator at regular intervals Use oil free compressed air 2 bar max to clean Maintain a certain distance from the radiator to avoid damage to the radiator fins Refer to the maintenance plans in the appendix for the cleaning intervals t n dusty or dirty work conditions clean more frequently than indicated in the mainte nance plans An insufficient coolant level reduces the heat dissipation capacity as well and can lead to engine damage Therefore t Check the coolant level at regular intervals Refer to the maintenance plans in the appendix for the intervals t f coolant must be added frequently check the cooling system for leaks and or con tact your dealer t Never fill in cold water coolant if the engine is warm t After filling the expansion tank make a test run with the engine and check the coolant level again after stopping the engine The use of the wrong coolant can destroy the engine and the cooler Therefore ts Add enough antifreeze compound to the coolant but never more than 50 If pos sible use brand name antifreeze compounds with anticorrosion additives t Observe the coolant compound table see chapter 6 12 Coolant compound table on page 6 4 t Do not use cooler cleaning compounds if an antifreeze compound has been added to the coolant otherwise this causes sludge to form which can damage the engine Once you have filled the expansion tank t
13. Wheelbase 1960 mm Outside turning radius 4000 mm Hill climbing ability 50 theoretically Safe authorised inclination 25 in all drive positions BA 3001 En Edition 4 0 345001b610 fm 6 5 aT WACKER Specifications NEUSON 6 14 Dimensions model 3001 swivel skip 3125 2610 J Ta S d l 1020 dd 1960 1160 Hill climbing ability Safe authorised inclination p L140 Fig 48 Machine dimensions model 3001S Main data Model 3001S Dead weight 2550 kg Overall height 2670 mm Overall height with rollbar folded down 1870 mm Overall height without rollbar 1870 mm Overall width 1785 mm Ground clearance 280 mm Wheelbase 1960 mm Outside turning radius 3950 mm 50 theoretically 25 in all drive positions BA 3001 En Edition 4 0 345001b610 fm WACKER ioe NEUSON Specifications 6 15 Dimensions model 3001 S 2 2 metres high with skip dumped out option 1850 14 00
14. AN Danger Incorrect crane handling of the machine Danger of accidents t Make sure no one is near the machine t Have loads fastened and crane operators instructed by experienced per sons only The person giving the instructions to the crane operator must be within sight or sound of him t Make sure the crane and the lifting gear cables chains have sufficient lift ing capacity ts Raise the machine only if the skip is empty ts Stay clear of suspended loads ts t is essential that you read the safety instructions at the beginning of this chapter and follow any other safety instructions relevant in your country Machine 3001 S F Load the machine as follows e Empty the skip e Lower the skip Stop and park the machine Lock the control levers see chapter 3 18 Locking the control levers on page 3 28 e The rollbar can be lowered to reduce the transport height e Put the centre pivot strut in place see chapter 3 17 Centre pivot strut on page 3 28 e Use suitable lifting gear chains etc t Make the lifting gear pass through bracket 1 on the edge of the skip and fasten it on eye hook 2 on the chassis Fig 44 Craning operation Slowly raise the machine BA 3001 En Edition 4 0 345001b330 fm 3 29 WACKER NEUSON Operation Machine 3001 S 2 2 metres high with skip dumped out Load the machine as follows e Empty the skip e Lower the skip e Park the machine on firm and level ground
15. After 1500 s h Once a year or after 1000 s h Every 500 s h Every 250 s h once a day Every 50 s h Maintenance work u s Sinoy adIAJas uejd a2upuauEIN ued D JE EM UIEID JOJEJEdaS JO EM YIM JO Ajessaoau JI UEap La 11E 84 YOBUD abewep Jo 11y y2 y9 ng ainssaid pue sye j JO s soy pue Bunesy swazs s Huljood Y29349 Alessadeu j UE UIP JO JIO 3NespAy pue dulbus 104 soyeIpes Y29490 e SONP JEE USD IO 21UDEIDAL uejoo9 aUIDU2 lo ui u7 e Kessav au JI y y Jenaozew Huimojjo au Y29049 lt gt yom uonsedsu Jayyeaig yug IO JNEJIp H o IO 21UDEIDAL WOSUI Jo 10 20DEID U IO ayelg lo xoque Jajsuel IO GIEL o IO JEUSIOLIG e WIEIOO JUDWAIO Io Iy o UNI 1S9 Jaye SA9 IO Y92942 SeBueYO Jo pue jio Duouo y no UE gt sabueyo ou pue Dm Ten Se JouNjOBjNUeW JUsWWYOe e OU Jo jenuew soueus UIeW pue uonesado au 0 19491 se jd JUaLUYOeWe au UO YOM DULU PUL BdIAAS JO4 UOI ALIOSAP YONA MOIAJOAO uEId BDUeUdJUIEW FL BA 3001 En Edition 4 0 345001b540 fm 9 34 Maintenance Dech WACKER NEUSON Authorised workshop Customer After 1500 s h o S D lt O Gel de E E E S S D o rey 12 o Ch Gei co e gt gt D 3 D En 9 Ce gt
16. EI mg gg EE Hiki Ce OAN 3 4 instrument panel overview Pos Description 39 Hazard warning switch 40 Preheating start switch 41 Hour meter 42 Not assigned 43 High beam telltale blue 44 Preheating telltale yellow 45 Hydraulic oil filter telltale red 46 Not assigned 47 Alternator charge function telltale red 48 Parking brake telltale red 49 Engine oil pressure telltale red 50 Coolant temperature telltale red 51 Turn indicator telltale green 52 Not assigned 53 Fuel level indicator 54 Low speed switch turtle BA 3001 En Edition 4 0 345001b320 fm 3 5 Operation 3 9 Putting into operation Safety instructions WACKER NEUSON Use footholds and handles 38 to access and leave the machine Never use control elements as handles Never get on or off a moving machine Never jump off the machine Putting the machine into operation for the first time Running in period 3 6 Important information The machine may be put into operation by authorised staff only see chapter Selection and qualification of staff basic responsibilities on page 2 4 and see chapter 2 Safety instructions on page 2 1 of this Operator s Manual The staff must have read and understood this Operator s Manual before putting the machine into operation The machine may only be used in technically perfect condition in accordance with its designated use and the instructions set forth in the Operator s Manual
17. Maintenance 5 7 V belt Checking V belt tension Fig 35 Checking V belt tension 5 16 WACKER NEUSON AN Danger Only check or retighten replace the V belt when the engine is stopped Danger of personal injury t Stop the engine before carrying out inspection work in the engine compart ment t Disconnect the battery t Let the engine cool down AN Caution Cracked and stretched V belts cause engine damage ts Have the V belt replaced by an authorised workshop Check the V belt once a day or every 10 service hours and retighten if necessary Retighten new V belts after about 15 minutes of running time Check as follows t Stop the engine t Remove the key and carry it with you t Disconnect the battery t Let the engine cool down t Open the engine cover t Carefully check V belt 1 for damage cracks or cuts t Replace the V belt if it touches the base of the V belt groove or if the pulleys are dam aged If the V belt is damaged t Have the V belt replaced by authorised staff t Press with your thumb about 100 N to check the deflection of the V belt between the crankshaft disc and the fan wheel A new V belt should have a deflection of 6 to 8 mm a used V belt after about 5 minutes running time should have a deflection of 7 to mm t Retighten the V belt if necessary BA 3001 En Edition 4 0 345001b520 fm WACKER NEUSON Maintenance AN Caution Overtightening the V belt can damag
18. Proceed in the reverse order to do this unscrew the screw as far as it will go 3 27 WACKER NEUSON Operation 3 17 Centre pivot strut AN Danger Put the red centre pivot strut in place before loading the machine The centre pivot strut connects the front and rear chassis to prevent steering movements via the articulated joint when crane handling the dumper Procedure to follow t Remove the spring plug from pin B t Turn centre pivot strut A towards the rear chassis t Secure centre pivot strut A with the spring plug and pin B eee eh e e E EA ed pe z ee TS N Ce Ko H dees e E e RE m Fig 42 Centre pivot strut Notice Before putting the machine into operation again mount the centre pivot strut back onto the front chassis again by means of pin B 3 18 Locking the control levers Lock the control lever for the skip during road travel t This avoids unintentional actuation of the skip Lock as follows t Remove split pin A from bracket B t Fold bracket B to the front t nsert split pin A in bracket B Fig 43 Locking the control lever Unlock in the reverse order 3 28 BA 3001 En Edition 4 0 345001b330 fm WACKER e NEUSON Operation 3 19 Crane handling the machine Safety instructions The crane and the lifting gear must have suitable dimensions e Crane handling the machine requires suitable lifting gear e Secure the machine against unintentional movement
19. Test run the engine t Stop the engine t Let the engine cool down t Check the coolant level again d Environment Use a suitable container to collect the coolant as it drains and dispose of it in an environ mentally friendly manner BA 3001 En Edition 4 0 345001b510 fm 5 9 Maintenance Checking filling up coolant 5 10 WACKER NEUSON AN Danger Never open the coolant tank and never drain coolant if the engine is warm since the cooling system is under high pressure Danger of burns ts Wait at least 15 minutes after stopping the engine t Wear protective gloves and clothing t Open filler cap B to the first notch and release the pressure t Make sure the coolant temperature is sufficiently low so you can touch the radiator plug with your hands Danger Antifreeze is flammable and poisonous Danger of accidents ts Keep away from flames ts Avoid eye contact with antifreeze e If antifreeze comes into contact with the eyes Immediately rinse with clean water and seek medical assistance BA 3001 En Edition 4 0 345001b510 fm WACKER NEUSON E Fig 29 Radiator BA 3001 En Edition 4 0 345001b510 fm Maintenance Checking the coolant level t Proceed as follows e Park the machine on level ground Stop the engine e Remove the key and carry it with you e Let the engine and the coolant cool down Open the engine cover e Check the coolant level on the transpa
20. a P N 888888 8 CH neuson BA 3001 En Edition 4 0 345001b320 fm Operation 52 Not assigned 48 Parking brake telltale red Comes on if the parking brake is applied In this case t Actuate lever 28 to release the parking brake 43 High beam telltale blue Comes on if high beam is on AN Caution Make sure no other road users are dazzled during road travel t Switch on low beam 51 Turn indicator telltale green Flashes if the turn indicators are switched on 41 Hour meter Counts the engine service hours with the engine running 53 Fuel level indicator Refuel immediately if the fuel level indicator reaches minimum Otherwise the fuel system must be bled if it is run dry 3 11 Operation Before starting the engine Starting the engine general Procedure Fig 21 Preheating start switch N 888888 8 GH neuson Fig 22 Telltales 3 12 WACKER NEUSON ts Adjust your seat position see Seat adjustment on page 3 20 DH Notice All controls must be within easy reach You must be able to press the accelerator and brake pedals to their limit positions ts Fasten your seat belt see Seat belt on page 3 21 e Do not fasten your seat belt if the rollbar is not raised t Check whether all levers and pedals are in neutral position ts Press the accelerator pedal to the centre position between minimum and maximum if the engine is cold e The starter cannot b
21. and only by safety conscious persons who are fully aware of the risks involved in operating the machine Go through the Start up checklist in the following chapter Handle the machine carefully during its first 50 operating hours The future performance and service life of the machine are heavily dependent on the observance of the following recommendations during the running in period Do not overload the machine but at the same time do not drive too cautiously either as the machine will never reach its proper operating temperature Do not run the engine at high speed for extended periods Increase the load gradually whilst varying the engine speed Strictly observe the maintenance schedules in the appendix see chapter 5 14 Maintenance plan overview on page 5 34 BA 3001 En Edition 4 0 345001b320 fm WACKER e NEUSON Operation Check lists The checklists below are intended to assist you in checking and monitoring the machine before during and after operation These checklists cannot claim to be exhaustive they are merely intended as an aid for you in fulfilling your duties as a conscientious operator The checking and monitoring jobs listed below are described in greater detail in the follow ing chapters lf the answer to one of the following questions is NO first rectify the cause of the fault before starting or continuing work Start up checklist Check the following points before putting the machin
22. carry out work on the fuel system in the vicinity of naked flames or sparks t No smoking no fire ss Environment Use a suitable container to collect the fuel as it drains and dispose of it in an environmen tally friendly manner DH Notice Do not run the fuel tank completely dry Otherwise air is drawn into the fuel sys tem This requires bleeding the fuel system see Bleeding the fuel system on page 5 4 DH Notice Fill up the tank with the correct fuel type at the end of each working day This pre vents condensation water from forming in the fuel tank over night Do not fill the tank completely but leave some space for the fuel to expand 5 3 Maintenance Stationary fuel pumps Fig 24 Refuelling from a barrel Diesel fuel specification Bleeding the fuel system 5 4 WACKER NEUSON General Only refuel from stationary fuel pumps Fuel from barrels or cans is usually dirty Even the smallest particles of dirt can cause e Increased engine wear e Malfunctions in the fuel system and e Reduced effectiveness of the fuel filters Refuelling from barrels If refuelling from barrels cannot be avoided note the following points see fig 24 e Barrels must neither be rolled nor tilted before refuelling e Protect the suction pipe opening of the barrel pump with a fine mesh screen e Immerse it down to a max 15 cm above the floor of the barrel e Only fill the tank using ref
23. for example to lifting and lowering pipes shaft rings or containers with earth moving machines The earth moving machine may be used for applications with lifting gear only if the prescribed safety devices are in place and functional In the case of hydraulic excavators these are for example e Safe possibilities of slinging and securing lifting gear e Load diagram e And in addition for hydraulic excavators with an authorised load of over 1000 kg or an overturning moment of over 40 000 Nm e Safe load indicator e Hose burst valve s on the boom lift ram s 7 7 Safety instructions for operation of earth moving machines 7 6 11 3 7 6 11 4 7 6 11 5 7 6 11 6 7 6 11 7 7 6 11 8 1 1 7 7 4 7 7 2 7 7 3 7 7 4 7 7 9 7 7 6 L 7 7 8 7 8 WACKER NEUSON The load must be secured so as to prevent it from falling or slipping Persons guiding the load or securing it must stay in visual contact with the machine operator The machine operator must guide the load the nearest possible to the ground and avoid any oscillating or swinging movements The earth moving machine may be driven with a raised load only if the path of the machine is as level as possible When using earth moving machines for lifting gear applications the persons attach ing or securing loads may approach the boom from the side only and only after the machine operator has given his permission The machine operator may give his p
24. le LLI LLI woo 3 E O y S Sinoy adIAJas uejd a2upuaueN J C abed uo uejd uonesuqgn aas s uUaUuddWOd Sel quasse DuuwoOL ay oun Ir Clemes uopgaugn jnys se Jon aulbuy jenue Jojes8dQ pue sjaqe aAiseypy SS9N0B JO SSOUI ULS D usw edwod sulbue ul syew Hulje nsu UONDUN 3934109 JO S9je 9 YOOUD Samu SUIT 490 Uld ss u yf 10 SM 19S VO ewep 104 Spo uojsid Y29949 SNE Buyu eunssaud Hewud Jo oun INSS Jd SUONOBUUOD DINDEIa Wass BunesUuad uonouns pue Aejd Buneaq suonoauuos dI 09 8 pue Jaye s LOIEUaUE Y29049 s nu Gau d p peau aunssaud up ebewep yooyo aA AeSSadeu H Jop PdI IISIP YIM dn ll4 alAjoNDa a Ayayeq yOouD yug jan jasaip du ou SOEN pue s jzzou UONIATU Y92949 nss d pue uono ful dwind uo o fu en Aressadeu JI ysnipy aoueseajo ONE yOouy uo ipuos pue ewep 10 Ulass zsneyx yOsyy UOISUS pue UOI IPUOD 2q A 2949 M se Janpejnuew IWUSUIUDEUE y Jo jenuew apueuaurew pue uonesado y 0 13491 se jd Juawyoeye y UO YOM SCUEUSIUIELU pue 3A S 104 uonduos p yoM M IAJ AO uejd BDUeUdJUIEW FLUG 5 35 BA 3001 En Edition 4 0 345001b540 fm wy WACKER NEUSON Maintenance Authorised workshop Customer After 1500 s h Us 00G Aoue uo Us OG e aun JSUy BY Y90949 unas U S 00G 1470 Aland SoAIEA BU pue s jzzou uoy fu y Y29490 BUIDIAJaS ue 000
25. must not be obstructed by foreign bodies paper or sim ilar otherwise the buckle latch cannot lock into place After an accident the belt strap is stretched and no longer serviceable In an accident the seat belt Will not provide adequate protection t Replace the seat belt after an accident ts Have fastening points and seat fixture checked for bearing capacity Seat belt C is for the driver s safety during work on construction sites and during road travel Fastening the seat belt ts Fasten seat belt C as follows before moving the machine e Hold belt on buckle latch A and run it slowly and steadily over the hips to buckle B e Insert buckle latch A into buckle B with an audible click pull test DH Notice Fasten the seat belt only if the rollbar is raised Fig 37 Fastening the seat belt BA 3001 En Edition 4 0 345001b330 fm 3 21 WACKER NEUSON Operation Unfastening the seat belt t Unfasten seat belt A as follows e Hold the seat belt Press red button D on buckle C Latch B is released from buckle C by spring pressure e Slowly return the seat belt to the retractor Fig 38 Unfastening the seat belt Engine cover Opening t Stop the machine t Let the engine cool down t Press buckle A of the engine cover downwards and pull shackle C to the front t Pull the engine cover upwards with handles B until the red safety prop S locks into place Closing t Press safety strut S to the
26. oper ating temperature is reached 47 Alternator charge function telltale red AN Caution The coolant pump no longer runs if the V belt is faulty Danger of engine overheating or breakdown If telltale comes on with the engine running t Stop the engine immediately and ts Have the cause repaired by an authorised workshop The V belt or the charging circuit of the alternator is faulty if the telltale comes on with the engine running The battery is no longer charged 49 Engine oil pressure telltale red Comes on if the engine oil pressure is too low In this case t Stop the machine t Stop the engine immediately and check the oil level The telltale comes on when the ignition is turned on and goes out as soon as the engine runs 50 Coolant temperature telltale red AN Danger Never open the radiator and never drain coolant if the engine is warm since the cooling system is under high pressure Danger of burns ts Wait at least 10 minutes after stopping the engine ts Wear protective gloves and clothing t Open the cap to the first notch and release the pressure 44 Preheating telltale yellow Comes on if the key in the preheating start switch is in position 2 A glow plug preheats the air in the combustion chamber of the engine when the key is in this position The telltale goes out as soon as preheating temperature is reached 15 20 sec BA 3001 En Edition 4 0 345001b320 fm WACKER NEUSON
27. out service maintenance and repair work only if the e machine is positioned on firm and level ground e the forwards reverse lever is in neutral e the parking brake is applied the skip is lowered or if the dumped out skip is secured with the maintenance strut e the engine is at a standstill e ignition key is removed and e the machine has been secured against unintentional movement Should maintenance or repair be inevitable with the engine running Observe the specific safety instructions in the work manual e Keep a Safe distance from all rotating and moving parts e g fan blades V belt drives PTO shaft drives fans etc e Prior to carrying out assembly work on the machine make sure no movable parts will roll away or start moving e To avoid the risk of accidents parts and large assemblies being moved for replacement purposes must be carefully attached and secured to lifting gear Use only suitable lifting gear and suspension systems in a technically perfect state with adequate load bearing capacity Stay clear of suspended loads 2 8 BA 3001 En Edition 4 0 345001b210 fm WACKER NEUSON BA 3001 En Edition 4 0 345001b210 fm Safety instructions Always use specially designed or otherwise safety oriented ladders and working platforms to carry out overhead assembly work Wear a safety harness when carrying out maintenance work at greater heights Remove dirt snow and ice from all handles and footholds
28. place wheel chocks under the wheels to make sure the machine will not roll away under its own weight Fig 32 Neutral SE AN Caution Never stop the engine under full load otherwise it can be damaged due to overheating Let the engine briefly run at idling speed with no load before you switch it off DH Notice Secure the machine against unauthorised operation e Remove the key 3 18 BA 3001 En Edition 4 0 345001b330 fm WACKER e NEUSON Operation AN Danger Always stay clear of the machine as you load it with an excavator or other machines AN Caution Incorrect loading causes severe damage on the machine ts Make sure the payload is not exceeded ts Make sure the driver s visibility is not impaired Loading the machine Danger of personal injury e Before loading t Select the neutral position with the drive lever t Lower the skip ts Apply the parking brake t Stay clear of the control stand and of the danger area for reasons of safety Fig 33 Loading the machine e Once loading is over t Remove dirt debris dust etc from the control elements t Remove loose material BA 3001 En Edition 4 0 345001b330 fm 3 19 Operation 3 10 Seat adjustment Weight adjustment Fig 36 Backrest adjustment WACKER NEUSON AN Danger Never change the seat position when driving or working see Before starting the engine on page 3 12 Danger of accidents t Adj
29. warning system responds Oil level too low 5 7 Oil level too high 5 7 Dirty air filter 5 14 Dirty oil radiator fins Defective fuel injector Insufficient engine output Oil level too high Fuel grade does not comply with specifications Dirty air filter Wrong valve clearance 5 7 5 32 5 14 Injection line leaks Defective fuel injector Engine does not run on all cylinders Injection line leaks Defective fuel injector Insufficient or no engine oil pressure Engine oil consumption too high Oil level too low 5 7 Machine inclination too high max 25 Wrong SAE grade of engine lubrication oil Oil level too high 5 32 BA 3001 En Edition 4 0 345001b410 fm Machine inclination too high max 25 4 1 WACKER Troubleshooting NEUSON Problem Possible causes See Sis Oil level too high 5 7 Machine inclination too high max 25 Engine starting temperature too low ie Fuel grade does not comply with specifications 5 32 Engine smoke Wrong valve clearance Defective fuel injector Dirty air filter 5 14 Black Wrong valve clearance Defective fuel injector 4 2 BA 3001 En Edition 4 0 345001b410 fm WACKER NEUSON Maintenance 5 Maintenance 5 1 Introduction Operational readiness and the service life of machines are heavily dependent on mainte nance It is therefore in the interest
30. y Jo jenuew apueuaurew pue uonesado y 0 13491 se jd Juawyoeye y UO YOM BoUBUE UIEW pue SOSS 104 uoiduos p YONA M IAJ AO uejd BDUeUdJUIeEW FLUG BA 3001 En Edition 4 0 345001b540 fm 5 36 WACKER i NEUSON Maintenance 5 15 Lubrication plan Fold down the red maintenance strut before carrying out maintenance work with the skip raised 3001 front skip 3001 swivel skip BA 3001 En Edition 4 0 345001b560 fm 5 37 WACKER NEUSON Maintenance 5 38 BA 3001 En Edition 4 0 345001b560 fm WACKER NEUSON 6 Specifications Specifications 6 1 Chassis Sturdy steel sheet chassis rubber mounted engine 6 2 Engine Engine Model 3001 AC31 AD371 Model 3001 Tier 3 AE 31 Product Yanmar diesel engine Type S3TNV88 KNSV 3TNV88 BKNSV Design Water cooled 4 stroke diesel engine No of cylinders 3 Displacement 1642 om Nominal bore and stroke 88 x 90 mm Output 26 kW 5 at 2800 rom Interm torque 108 9 Nm at 1680 rom 106 5 Nm at 1680 rom Max engine speed without load Idling speed Fuel injection system Starting aid 2800 rom 25 rpm 1000 rpm 25 rom Direct injection Preheater preheating time 15 seconds Glow elements preheating time 10 15 sec onds Max inclined position engine no longer sup plied with oil Exhaust values according to 6 3 Travelling drive 6 4 Brakes BA 3001 En
31. 10 fm Safety instructions Work on the hydraulic equipment of the machine must be carried out only by persons having specific technical knowledge and experience in hydraulic systems Check all lines hoses and screw connections regularly for leaks and obvious damage Repair any damage and leaks immediately Splashed oil can cause injury and fire In accordance with the Operator s Manual instructions for the respective assembly release the pressure in all system sections and pressure lines hydraulic system to be opened before carrying out any implementing repair work Hydraulic and compressed air lines must be laid and fitted properly Make sure no connections are interchanged The fittings lengths and quality of the hoses must comply with the technical requirements During operation all sound baffles must be closed Wear ear protectors if necessary When handling oil grease and other chemical substances e g battery electrolyte sulphuric acid observe the product related safety regulations safety data sheet Be careful when handling hot consumables risk of burning or scalding When handling the battery observe the specific safety instructions and regulations relevant to accident prevention Batteries contain sulphuric acid caustic Especially when charging batteries as well as during normal operation of batteries an oxyhydrogen mixture is formed in the battery cells danger of explosion In case of a frozen ba
32. If the dumper is used on construction sites for towing trail ers weight down the skip with 25 of the payload However the towed equipment includ ing the weight in the skip may not exceed the dumper s payload Secure the towing pin of the towing gear with a split pin 2 7 WACKER NEUSON Safety instructions 2 6 Safety instructions for maintenance e Avoid any operational mode that might be prejudicial to safety e Observe the adjustment maintenance and inspection activities and intervals set forth in the Operator s Manual including information on the replacement of parts partial equipment These activities must be carried out by technical staff only e The machine may not be serviced repaired or test driven by unauthorised staff Brief the staff the driver before beginning special operations and maintenance work Appoint a person to supervise the activities e In any work concerning the operation conversion or adjustment of the machine and its safety oriented devices or any work related to maintenance inspection and repair observe the start up and shut down procedures set forth in the Operator s Manual and the information on maintenance work e f required secure the maintenance area appropriately e Prior to carrying out service maintenance and repair work attach a warning label such as Repair work do not start machine to the ignition lock or to the control elements Remove the ignition key e Carry
33. International Summer or winter Diesel fuel diesel fuel BS 2869 A1 BS 2869 A2 G Radiator Coolant Soft water antifreeze ASTM D4985 Year round 8 50 Distilled water antifreeze ASTM D4985 mee SAEBSWOOLS o AE85W90L nce a year or Axles Gearbox oil API GL4 MIL L 2105 every 1000 s h ea Transfer gearbox The capacities indicated are approximative values the oil level check alone is relevant for the correct oil level Capacities indicated are no system fills According to DIN 51524 section 3 According to DIN 51524 section 3 Hydraulic ester oils HEES KF2K 25 according to DIN 51502 multipurpose lithium grease with MoS additive Standard acid proof grease According to DIN 51524 section 3 First replacement after 50 service hours OS SNLO OT geg 5 32 BA 3001 En Edition 4 0 345001b530 fm WACKER NEUSON Maintenance Oil grades for the diesel engine depending on temperature Engine oil grade Engine oil grade grade p Ambient temperature C temperature p Ambient temperature C el o o s ols se s s la NEE 10W 40 ACEA E3 E4 E5 ALL KX Oil grades for the hydraulic system depending on temperature KE lics oil Ambient temperature KE DEREOEOREERRREERRRRCHERECRERER HVLP mee Ge Po SONG dl Power VG68 a OL a BA 3001 En Edition 4 0 345001b530 fm 5 33 Av WACKER NEUSON Maintenance Authorised workshop Customer
34. OK Is the signalling and warning system OK Every week t Check once a week Cable and earth connections e Battery charge condition see Battery on page 5 29 e Condition of battery terminals 9 27 Maintenance WACKER NEUSON Instructions concerning specific components Alternator 5 28 Cables bulbs and fuses Always observe the following instructions e Defective components of the electrical system must always be replaced by an authorised expert Bulbs and fuses may be changed by unqualified persons When carrying out maintenance work on the electrical system pay particular attention to ensuring good contact in leads Always observe the following instructions e Only test run the engine with the battery connected e When connecting the battery make sure the poles are not inverted e Always disconnect the battery before carrying out welding work or connecting a quick battery charger BA 3001 En Edition 4 0 345001b530 fm WACKER NEUSON Battery BA 3001 En Edition 4 0 345001b530 fm Maintenance AN Danger Battery acid is highly caustic Danger of caustic injury Therefore when recharging and or working near the battery ts Always wear goggles and protective clothing with long sleeves If acid is spilt t Thoroughly rinse all affected surfaces immediately with plenty of water t Thoroughly wash any part of the body touched by the acid immediately with plenty of water and se
35. Operator s Manual Dumper Machine model 3001 Edition 4 0 Language EN Article number 1000172672 WACKER NEUSON Documentation Description Order no Operator s Manual 1000172672 Service manual 1000154252 Spare parts list 1000173900 Legend Edition Issued 11 2009 01 2010 Copyright 2010 Wacker Neuson Linz GmbH Linz Leonding Printed in Austria All rights reserved No part of this publication may be reproduced translated or used in any form or by any means graphic electronic or mechanical including photocopying recording taping or information storage or retrieval systems without prior permission in writing from the manufacturer The cover features the machine with possible optional equipment Translation of original Operator s Manual WACKER NEUSON Wacker Neuson Linz GmbH Haidfeldstr 37 A 4060 Linz Leonding Tel 43 0 732 90 5 90 0 E mail verkauf wackerneuson com www wackerneuson com Document BA 3001 En Order no 1000172672 Edition 40 WACKER NEUSON Table of contents BA 3001 En Ausgabe 4 0 Ba345001en4_0IVZ fm Introduction Important information on this Operator s Manu 1 1 ENER W 1 2 Seite 1 2 EC declaration of conformity dumper 3001 ou cccccscssesessssssecsecssesseestessesesaeeees 1 3 Type labels and component numbers sccccsecssssssessessssseserserssesseeseeseesaesrseeeas 1 4 Other signs ANd E el EE 1 6 Safety instructions Identific
36. R NEUSON 1 6 Other signs and symbols Fig 7 Eye hook label Hebeband Kranhaken hook of crane lifting belt Elingue en ruban Crochet de grue B gel Hub se handle e stop ey Eilleton de levage TJ Knicksperre einlegen en articulation resi i fast stance Appliquer le dispositif de blocage de l articulation Fig 8 Label with indications for loading the machine Fig 9 Noise level label Fig 10 Driving on slopes 1 6 The following states signs and symbols which are not unequivocally comprehensible They do not contain explanatory text and are not explained in the following chapters Meaning Machine is raised by the eye hooks see chapter 3 19 Crane handling the machine on page 3 29 Location On the rear chassis next to the eye hook Meaning Loading indications for machine see chapter Tying down the machine on page 3 32 Location On the engine cover Meaning Noise levels produced by the machine Lwa sound power level Other information see chapter 6 11 Noise levels on page 6 4 Location On the engine cover Meaning This label indicates the maximum authorised angle of inclination for driving on slopes whatever the position of the machine Location On the rear chassis BA 3001 En Edition 4 0 345001b110 fm WACKER NEUSON
37. SON Operation 3 14 Dumper 3001 swivel skip operation AN Caution Driving with a dumped out skip is prohibited Material that sticks in the skip may be dumped out only to the front in the straight ahead position of the dumper The working speed of the skip is set with the travel of the control lever and with the accelerator pedal When dumping material into a pit a firm resistance beam is required for propping the front wheels ts Never drive up to a pit only with the brakes Lowering the skip too rapidly and knocking it against the chassis can cause damage and the dumper to tip over Set the skip to the required position before dumping out the skip Position Lever Function A t Lever forwards Dumps out the skip B t Lever pulled backwards gt Lowers the skip C t Lever to the left gt Skip swivels to the left D t Lever to the right Skip swivels to the right Swivelling the skip Before swivelling the skip press the lever forwards to raise it until lock cog T is raised from lock recess K The skip can then be swivelled The normal position of the skip is the position in which the skip is in centre position and in which lock cog T engages in lock recess K BA 3001 En Edition 4 0 345001b330 fm 3 25 Operation 3 15 Rollbar Fig 40 Rollbar WACKER NEUSON AN Danger The rollbar is very heavy folding it up or down is very Dangerous ts Two persons are required for raising or lower
38. Technical data dimensions and weights are given as an indication only Responsibility for errors or omissions not accepted No reproduction or translation of this publication in whole or part without the written con sent of Wacker Neuson Linz GmbH All rights under the provision of the Copyright Act are reserved Wacker Neuson Linz GmbH Haidfeldstr 37 A 4060 Linz Leonding Austria WACKER NEUSON
39. _OIVZ fm WACKER NEUSON A ee 1 1 Eegeregie 5 14 B Biodegradable oil E 5 22 C Check SIG sca svntesise dessus yn caeeae nna aia i aies 3 7 Crane handling bracket AA 3 29 D Designated use and exemption from liability 2 2 Driving on public ul 3 14 Divina Ne GUMDON 3 9 F Fastening the e 3 21 SES Kielen 5 32 Important information On this Operator s Manual 1 1 Instrument panel Overview cccecsssessssessssersseseeeserseseeesasers 3 2 3 3 3 4 L Baal de 1 2 M Machine Brief description WE 1 2 Loading and transporting sssesessssesesrsreseresesrsreresrsrsrsrsresrsrsrerens 3 31 Maintenance A OE a eE T E 5 15 lee Ee 5 22 Checking the coolant eye 5 10 Checking the engine oil level 5 7 Checking the hydraulic Oil eye 5 19 CIGANINO eege 5 30 Electrical SySIEMi sucesar kaiii RRE ai 5 27 Engine and hydraulics cooling system AA 5 9 Engine lubrication system EE 5 7 Sieten E 5 8 FITS e TT 5 10 FING Up ere ee UE 5 20 Fluids and WIIG TE 5 32 FUER Y SIC Mili eE E 5 3 General maintenance Work csecssscesescsessscsssseesersssssersetareeeess 5 30 Hydraulic pressure EE 5 23 Hydraulic system 5 ansacasecisatinaeccavensaccuvesasnvaraeastutentsasseviectonnencemiadsons 5 18 Instructions concerning specific components s s s 5 28 Maintenance plan s sssessssssesresssssrsssrsrsrssrsrnrsrennssnrsrennnnsrsrsrsnennnnse 5 34 Pivots and MISS sssrinin i 5 31 Replacing the fuel filter oo sccs
40. achine If possible do not park the dumper on slopes If this cannot be avoided use wheel chocks etc Lower the skip before leaving the dumper Apply the parking brake only in an emergency when driving the machine Keep the base plate of the skip in a clean condition so that the material is easily dumped out of the skip Load only material that can be easily dumped out Dump out sticky or frozen material only to the front and with the dumper in straight ahead position on level ground As you raise the skip watch whether the material is dumped out before fully raising the skip Failure to watch whether the material is dumped out correctly can cause the dumper to tip over BA 3001 En Edition 4 0 345001b210 fm WACKER NEUSON Trailer operation BA 3001 En Edition 4 0 345001b210 fm Safety instructions e Never drive too close to the edges of pits precipices etc since the pressure of the wheels on the ground can cause the edge to give way If edges are secured sufficiently and a barrier prevents the ground from giving way you may drive closer to edges of pits precipices etc e Never dump material into trenches in which there are persons If the driver cannot see into the trench he must be instructed by a person who can see into the trench e Always make sure the brakes are in a perfect condition In spite of being equipped with towing gear the dumper is not a tractor and may not be used as such in difficult terrain
41. an be switched on in work operation if users of public roads are not dazzled Adjust the drive speed to your abilities and the circumstances Always adapt your drive speed to the road and ground conditions and to the visibility conditions Ask someone to guide you in case of difficult passages or obstacles Always void tipping over the dumper by driving appropriately and slowly as required This applies in particular to rough terrain the edges of trenches curves and emergency braking Use only the low speed range when driving off road turtle telltale on the instrument panel Proceed with extreme care when working on slopes The dumper can be driven on firm ground in all positions on slopes up to 25 steep Drive on slopes that are less steep if you expect the wheels on one side to sink in When driving on slopes steeper than 25 drive the loaded dumper only with the skip facing uphill Le drive downhill reversing When driving downhill with an empty skip on slopes steeper than 25 the skip must face downhill Make sure the engine cover is closed and locked before starting the dumper When driving downhill with a full skip drive slowly and reduce engine speed by slowly reducing the pressure on the accelerator pedal The dumper brakes hydraulically at idling speed of the diesel engine The centre of gravity of the payload is shifted to the front on slopes Reverse downhill if you are not sure Apply the parking brake when parking the m
42. ation Of warnings ANd dangers ccesscscccsscssssscseessssssessesecsessseesesesateass 2 1 WAV IAIN eer 2 1 Designated use and exemption from liability 2 2 General conduct and Safety instructions ccccccsscssesesssesssssecscssssssesessessesateaeees 2 3 Organisational measures cccccsessessseesssessecsecsscsssesesesseseesessasesesatsaseaseeseess 2 3 Selection and qualification of staff basic responsibilities 00 0 eee 2 4 Safety instructions regarding operation cececcccscsseseessssssessecsesseseeseeeesseseseesasees 2 5 Klub CHE 2 5 Trailer operation E 2 7 Safety instructions for maintenance cccccccecccsscsecssessssssessesessesseseseesseseessesatsatees 2 8 Warning of special hazards ou cccccccsscssessssssecsecsecsscsssessessesessessessesaesaseseesansatees 2 10 Seier 2 10 Gas dust steam SMOKE oo ec ceeccessccessesenseceseeecsesesseneeseeeeseenesennetennesenteseneey 2 10 Fd MN NS eege Ee 2 11 IONS eebe 2 11 Oil grease and other chemical substances snensssenenseseisrsenrrsrrrsrrinrsnnn 2 11 SELULA gedet 2 11 KE 2 11 Operation Description of 3001F components overview eccessesessecssersrseeessserseeeserten 3 2 Description of 3001S Components overview cccesssesesteesetsssesstecesersieesserten 3 3 Control Stand Overview cceccesesssssssssssscsesssssssessesseseesesseseeseesaesaesesseseesarsensansasees 3 4 Instrument panel Overview ccccccecsscssessesesscsecsesses
43. cal system may only be carried out by a technician with appropriate training in accordance with the applicable electrical engineering rules Inspect and check the electric equipment of the machine at regular intervals Defects such as loose connections or scorched cables must be rectified immediately Observe the operating voltage of the machine attachments Always remove the earthing strap from the battery when working on the electrical system or when carrying out welding work Starting with a battery jump cable can be dangerous if carried out improperly Observe the safety instructions regarding the battery Operate the machine only on adequately ventilated premises Before starting internal combustion engines or operating fuel operated heating systems on enclosed premises make sure there is sufficient ventilation Observe the regulations in force at the respective site Carry out welding flame cutting and grinding work on the machine only if this has been expressly authorised There can be a risk of explosion and fire for example Before carrying out welding flame cutting and grinding work clean the machine and its surroundings from dust and other inflammable substances and make sure the premises are adequately ventilated danger of explosions BA 3001 En Edition 4 0 345001b210 fm WACKER NEUSON Hydraulics Noise Oil grease and other chemical substances Battery Tyres BA 3001 En Edition 4 0 345001b2
44. cavation secure the machine with suitable wheel chocks or other auxiliary means Always watch the material as you dump out the skip make sure the material is dumped out evenly and does not remain stuck in the skip otherwise the machine could tip over Do not dump the load when working on sloping ground No transporting of persons animals etc in the skip Driving with a dumped out skip is prohibited Always carry out precise and smooth control movements do not carry out abrupt movements Do get on or off the machine when it is moving Avoid dangerous work conditions on the work site do not work in severe weather and make sure no one is at risk Always fasten your seat belt when working with machines with rollover protection struc tures 3 23 WACKER NEUSON Operation 3 13 Dumper 3001 front skip operation AN Caution Driving with a dumped out skip is prohibited The working speed of the skip is set with the travel of the control lever and with the accelerator pedal When dumping material into a pit a firm resistance beam is required for propping the front wheels ts Never drive up to a pit only with the brakes Lowering the skip too rapidly and knocking it against the chassis can cause damage and the dumper to tip over Position Lever Function A t Lever pushed forwards Dumps out the skip B t Lever pulled backwards Lowers the skip 3 24 BA 3001 En Edition 4 0 345001b330 fm WACKER r NEU
45. ct the battery Cover the battery with insulating material as you carry out repair work in the area of the battery do not place any tools whatsoever on the battery In the case of earth moving machines with electric drives switch off the electric equipment and if necessary the movable connecting lines as well and secure against unintentional or unauthorised start up Open or remove protective devices of moving machine parts only if the drive has been switched off and secured against unauthorised start up Protective devices are e g engine covers doors protective screens trims etc Fit all the protective devices back on again correctly once assembly maintenance or repair work is over Welding work on load bearing elements of the earth moving machine e g lattice booms loader units may be carried by only in compliance with the acknowledged welding regulations Do not carry out any welding boring or drilling on rollover protection structures ROPS or canopies FOPS that could affect the stability of this equipment Any modification such as welding the hydraulic or compressed air system may be carried out only with the manufacturer s authorisation Before starting work on the hydraulic system release the control and the back pres sures and the pressure inside the tank Use only the hoses and lines prescribed by the manufacturer Install and route hydraulic hoses and lines correctly No smoking and no naked flames du
46. d with metal chippings Otherwise follow on damage can result op Environment Collect drained hydraulic oil and biodegradable oil in a suitable container Dispose of drained oil and used filters by an ecologically safe method Always contact the relevant authorities or commercial establishments in charge of oil dis posal before disposing of biodegradable oil BA 3001 En Edition 4 0 345001b520 fm WACKER NEUSON Maintenance AN Caution Do not fill up oil if the oil level is above the FULL mark otherwise the hydraulic system can be damaged and escaping oil can cause serious injuries t Check the hydraulic oil level each time the machine is put into operation or once a day Checking the hydraulic oil level t Proceed as follows Park the machine on level ground e Retract all hydraulic rams t Fully dump in the skip e Stop the engine e Sight glass A is located under the right hand side mudguard e Check the oil level on sight glass A The oil level must be at the FULL level e A gauge element in sight glass A indicates the oil level Fig 37 Oil level indicator on the hydraulic oil tank H the oil level is lower Fill up hydraulic oil The oil level varies according to the machine s operating temperature Machine condition Temperature Oil level e Before putting into Between 10 and 30 C LOW mark operation Normal operation Between 50 and 90 C FULL mark DH Notice Measure the oil leve
47. e competent organisation person immediately If necessary stop the machine immedi ately and lock it Inthe event of malfunctions stop the machine immediately and lock it Have any defects rectified immediately Start and operate the machine from the seat only e Carry out start up and shut down procedures in accordance with the Operator s Manual and observe the telltales e Before putting the machine into operation start up moving make sure no one is at risk by putting the machine into operation Before driving the machine and also after interrupting work check whether the service brake the parking brake the drive must be switched off if the parking brake is applied and the signalling and the light systems are functional e When driving on public roads ways and places observe the local traffic regulations in force and if necessary make sure beforehand that the machine Is in a condition perfectly compatible with these regulations e Always switch on the lights in conditions of poor visibility and after dark e Do not carry any other persons apart from the driver e When crossing underpasses bridges and tunnels or when passing under overhead lines always make sure there is enough clearance e Always keep at a safe distance from the edges of building pits and slopes e When working in buildings or in enclosed areas look out for e Height of the ceiling clearances e Width of entrances e Maximum load of ceil
48. e raised machines or equipment attachments Avoid contact with hot parts such as the engine block or the exhaust system during the operation of the machine and for some time afterwards danger of burns Retainer pins can fly out or splinter when struck with force danger of personal injury Do not use starting fuel This especially applies to those cases in which a heater plug intake air preheating is used at the same time danger of explosions Apply special care when working on the fuel system increased danger of fire 2 9 Safety instructions WACKER NEUSON 2 7 Warning of special hazards Electrical energy Gas dust steam smoke 2 10 Use only original fuses with the specified current rating Switch off the machine immediately and rectify the malfunction if trouble occurs in the electrical system When working with the machine maintain a safe distance from overhead electric lines lf work must be carried out close to overhead lines the equipment attachments must be kept well away from them Caution danger Get informed on the prescribed safety distances lf your machine comes into contact with a live wire Do not leave the machine e Drive the machine out of the danger area e Warn others against approaching and touching the machine e Have the live wire de energised Do not leave the machine until the line that has been touched or damaged has been safely de energised Work on the electri
49. e actuated if e the engine is already running start repeat interlock e the drive lever is not in neutral position e the parking brake is not applied e Do not run the starter for more than 10 seconds e Wait about 1 minute so the battery can recover before trying again After you have completed the starting preparations t nsert the ignition key in preheating start switch 40 t Turn the ignition key to position 1 t Check whether the following telltales come on e Telltale 49 for engine oil pressure gt Telltale 44 for alternator charge function ts Replace defective telltales immediately t Turn the ignition key to position 2 and hold it in this position until the preheating telltale goes out t Turn the ignition key to position 3 and hold it in this position until the engine starts f the engine does not start after 10 seconds t nterrupt the start procedure and try again after 1 minute gt f the engine still does not start after the second try t Contact a Wacker Neuson workshop for troubleshooting gt As soon as the engine runs t Release the ignition key When the engine runs smoothly increased engine speed i Notice In general a battery delivers less energy in cold conditions Therefore make sure the battery is always well charged BA 3001 En Edition 4 0 345001b330 fm WACKER e NEUSON Operation When the engine has started t Check whether all telltales have gone
50. e into operation or starting the engine Enough fuel in the tank ue 5 3 Coolant level OK ug 5 10 Remove water in the diesel fuel prefilter 5 4 Engine oil level OK e 5 7 Oil level in hydraulic oil tank OK ug 5 79 V belt condition and tension checked ue 5 76 Lubrication points greased 5 37 Check hydraulic hoses connections and ram seals for leaks Firm position of battery terminals Tyres checked for cracks cuts etc 1 5 24 Footholds clean Engine cover locked with the buckle 3 22 Especially after cleaning maintenance or repair work gt Rags tools and other loose objects removed Correct seat position 3 20 Rollbar raised Seat belt fastened ug 3 27 BA 3001 En Edition 4 0 345001b320 fm 3 7 WACKER Operation NEUSON Operation checklist After starting the engine and during operation check and observe the following points 1 Anyone dangerously close to the machine 9 Telltales for engine oil pressure and alternator charge function gone out 1 3 10 Temperature indicators for engine coolant do not come on 3 10 Accelerator and brake pedals working correctly ug 3 14 Parking checklist Check and observe the following points when parking the machine Skip lowered Drive lever in neutral position Parking brake applied Ignition key removed When parking on public r
51. e serious infections could set in lf the hydraulic oil in the sight glass is cloudy this indicates that water or air has penetrated the hydraulic system This can cause damage to the hydraulic pump Oil or fuel flowing out of high pressure lines can cause fire or malfunctions and severe injuries or damage to property Interrupt work immediately if slack nuts or damaged hoses and lines are detected t Contact your Wacker Neuson dealer immediately Replace the hose or line if one of the problems mentioned below is detected ts Damaged or leaky hydraulic seals t Worn or torn shells or uncovered reinforcement branches ts Expanded shells in several positions t Entangled or crushed movable parts t Foreign bodies jammed or stuck in protective layers AN Caution Dirty hydraulic oil lack of oil or wrong hydraulic oil Danger of severe damage to the hydraulic system t Take care to avoid contamination when working t Always fill in hydraulic oil using the filling screen t Only use authorised oils of the same type see chapter 5 13 Fluids and lubricants on page 5 32 t Always fill up hydraulic oil before the level gets too low see Filling up hydraulic oil on page 5 20 ts f the hydraulic system is filled with biodegradable oil then only use biode gradable oil of the same type for filling up observe the sticker on the hydraulic oil tank t Contact customer service if the hydraulic system filter is contaminate
52. e the V belt the V belt guide and the water pump bearing Avoid contact of oil grease or similar substances with the V belt Retightening the V belt t Check V belt tension see Checking V belt tension on page 5 16 e Retighten as follows t Stop the engine t Fold the control lever base up t Remove the key and carry it with you t Disconnect the battery or the battery master switch t Let the engine cool down t Open the engine cover t Slacken fastening screws 2 of alternator 3 t Use a suitable tool to push the alternator in the direction of arrow A until reaching the correct V belt tension fig 36 t Keep the alternator in this position and at the same time retighten fastening screws 2 t Check V belt tension again and adjust it if necessary e t Connect the battery or the battery master switch Fig 36 Retightening the V belt 7 t Close the engine cover BA 3001 En Edition 4 0 345001b520 fm 5 17 Maintenance 9 8 Hydraulic system Specific safety instructions 5 18 WACKER NEUSON Release the pressure in all lines carrying hydraulic oil prior to any maintenance and repair work To do this Lower all hydraulically controlled attachments e Move all control levers of the hydraulic control valves several times Hydraulic oil escaping under high pressure can penetrate the skin and cause serious injuries Always consult a doctor immediately even if the wound seems insignificant otherwis
53. ections and attachments sesnsnensesesnenesesnsrsrsnnnariisrnrsrnnnrerennne 5 31 PIVO ana NINOS scnuiticcaenoneesevenedeas anaes dasuaiutentnedeaicenchieabuatentesuendiesmmeensecnivtets 5 31 FTES na IUDNCANIS serceniserrceseiniiennnina a i a a aeaiia 5 32 Maintenance plan overview cccecsssscssescssccsssecessseesecsssecesseeeseseeseseseesaseeaten 5 34 LUDNICA DIAN WE 5 37 Specifications TVS EE 6 1 ENOO vereren E E A E 6 1 Traveling Be E 6 1 Sie EEN 6 1 Steering SV GIGI EE 6 2 Work hydraulics veer 6 2 le WE 6 2 Mee le IEN 6 2 Electrical system EE 6 2 PUSO DO eege 6 3 Ee 6 3 KEEN 6 4 Kl 6 4 Coolant compound REI 6 4 Dimensions model 3001 front skip s s s sssnsnnsnsnsnsnsnnnnsrsnsnsrurisnnrnrnnnnuninnnnresnnrsrsnns 6 5 Dimensions model 3001 swivel skip sssnsnsnsnsnsnsnsnsnnnisrsrsrsrsrnnininsrnrsrsrnrnresnnrsrnnns 6 6 Dimensions model 3001 S 2 2 metres high with skip dumped out option 6 7 Safety instructions for operation of earth moving machines BA 3001 En Ausgabe 4 0 Ba345001en4_0IVZ fm l 3 WACKER NEUSON Preliminary COMMA sestesistecu stencentubeutedoconcdtucventytustuneotebeaticdestadeaseeaisiamaedesienscaidbecensent 7 1 W llef 7 1 HE eegene 7 2 Mise 7 3 SEU 7 3 Ale NEE 7 4 Assembly Maintenance repair cccccccccccesccsesssccssccsesssccseseessesesceessessaessaseatens 7 8 Towing and transporting EE 7 10 Vleit elle W 7 10 BA 3001 En Ausgabe 4 0 Ba345001en4
54. ed Parking brake with mechanical braking effect on the front axle Press parking brake 28 forwards to release it DH Notice Hitting parking brake 28 with your hand to release it can damage the lever Pull up the lever to apply parking brake 28 Use switch 54 to switch over between low and high speed The green telltale turtle in the switch comes on if low speed is enabled The green telltale in the switch goes out if high speed is enabled Operation 3 9 Driving on slopes Specific safety instructions 3 16 WACKER NEUSON Follow these safety instructions carefully when driving on slopes in order to avoid acci dents t Dump in the skip when driving the machine t Also drive in low speed on slopes t When driving the machine make sure you can stop safely any time if the machine Starts to skid or if it becomes unstable t Avoid swivelling the skip downhill on slopes otherwise the machine can lose its bal ance and tip over Always dump out the skip uphill t Do not drive across slopes steeper than 25 otherwise the machine can tip over later ally ts Always drive straight ahead when driving uphill or downhill Driving diagonally or at an angle to the slope is very dangerous t Drive slowly in meadows on leaves or wet steel plates The machine can slip even if the ground is level BA 3001 En Edition 4 0 345001b330 fm WACKER e NEUSON Operation Driving on slopes wi
55. ek medical attention at once Especially when charging batteries as well as during normal operation of batteries an oxyhydrogen mixture is formed in the battery cells Danger of explosion t Avoid naked lights and sparks in the vicinity of the battery and do not smoke t Do not attempt to jump start the machine if the battery is frozen or if the acid level is low The battery can rupture or explode e Replace the battery immediately t Always disconnect the negative terminal from the battery before starting repair work on the electrical system Battery A is located underneath the engine cover The battery is maintenance free How ever have the battery checked at regular intervals to make sure the electrolyte level is between the MIN and MAX marks Checking the battery requires it to be removed and must be carried out by an authorised Always follow the specific battery safety instructions D Notice Do not disconnect the battery while the engine is running WACKER Maintenance NEUSON 5 12 General maintenance work Cleaning Cleaning the machine is divided into 2 separate areas e Exterior of the machine e Engine compartment The wrong choice of cleaning equipment and agents can impair the operating safety of the machine on the one hand and on the other undermine the health of the persons in charge of cleaning the machine It is therefore essential to observe the following instructions Ge
56. er components of the machine are installed as an option BA 3001 En Edition 4 0 345001b320 fm 3 1 Operation 3 1 Description of 3001F components overview O GA Description Rear chassis Front chassis Articulated joint Seat Control stand Mudguard Engine cover Skip Tilt ram Steering ram Rollbar Oo CON DO Om FP W N ec oo 3 2 WACKER NEUSON BA 3001 En Edition 4 0 345001b320 fm WACKER r NEUSON Operation 3 2 Description of 3001S components overview Pos Description 12 Rear chassis 13 Front chassis 14 Swivelling console 15 Articulated joint 16 Seat 17 Control stand 18 Mudguard 19 Engine cover 20 Swivel centring 21 Skip 22 Offset ram 23 Tilt ram 24 Steering ram 25 Rollbar BA 3001 En Edition 4 0 345001b320 fm 3 3 Operation 3 3 3 4 Pos 26 27 28 29 30 31 32 33 34 35 36 37 38 Control stand overview Description Accelerator pedal Service brake Parking brake Lever backrest adjustment Forwards reverse control Turn indicator lever horn Round display element Lever for horizontal seat adjustment Skip control lever Light switch Low speed switch turtle Footrest Handle WACKER NEUSON Rollbar not included in this figure for a clearer graphic representation BA 3001 En Edition 4 0 345001b320 fm WACKER NEUSON Operation Q
57. ermission only after the machine is at a standstill and the work attachment no longer moves Do not use any lifting gear ropes chains which is damaged or not sufficiently dimensioned Always wear protective gloves when working with lifting gear Assembly maintenance repair The earth moving machine may be assembled modified or disassembled only in accordance with the Operator s Manual of the manufacturer and only under the supervision of suitable staff appointed by the contractor For instance work on the e Brake e Steering e Hydraulic and e Electrical systems of the earth moving machine may be carried out only by specially trained staff Stability must be ensured at all times during maintenance work Secure the work equipment against movement by lowering it to the ground or by taking appropriate measures e g supporting brackets or sleeves If necessary secure the upper carriage of the excavator against rotation When carrying out maintenance and repair work on an earth moving machine with an articulated joint secure the joint with a positive lock when working in the area of the articulated joint When installing or removing counterweights hitch them only at the points provided for by the manufacturer When jacking up the earth moving machine place the lifting device in a position that will avoid slipping Installing or placing the lifting device in inclined positions is not permissible Secure the raised earth m
58. ervals or those specified in the Operator s Manual for routine checks inspections and maintenance work For service inspection maintenance or repair work tools and workshop equipment adapted to the task on hand are absolutely indispensable Selection and qualification of staff basic responsibilities Any work on or with the machine must be carried out by reliable staff only Do not let unauthorised persons drive or work with the machine Observe statutory minimum age limits Employ only trained or instructed staff on the machine and clearly and unequivocally define the individual responsibilities of the staff for operation set up maintenance and repair Define the machine operator s responsibilities also with regard to observing traffic regulations Give the operator the authority to refuse instructions by third parties that are contrary to safety Do not allow persons to be trained or instructed or persons taking part in a general training course to work on or with the machine without being permanently supervised by an experienced person Work on the electrical system and equipment on the undercarriage and the steering and brake systems may be carried out only by skilled staff which has been specially trained for such work Work on the hydraulic system of the machine must be carried out only by staff with special knowledge and experience in hydraulic equipment Seal off the danger area should it not be possible to keep a safe d
59. f hitched loads Also bear in mind uneven ground resulting in an inclined position and hence in a shorter dis tance of the earth moving machine to overhead electric lines Both overhead electric lines and the work equipment can be deflected even by slight wind resulting in a reduced distance from the lines If no sufficient distance can be kept to overhead electric lines and contact lines the contractor must take other safety measures to avoid current transfer after having agreed upon these activities with the owner or operator of the lines This can be achieved for instance by e switching off the current e re routing the overhead electric line e protecting overhead electric lines by installing them underground or e limiting the work range of the earth moving machine BA 3001 En Edition 4 0 345001b710 fm WACKER NEUSON 7 6 8 5 7 6 9 7 6 10 7 6 10 1 7 6 10 2 7 6 10 3 7 6 10 4 7 6 10 5 7 6 11 7 6 11 1 7 6 11 2 BA 3001 En Edition 4 0 345001b710 fm Safety instructions for operation of earth moving machines In case of a current transfer or if the machine touches a live wire the following rules apply Do not leave the control stand e Warn others against approaching and touching the machine e If possible move the work equipment or the entire earth moving machine out of the danger area e Have the live wire de energised e Leave the machine only after the damaged line the line yo
60. h to the machine so that the jump leads can reach to connect the two batteries t Let the engine of the jump starting vehicle run t First connect one end of the red jump lead to the terminal of the flat battery then Flat battery connect the other end to the NS terminal of the starting battery e 12V t Connect one end of the black jump lead to the terminal of the starting battery S t Connect the other end of the black jump lead onto a solid metal component fimly mounted on the engine block or onto the engine block itself Do not connect it to the negative terminal of the flat battery as otherwise explosive gas emerging from the bat tery can ignite if sparks are formed vr Ze t Start the engine of the machine with the flat battery Once the engine has started Je 2 V ts With the engine running disconnect both jump leads in exactly the reverse order first E Starting remove the terminal then the terminal this prevents sparking in the vicinity of battery the battery Fig 23 Starting aid with jump leads BA 3001 En Edition 4 0 345001b330 fm 3 13 Operation WACKER NEUSON Special instructions for driving on public roads Moving off Fig 25 Accelerator pedal 3 14 The machine is subject to the Applicable legal regulations of your country Also observe the applicable regulatio
61. he engine at engine standstill only Danger of personal injury t Stop the engine before cleaning AN Caution When cleaning the engine with a water or steam jet ts The engine must be cold t and do not point the jet directly at electric sensors such as the oil pressure switch The humidity penetrating any such sensors causes them to fail and leads to engine damage All screw connections must be checked regularly for tightness even if they are not listed in the maintenance schedules ts Engine fastening screws ts Fastening screws on the hydraulic system t Line and pin fastenings on the attachment Retighten loose connections immediately Contact an authorised workshop if necessary Lubricate all mechanical pivots on the machine such as joints and fittings at regular inter vals even if they are not listed in the lubrication plan 5 31 WACKER Maintenance NEUSON 5 13 Fluids and lubricants Component application cal Specification SE API CF CEA Cl 4 15 C Diesel engine Engine oil ACEA E3 E4 ES 45 C 5 25 JASO DH 1 Hydraulic oil HVLP46 Hydraulic oil tank y PANOLIN HLP Synth 46 Reen gen Biodegradable o FINA BIOHYDRAN SE 46 BPBIOHYDSE 46 BPBIOHYDSE 46 SE 46 All lubrication points Grease nipples KF2K 25 Battery terminals Acid proof grease FINA Marson L2 2 D ASTM D975 94 USA 1 D ASTM D975 94 USA Depending on outside tempera EN 590 96 EU fires ISO 8217 DMX
62. he fuel prefilter as follows e Ifthe red indicator ring D in sight glass E rises t Remove and clean the housing sight glass t Remove and clean filter insert B t Mount filter insert t Mount the housing sight glass with the maintenance display red ring and spring D t Open stop cock A Interrupt fuel supply as follows t Turn ball type cock A to the OFF mark gt Fuel supply is interrupted t Turn ball type cock A to the ON mark Fuel supply is open again Be Environment Thread A is fitted with a hose Collect the water as it drains with a suitable container and dispose of it in an environmentally friendly manner 5 5 WACKER Maintenance NEUSON Replacing the fuel filter AN Danger If the fuel as it drains comes into contact with hot engine parts or the exhaust system there is an increased Danger of burns t Never change the fuel filter if the engine is hot op Environment Use a suitable container to collect the fuel as it drains and dispose of it in an environmen tally friendly manner Removing the fuel filter t Close fuel cock B t Slacken union nut A Caution the filter housing contains fuel t Remove filter housing C Mounting the fuel filter t Mount all elements in the reverse order with a new filter element t Open the stop cock on the water separator again t Bleed the fuel system see Bleeding the fuel system on page 5 4 Fig 26 WT _ e ts Make a test r
63. he work area that might put persons at risk lf there are underground electric lines determine the positions and the routing of these lines and define and carry out the required safety measures after having agreed upon these activities with the owner or operator of the lines Before starting excavation work clearly mark the routing of lines in the area of the construction site in the presence of the owner or operator If the position of lines cannot be determined dig trenches to search for the lines by hand if necessary If the machine operator damages or unexpectedly comes across underground elec tric lines or their protective covers he must stop work immediately and inform the person supervising the activities Working next to overhead electric lines When working next to overhead electric lines and contact lines with the earth mov ing machine maintain a safe distance depending on the rated voltage of the lines between these lines and the earth moving machine and its work equipment in order to avoid any current transfer This also applies to the distance between these lines and attachments or loads The following safe distances apply in Germany Rated voltage Safe distance Up to 1000 V 1 0m Over1 kVto110 kV 3 0 m Over 110 kV to 220 kV 4 0m Over 220 kV to 380 kV Or unknown rated voltage 5 0 m In doing so also bear in mind all work movements of the earth moving machine e g boom positions swinging of ropes and the size o
64. ician fire bri gade helicopter before starting work Check whether the first aid kit is installed and whether its contents are in compliance with regulations You must be familiar with the location and the operation of fire extinguishers on the earth moving machine and with the local fire alarm and fire fighting facilities Secure loose parts such tools or other equipment on the earth moving machine Secure open doors windows covers lids etc to prevent them from closing unin tentionally BA 3001 En Edition 4 0 345001b710 fm WACKER NEUSON 7 4 Danger area 1 4 1 7 4 2 7 4 3 7 4 4 7 49 7 4 6 1 4 1 7 4 8 7 5 Stability 7 5 1 7 5 2 7 5 3 7 5 4 1 5 5 BA 3001 En Edition 4 0 345001b710 fm Safety instructions for operation of earth moving machines All persons must stay clear of the danger area of the earth moving machine The danger area is the area around the earth moving machine in which persons are at risk by work specific movements of the earth moving machine its work equipment and attach ments by slewing or falling material or by falling work equipment The machine operator may work with the earth moving machine only if no one is in the danger area The machine operator must give warning signs in case of danger for persons The machine operator must stop work with the earth moving machine if persons do not leave the danger area in spite of his warnings Do
65. ightening torque 410 Nm Ci Fig 30 Retighten the axle fastening screws 5 12 BA 3001 En Edition 4 0 345001b510 fm WACKER NEUSON Rear axle Fig 31 Retighten the axle fastening screws BA 3001 En Edition 4 0 345001b510 fm Proceed as follows t Park the machine on firm and level ground t Prevents the machine from rolling away t Retighten all 8 fastening screws B Tightening torque 410 Nm Maintenance 5 13 WACKER Maintenance NEUSON 5 6 Air filter AN Caution The filter cartridge will be damaged if it is washed or brushed out Bear in mind the following to avoid premature engine wear t Do not clean the filter cartridge ts Replace the filter cartridge when the telltale comes on ts Never reuse a damaged filter cartridge t Ensure cleanliness when replacing the filter cartridge Control element A on the air filter monitors the filter cartridge t Replace filter B if Control element A indicates air filter contamination e According to the maintenance plan DH Notice For applications in especially dusty environment replace or clean the air filter more frequently AN Caution Filter cartridges degrade prematurely when in service in acidic air for longer periods of time This risk is present for example in acid production facilities steel and aluminium mills chemical plants and other nonferrous metal plants t Replace filter B after 50 service hours at the la
66. ignated use and exemption from liability The machine is intended for e Moving earth gravel coarse gravel or ballast and rubble Every other application 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 user alone will bear the risk Designated use also includes observing the instructions set forth in the Operator s Manual and observing the maintenance and service conditions The safety of the machine can be negatively affected by carrying out machine modifica tions without proper authority and by using spare parts equipment attachments and optional equipment which have not been checked and released by Wacker Neuson GmbH Wacker Neuson GmbH will not be liable for damage resulting from this Wacker Neuson GmbH shall not be liable for personal injury and or damage to property caused by failure to observe the safety instructions and the Operator s Manual and by the negligence of the duty to exercise due care when e handling e Operating e servicing and carrying out maintenance work and e repairing the machine This is also applicable in those cases in which special attention has not been drawn to the duty to exercise due care in the safety instruc tions the Operator s Manuals and maintenance manuals machine engine e Read and understand the Operator s Manual before starting up servicing or repairing the machine Observe the safe
67. ily visible e g by means of high visibility warning clothes They must maintain visual contact with the machine operator When carrying out their duty persons giving instructions must not be assigned other tasks that could distract them from their duty Operation with risk of falling objects In case of danger of heavy objects falling down use earth moving machines only if the driver s seat is equipped with a canopy FOPS and with an additional front pro tection in the case of excavators When working in front of earth and rock walls if possible position and operate the earth moving machine with the control stand and the access to the control stand facing the side opposite the wall Demolition work may be carried out with earth moving machines only if no persons are at risk When carrying out demolition work with excavators e g with demolition balls make sure the weight of the ball matches the boom length and the load bearing Capacity of the machine lf possible the highest point of the work equipment of the earth moving machine must be higher than structure to be demolished 7 5 Safety instructions for operation of earth moving machines 7 6 7 7 6 7 1 7 6 7 2 7 6 7 3 7 6 7 4 7 6 8 7 6 8 1 7 6 8 2 7 6 8 3 7 6 8 4 7 6 WACKER NEUSON Working in the area of underground electric lines Before excavating with earth moving machines find out whether there are any underground electric lines in t
68. ing the rollbar AN Caution Do not fasten the seat belt when driving with the rollbar lowered Raising the rollbar ts Place the machine on level ground ts Raise the rollbar ts Fasten the rollbar with lock pins A and secure these pins with split pins Lowering the rollbar ts Place the machine on level ground t Remove the split pins from lock pins A ts Remove lock pins A t Slowly and carefully lower the rollbar with the help of a second person BA 3001 En Edition 4 0 345001b330 fm WACKER NEUSON 3 16 Towing Opening the high pressure circuit Fig 41 Opening the high pressure circuit BA 3001 En Edition 4 0 345001b330 fm Operation AN Caution The dumper is equipped with towing gear at the rear and a towing lug at the front Only this equipment may be used for towing Open the high pressure circuit before towing the machine There are two HP pressure limiting valves on the pump under the floor panel one on the upper left and the other on lower left Proceed as follows t Slacken locknut ws 14 part 2 and unscrew it to the end of the screw t Screw in the screw with allen key ws 4 part 1 until you can feel a firmer resistance t Then screw in a further half revolution AN Caution Screwing in any further damages the valve t Retighten the locknut t You can now slowly tow the machine max 1 kph over a short distance max 1 km t Then put the valves back into operation again
69. ings and floors Sufficient room ventilation danger of poisoning exhaust BA 3001 En Edition 4 0 345001b210 fm 2 5 Safety instructions 2 6 WACKER NEUSON Avoid any operation that might be a risk to machine stability On sloping terrain always adapt your drive speed to the prevailing ground conditions Never change to lower gear on a slope but always before reaching it Before leaving the seat always secure the machine against unintentional movement and unauthorised use Before starting work check whether all safety devices are properly installed and functional dirt has been removed from all footholds Before moving the machine or before taking up work e Make sure visibility is sufficient e Adjust your correct seat position never adjust the seat when driving or working e Always fasten the seat belt if the rollbar is raised e Inspect the immediate area children In the work area the operator is responsible for third parties Caution when handling fuel increased danger of fire e Make sure fuel does not come into contact with hot parts Do not smoke during refuelling and avoid fire and sparks Stop the engine during refuelling and do not smoke Never get on or off a moving machine Never jump off the machine Should it be too dark for carrying out work safely provide additional lighting of the work area Installed work lights must not be switched on for travel on public roads They c
70. inse all affected surfaces immediately with plenty of water t Thoroughly wash any part of the body touched by the acid immediately with plenty of water and seek medical attention at once e Especially when charging batteries as well as during normal operation of batteries an oxyhydrogen mixture is formed in the battery cells danger of explosion e Do not attempt to jump start the machine if the battery is frozen or if the acid level is low The battery can rupture or explode t Replace the battery immediately e Avoid naked flames and sparks and do not smoke in the vicinity of open battery cells otherwise the gas produced during normal battery operation can ignite e Use only 12 V power sources Higher voltages will damage the electric components e When connecting the battery leads make sure the poles are not inverted otherwise sensitive electric components will be damaged e Do not interrupt voltage carrying circuits at the battery terminals because of the danger of sparking e Never place tools or other conductive articles on the battery danger of short circuit e Disconnect the negative battery terminal from the battery before starting repair work on the electrical system e Dispose of used batteries properly Service and maintenance work at regular intervals BA 3001 En Edition 4 0 345001b530 fm Before driving the machine t Check every time before driving the machine Is the light system
71. instructions for operation of earth moving machines 7 6 7 6 1 7 6 1 1 7 6 1 2 7 6 1 3 7 6 1 4 7 6 2 7 6 2 1 7 6 2 2 7 6 3 7 6 3 1 7 6 3 2 7 6 3 3 7 6 3 4 7 6 3 5 7 6 3 6 7 6 3 7 7 6 3 8 7 6 3 9 7 4 Operation WACKER NEUSON General Machine operators must be appointed by the contractor for driving and servicing the earth moving machine Controls operating elements may be actuated by the driver or from the driver s seat only Use the footholds and surfaces provided for to access the machine Keep them clean to ensure a safe hold at all times lf the work equipment of the earth moving machine can be picked up and set down with a quickhitch the lock of which cannot be easily seen from the driver s seat for reasons of design or dirt take the following additional safety measures e The driver or another person must make sure that the work equipment is firmly hitched by checking the quickhitch connection itself e If this is not possible raise the work equipment only until you can check it is firmly hitched by dumping it in and out All other persons must stay clear of the danger area during this check Transporting persons Apart from the driver persons may be transported on earth moving machines only if specific places have been provided for by the manufacturer These places must be provided with firm seats and restraints to prevent falling off the earth moving machine Persons
72. istance Stop work if persons do not leave the danger area in spite of warning Keep out of the danger area Danger area The danger area is the area in which persons are in danger due to the movements of the 2 4 e machine e work equipment e additional equipment or e material e This also includes the area affected by falling material equipment or by parts which are thrown out The danger area must be extended by 0 5 m in the immediate vicinity of e buildings e scaffolds or e other elements of construction BA 3001 En Edition 4 0 345001b210 fm WACKER i NEUSON Safety instructions 2 5 Safety instructions regarding operation Normal operation e Avoid any operational mode that might be prejudicial to safety Before beginning work familiarise yourself with the surroundings and circumstances of the work site These are e g obstacles in the working and travelling area the soil bearing capacity and any necessary barriers separating the work site from public roads e Take the necessary precautions to make sure the machine is used only when in a safe and reliable state Operate the machine only if all protective and safety oriented devices e g removable safety devices soundproofing elements and exhausters etc are in place and fully functional e Check the machine at least once a day per work shift for visible damage and defects Report any changes incl changes in the machine s working behaviour to th
73. l 3001 F Model 3001S Drive speed 0 7 kph Drive speed 0 22 kph Articulation 37 Oscillation 15 Outside turning radius 4000 mm 3950 mm Hill climbing ability 50 theoretically Safe authorised inclination 25 in all drive positions left right Electrical system Alternator 12V 40A Starter 12 V 1 4 kW Battery 12 V 88 Ah BA 3001 En Edition 4 0 345001b610 fm WACKER NEUSON Specifications Fuse box Rated cur a Fuse number rent A Protected circuit F3 10 A Cutoff solenoid cutoff solenoid time lag relay 15A Drive solenoid valves Horn brake lights 15A Turn indicators 15A High beam Clearance light Hazard warning system Fig 45 Fuse box Relays The relays are located in the relay box under the floor panel of the control stand Fig 46 Relays BA 3001 En Edition 4 0 345001b610 fm und EK Protected circuit F1 F2 Main fuses K 6 Preheating time lag relay K7 Start high current relay K8 Cutoff solenoid time lag relay K9 Cutoff solenoid switching relay K 10 Turn indicator relay K32 Start interlock relay K33 Low beam relay K34 High beam relay V2 Diodes 6 3 Specifications 6 10 Tyres 6 11 Noise levels WACKER NEUSON Tyre pressure Model Tyre size Load bearing Front Rear capacity 3001 SIF 11 5180 x 15 3 PRIO 3001 S 2 2 met
74. l of the hydraulic system only after the machine reaches its operating temperature BA 3001 En Edition 4 0 345001b520 fm 5 19 WACKER Maintenance NEUSON Filling up hydraulic oil AN Danger Removing the filler plug can cause oil to escape Danger of accidents t Carefully unscrew the plug to slowly reduce the pressure inside the tank Do not fill up the hydraulic oil unless the engine is stopped Otherwise hydraulic oil will overflow at the filler opening on the hydraulic tank t Fill up as follows Park the machine on level ground e Retract all hydraulic rams e Stop the engine Clean the area around filler inlet B with a cloth Open filler inlet B With the filter insert in place Fill up hydraulic oil e Check the hydraulic oil level on sight glass A Fill up if necessary and check again an WT be e Firmly tighten plug B Fig 38 Hydraulic oil tank 5 20 BA 3001 En Edition 4 0 345001b520 fm WACKER NEUSON Changing hydraulic oil Fouling indicator for hydraulic oil filter Fig 41 Hydraulic reflux filter BA 3001 En Edition 4 0 345001b520 fm Maintenance DH Notice Only change the hydraulic oil if it is warm about 50 C Lower the skip in centre position before draining the oil dumper in straight ahead position t Open the drain plug to let the oil drain into a container t Check the hydraulic oil tank for contamination and clean if nece
75. ly hitched by moving it in all positions In doing so all persons must stay clear of the danger area Replace hydraulic hosees as soon as the following damage is detected e Damage on the outside layer up to the inner ply e Embrittlement on the outside layer e Deformations in pressurised or unpressurised state which do not correspond to the original shape of the installed hose e Leaks e Damage on the hose fittings or on the connection between the fitting and the hose e Damage due to storage storage time of a hose must be under 2 years e Damage due to use beyond the service life service life is no longer than 6 years if used under normal load Check the coolant level only after the filler cap has cooled down Open the cap carefully to release overpressure The driver must immediately report damage to the person supervising the activities If drivers change he must also report to the next driver In case of defects affecting the operational safety of the earth moving machine put the machine out of operation until the defects have been remedied BA 3001 En Edition 4 0 345001b710 fm Wacker Neuson Linz GmbH keep abreast of the latest technical developments and con stantly improve their products For this reason we may from time to time need to make changes to diagrams and descriptions in this documentation which do not reflect products which have already been delivered and which will not be implemented on these machines
76. may access or leave the earth moving machine only after the machine operator has allowed them to do so and only after the machine is at a standstill Drive operation In order to ensure safe work adjust the seat the rearview mirrors and the controls before putting the earth moving machine into operation Fasten the seat belt if the earth moving machine is fitted with a rollover protection structure ROPS The windows must clean and free of mist or ice Do not use cold starting aids ether near heat sources naked flames or in poorly ventilated premises The layout of roads and paths must ensure smooth and safe operation i e they must be sufficiently wide have sufficient load bearing capacity and the slightest possible slopes Observe the load bearing capacity of bridges basement ceilings vaults etc before moving the machine on them Bear in mind the clear widths and heights of underpasses tunnels etc before driv ing through them When driving on steep slopes carry loads on the uphill side if possible in order to increase stability Do not drive downhill with the clutch disengaged Shift to a gear adapted to the ter rain before driving down a slope and do not shift gears on the slope BA 3001 En Edition 4 0 345001b710 fm 7 6 3 10 7 6 3 11 7 6 3 12 7 6 3 13 7 6 4 7 6 4 1 7 6 4 2 7 6 4 3 7 6 4 4 7 6 4 5 7 6 5 16 9 1 7 6 9 2 7 6 6 7 6 6 1 7 6 6 2 7 6 6 3 7 6 6 4
77. n Opt option Stated whenever controls or other components of the machine are installed as an option BA 3001 En Edition 4 0 345001b110 fm 1 1 Introduction 1 2 1 3 1 2 Brief description Regulations WACKER NEUSON The model 3001 dumper is a self propelled work machine Get informed on and follow the legal regulations of your country This machine is a versatile and powerful helper for moving earth gravel and debris on con struction sites and elsewhere The main components of the machine are e Rollbar e Hydraulic swivel skip or front skip e Yanmar three cylinder diesel engine e Sturdy steel sheet chassis Requirements to be met by the driver Earth moving machines may be driven and serviced only by persons who meet the follow ing requirements e 18 years or older e Physically and mentally suited for this work e Persons have been instructed in driving and servicing the earth moving machine and have proven their qualifications to the contractor e Persons are expected to carry out work reliably They have been appointed by the contractor for driving and servicing the earth moving machine Get informed on and follow the legal regulations of your country BA 3001 En Edition 4 0 345001b110 fm WACKER NEUSON Introduction 1 4 EC declaration of conformity dumper 3001 WACKER NEUSON EC Declaration of Conformity According to Machine Directive 2006 42 EC appendix II A Manufacture
78. n tscascsecaucocteassicatsenatetecensioeectersteueatentan 2 3 Ee E 2 1 W I 2 8 BEER 2 5 Siet E 2 10 Trailers and EEN 2 7 oeat adjustMeENi sssrin ARR 3 20 Backrest adjustment oeeeteeiuueeieeteciuuee geesde ie 3 20 Horizontal adjustment A 3 20 Weight adjustment ccscsssssscsssssssersscsessesrsessesssersesssersasereeses 3 20 Seat Doll eege 3 21 Signs and Symbols csancranasaninnnaninannan as 1 6 PoC CANONS escana E 6 1 OE 6 1 Coolant compound ee 6 4 PGE SIGNS arra 6 5 6 6 Electrical system E 6 2 POOO epe a E E 6 1 Vi 6 4 REIN ANG eet 3 13 T HE Si e E E E E E T 3 10 HK 5 24 W eege 2 1 l 5 WACKER Index NEUSON l 6 BA 3001 En Ausgabe 4 0 Ba345001en4_0SIX fm WACKER f NEUSON Introduction 1 introduction 1 1 Important information on this Operator s Manual Please store the Operator s Manual in the storage bin under the engine cover 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 operators but it also serves as a reference for experienced ones It helps to avoid dangerous situations and reduce repair costs and downtimes Furthermore the reliability and the service life of the machine will be increased by following the instructions in the Operator s Manual This is why the Operator s Manual must always be kept at hand on the machine Your own safety as well as the safety of others depends to a great exte
79. nce work once a day e Visual check of the tyre condition e Check the tyre pressure e Tyre and rim outside and inside for damage e Check for wear e Remove foreign bodies from the tyre tread e Remove traces of oil and grease from the tyres 5 24 BA 3001 En Edition 4 0 345001b530 fm WACKER NEUSON Maintenance AN Caution The wheels are heavy and can damage the threads on the wheel studs if they are handled incorrectly t Use suitable assembly tools such as covering sleeves for the studs a jack etc Wheel change Removing Proceed as follows ts Park the machine on level and firm ground and prevent it from rolling away t Slightly loosen the wheel nuts of the wheel you want to remove ts Place a jack under the axle body making sure it is standing firmly t Raise the side of the axle from which you want to remove the wheel t Check the machine is standing firmly t Completely remove the wheel nuts t Remove the wheel Fitting the wheels Proceed as follows t Place the wheel onto the wheel studs t Tighten all wheel nuts part way t Lower the raised axle t Tighten the wheel nuts to the prescribed torque of 350 300 Nm DH Notice Subsequent to changing wheels check the wheel nuts for tightness after 10 service hours tighten if necessary BA 3001 En Edition 4 0 345001b530 fm 5 25 Maintenance 5 10 Axles Checking the oil level and filling up oil Fig 43 Checking
80. neral instructions for all areas of the machine Cleaning with washing solvents e Ensure adequate room ventilation e Wear suitable protective clothing e Do not use flammable liquids such as petrol or diesel Cleaning with compressed air e Work carefully e Wear goggles and protective clothing e Do not aim the compressed air at the skin or at other people e Do not use compressed air for cleaning your clothing Cleaning with a high pressure cleaner or steam jet e Electric components and damping material must be covered and not directly exposed to the jet e Cover the vent filter on the hydraulic oil tank and the filler caps for fuel hydraulic oil etc e Protect the following components from moisture Engine e Electric components such as the alternator etc e Control devices and seals e Air intake filters etc Cleaning with volatile and easily flammable anticorrosion agents and sprays Ensure adequate room ventilation e Do not use unprotected lights or naked flames e Do not smoke 5 30 BA 3001 En Edition 4 0 345001b530 fm WACKER NEUSON Exterior of the machine Engine compartment Screw connections and attachments LA Pivots and hinges BA 3001 En Edition 4 0 345001b530 fm Maintenance AN Caution Cleaning the machine can cause engine damage t Protect the engine against humidity The following articles are generally suitable e High pressure cleaner e Steam jet AN Danger Clean t
81. ng V belt E 5 16 K iler 5 17 Pyara Sy SUSI ea T pcereneceanencecosnmaerat 5 18 Specific safety instructions ENEE 5 18 Checking the hydraulic oil level c ccscessssessssessssssesssseseeessaesesrseserseess 5 19 PINO UD url IO le e BE 5 20 Changing hydraulic WEE 5 21 Fouling indicator for hydraulic oil filter oo ee ceessesecsessecsscssseseesesseseeeeees 5 21 Replacing the hydraulic oil filter element nnnnnnenennnnnnnensnsnsnsreriniririsisrsrsen 5 21 Important information for the use of biodegradable oil 5 22 Checking hydraulic pressure lines c ccceccseeeessesessecsecsssecsscsssessessesensateates 5 23 KEE 5 24 MDE A ie see E E E EE ants 5 24 AEAEE ATAO E 5 25 PRN carat tte eli A E EN NE A A E E 5 26 Checking the oil level and filling up o 5 26 DAT OO r E E E E ena 5 26 OCU CAL SYSTEMI RE 5 27 Specific safety instructions ccccscesesesssssssssessesessessesesesseseesessesersesaesaseaees 5 27 Service and maintenance work at regular intervals ccccseseeesseseeseeeees 5 27 Instructions concerning specific components cceccececseeeeseeestesteseeseesaeees 5 28 ANEMI OR genge 5 28 BARI EE 5 29 General maintenance work ue 5 30 MVS AIG ar aE E A E E 5 30 General instructions for all areas of the machine ccccccseeeseeeteeteeeeeeeees 5 30 Exterior of the machine E 5 31 Engine compartment 6 crticucsiverwsiesncadedsaaiuwaterbosensessuansttevuntudensearnesbesmawrteantitts 5 31 Screw conn
82. not add engine oil above the MAX mark of oil dipstick t Use only the specified engine oil t Fill in the engine oil slowly so it can go down without entering the intake system lt a Environment Use a suitable container to collect the engine oil as it drains and dispose of it in an environ mentally friendly manner Filling up engine oil t Proceed as follows Clean the area around oil filler cap B with a lint free cloth Open filler cap B e Raise oil dipstick A slightly to allow any trapped air to escape Fill in engine oil e Wait about 3 minutes until all the oil has run into the oil sump e Check the oil level see Checking the oil level on page 5 7 e Fill up if necessary and check the oil level again e Close filler cap B e Push oil dipstick A back in as far as possible d k i d S S A i 1 e Completely remove all oil spills from the engin Fig 28 Filling up engine oil Completely remove all oil spills from the engine 5 8 BA 3001 En Edition 4 0 345001b510 fm WACKER NEUSON Maintenance 5 4 Engine and hydraulics cooling system The oil water radiator is located in the engine compartment behind the engine It cools the diesel engine and the hydraulic oil of the drive and work hydraulics The expansion tank for the coolant is located in the engine compartment next to the tool box Specific safety instructions e Dirt on the radiator fins reduces the cooler s heat dissipation capacity
83. not step onto the articulation of articulation steered earth moving machines if the engine is running Keep a sufficiently safe distance min 500 mm to fixed elements of construction e g buildings walls to be pulled down scaffolds or other machines to avoid danger of crushing If a safe distance cannot be kept seal off the area between fixed elements of con struction and the work range of the earth moving machine If the operator s visibility onto his drive and work range is impaired by work specific circumstances instruct the operator or seal off the drive and work range with a fixed barrier Always use drive and operate the earth moving machine ensuring stability and safety from turning over see also item 7 3 The operator must adapt his drive speed to the prevailing conditions and lower the work equipment the closest possible to the ground when driving on sloping or une ven terrain Follow the instructions given in the specific sections of the Operator s Manual of the manufacturer when using an earth moving machine equipped with additional outrig gers or supporting equipment for increasing stability Keep the earth moving machine at a safe distance from the edges of quarries pits ditches slopes or embankments to avoid danger of falling When driving or working near excavations shafts trenches or the edge of pits and embankments secure the earth moving machine to prevent it slipping or rolling away 7 3 Safety
84. ns for accident prevention of your country AN Danger Before pressing accelerator pedal 26 move the drive lever to the correct position for the required driving direction Danger of accidents t Slowly press the accelerator pedal to move off e Select the driving direction with drive lever B t Select the required driving direction t Move off by pressing accelerator pedal 26 Set the drive speed with accelerator pedal 26 and brake pedal 27 e Selecting another driving direction with the drive lever t Stop the machine t Select the required driving direction t Move off by pressing accelerator pedal 26 Accelerator pedal 26 sets the engine speed During drive operation the dumper is acceler ated as revs are increased During skip operation the skip dumps in or out more rapidly as revs are increased Press the pedal Engine speed rises Reduce the pressure on the pedal Engine speed is reduced Release the pedal Idling speed The forwards or reverse drive speed depends on the position of accelerator pedal BA 3001 En Edition 4 0 345001b330 fm WACKER NEUSON Hydraulic brake Fig 29 Hazard warning system BA 3001 En Edition 4 0 345001b330 fm Operation Hydrostatic drive Hydraulic service brake 27 with fully enclosed wet multdisc brakes in the front axle self adjusting braking effect on all four wheels DH Notice Use service brake 27 on slopes to slow down the machine as requir
85. nt on how the machine is moved and operated Therefore carefully read and understand this Operator s Manual prior to the first drive This Operator s Manual will help to familiarise yourself more easily with the machine thereby enabling you to use it more safely and efficiently Prior to the first drive carefully read chapter Safety Instructions as well in order to be prepared for possible dangerous situations as it will be too late for it during operation As a rule keep the following in mind Careful and prudent working is the best way to avoid accidents Operational safety and readiness of the machine do not only depend on your skill but also on maintenance and servicing of the machine This is why regular maintenance and serv ice work is absolutely necessary Extensive maintenance and repair work must always be carried out by an expert with appropriate training Insist on using original spare parts when carrying out maintenance and repair work This ensures operational safety and readiness of your machine and maintains its value Your Wacker Neuson dealer will be pleased to answer any further questions regarding the machine or the Operator s Manual Abbreviations symbols e This symbol stands for a list e Subdivision within lists or an activity Follow the steps in the recommended sequence t This symbol requires you to carry out the activity described gt Description of the effects or results of an activity n s not show
86. oads Machine adequately secured Kai When parking on slopes 6 Machine additionally secured with chocks under the wheels to prevent it from rolling away 3 8 BA 3001 En Edition 4 0 345001b320 fm WACKER e NEUSON Operation 3 6 Driving the dumper Preheating start switch overview 1 ng 0 2 Position Function Power consumer 3 0 Insert or remove the ignition key None Bag 8 All functions are operational 1 ON drive position A Telltales come on L 2 Preheats the engine 10 15 gt Until the preheating telltale seconds goes out O Starter is actuated 3 Starts the engine Fig 19 Preheating start switch Telltales must go out Accelerator pedal overview The accelerator pedal controls the revs as follows e Speed can be set continuosly with accelerator pedal 26 t Press down the accelerator pedal Engine speed rises t Reduce the pressure on the accelerator pedal Engine speed is reduced Fig 20 Accelerator pedal BA 3001 En Edition 4 0 345001b320 fm 3 9 Operation Telltales and warning lights overview o ii SW 3 10 WACKER NEUSON 45 Hydraulic oil filter telltale red Indicates inadmissibly high pressure in the hydraulic reflux line to the tank In this case t Have the hydraulic oil reflux filter checked and if necessary replaced by an authorised workshop t The telltale can come on briefly if the hydraulic oil is cold but goes out again once
87. of the machine owner to carry out the prescribed maintenance work Before carrying out service and maintenance work always read understand and follow the instructions given in e Chapter 2 SAFETY INSTRUCTIONS of this Operator s Manual Carry out the prescribed inspections and rectify any disorders before putting the machine into operation Secure open engine covers appropriately Do not open engine covers on slopes or in strong wind Dirt can be blown away and cause severe injuries when using compressed air Always wear protective goggles masks and clothing Daily service and maintenance work and maintenance according to maintenance plan A must be carried out by a specifically trained driver All other maintenance work must be carried out by trained and qualified staff only The maintenance plans indicate when the maintenance work mentioned below must be carried out see Maintenance plan overview on page 5 34 La Danger Mount the red maintenance strut before you carry out maintenance work with the skip raised Front skip maintenance strut Mount the maintenance strut as follows ts Raise the skip t Remove spring plug B from pin C t Remove pin C from guide D t Lower the skip until the holes of guide E and maintenance strut A are aligned t Insert pin C in guide E t Secure pin C with spring plug B Mount the maintenance strut back onto the skip in the reverse order if it is no longer needed mg
88. omplete or illegible Operator s Manual In addition to the Operator s Manual observe and instruct the operator in all other generally applicable legal and other mandatory regulations relevant to accident prevention and environmental protection These compulsory regulations may also deal with handling hazardous substances issuing and or wearing personal protective equipment or traffic regulations With regard to specific operational features e g those relevant to job organisation work sequences or the persons entrusted with the work supplement the Operator s Manual by corresponding instructions including those relevant to supervising and reporting duties Persons entrusted with work on the machine must have read and understood the Operator s Manual and in particular chapter Safety Instructions before beginning work This applies especially to persons working only occasionally on the machine e g set up or maintenance The user owner must check at least from time to time whether the persons entrusted with operation or maintenance of the machine are working in compliance with the Operator s Manual and are aware of risks and safety factors The user owner commits himself to operate and keep the machine in perfect condition and if necessary or required by law to require the operating or servicing persons to wear protective clothing etc In the event of safety relevant modifications or changes on the machine or of its behavio
89. operation and maintenance of earth moving machines In addition to the Operator s Manual also bear in mind the legal regulations concerning public road traffic and accident prevention These regulations may also deal with handling hazardous substances or wearing personal protective equipment Also bear in mind the existing safety regulations concerning specific work sites tunnels day drifts quarries pontoons contaminated areas etc Earth moving machines may be used only in compliance with their designated use and by following the instructions given in the Operator s Manual of the manufac turer Designated use means that the earth moving machine is used with the work equip ment for work in compliance with the European or national work safety regulations or that the earth moving machine is used for other work the manufacturer has deemed the machine to be suitable for The operator may not carry out any safety relevant modifications on the earth mov ing machine without the manufacturer s authorisation Spare parts must comply with the technical requirements specified by the manufac turer 7 1 Safety instructions for operation of earth moving machines 7 3 General 23 1 7 3 2 7 3 3 7 3 4 7 3 5 7 3 6 7 3 7 7 3 8 7 3 9 7 3 10 1 3 11 7 3 12 7 3 13 7 3 14 7 2 WACKER NEUSON Earth moving machines may be driven and serviced only by persons who meet the following requirements e Phy
90. out ts Let the engine warm up At cold temperatures t Increase the engine speed slowly t Do not run the engine at full load until it has reached its operating temperature Engine warm up Once it has started let the engine warm up at slightly increased idling revs Run the engine without load during the warm up phase drive lever in neutral position During the warm up phase check for unusual noise exhaust colour leaks malfunctions or damage In case of malfunctions damage or leaks park and secure the machine and find out the cause for the damage and have it repaired Jump starting the engine Supply battery Safety instructions e Never jump start the engine if the battery of the machine is frozen danger of explosion t Dispose of a frozen battery e The excavator must not touch the jump starting vehicle when connected with jump leads risk of sparking e The external power source must deliver 12 V higher supply voltages will damage the electrical system of the vehicles e Use only authorised jump leads which conform to the safety requirements and which are in perfect condition e The jump lead connected to the positive terminal of the starting battery must never be brought into connection with electrically conductive vehicle parts danger of short circuit e Route the jump leads so they cannot catch on rotating components in the engine compartment Procedure t Drive the jump starting vehicle close enoug
91. oving machine by supporting it with for instance support ing frames or trestles or with boards or square beams stacked crosswise Safely prop the earth moving machine immediately after it has been raised with the work equipment Working under a raised earth moving machine that is held only by the hydrau lics is not permissible BA 3001 En Edition 4 0 345001b710 fm 7 7 9 7 7 10 7 7 11 7 7 12 7 7 13 7 7 14 7 7 15 7 7 16 7 7 17 7 7 18 7 7 19 7 7 20 7 7 21 7 7 22 7 7 23 7 7 24 BA 3001 En Edition 4 0 345001b710 fm WACKER NEUSON Safety instructions for operation of earth moving machines Before replacing the bucket blades of scrapers make sure the buckets are set down on a base avoiding tipping or damage Maintenance and repair work on scraper buckets may be carried out only if the lock flap is secured Switch off all drives before carrying out maintenance and repair work An exception to this requirement is maintenance and repair work that cannot be carried out without a drive In case of danger it must be possible to switch off the drive immediately during this work Disconnect the battery before carrying out arc welding or before working on the electrical system of an earth moving machine fitted with an internal combustion engine First remove the negative terminal and then the positive terminal as you disconnect the battery Proceed in the reverse order as you reconne
92. r Wacker Neuson Linz GmbH Haidfeldstr 37 A 4060 Linz Leonding Product Machine designation Compact dumper Machine model 3001 Serial no Output kW 26 kW Measured sound power level 101 dB A Guaranteed sound power level 101 dB A Conformity assessment procedure Notified body according to Directive 2006 42 EC appendix XI Fachausschusse Bau und Tiefbau Pr f und Zertifizierungsstelle im BG PRUFZERT Landsberger Str 309 D 80687 Munich Distinguishing EU number 0036 Notified body according to Directive 2000 14 EC appendix VI TUV SUD Industrie Service GmbH Westendstr 199 D 80686 Munich Directives and standards We hereby declare that this product corresponds to the relevant regulations and requirements of the following Directives and standards 2006 42 EC old 98 37 EC 2004 108 EC old 89 336 EEC 2002 44 EC 2005 88 EC 2000 14 EC DIN EN ISO 12100 1 and 2 DIN EN 474 1 and 6 DIN EN 14121 DIN EN 3471 DIN EN 13510 EN ISO 3744 EN ISO 3746 DIN EN ISO 3449 a Leonding Ts Place date Thomas K ck Josef Erlinger Responsible for documentation Managing director BA 3001 En Edition 4 0 345001b110 fm 1 3 WACKER NEUSON Introduction 1 5 Type labels and component numbers Serial number The serial number is stamped on the machine chassis It is also located on the type label The type label is located at the rear right of the control stand Type label information Example 3001
93. r the use of other products which have not been recommended In addition ask the oil supplier for a written declaration of guarantee This guarantee is applicable to damage occurring on the hydraulic components which can be proved to be due to the hydraulic fluid Use only biodegradable oil of the same type for filling up In order to avoid misunder standings a label providing clear information is located on the hydraulic oil tank next to the filler inlet regarding the type of oil currently used The joint use of two different biodegradable oils can affect the quality of one of the oil types Therefore make sure the remaining amount of initial hydraulic fluid in the hydraulic system does not exceed 8 when changing biodegradable oil manufacturer indications Do not fill up with mineral oil the content of mineral oil should not exceed 2 in order to avoid foaming problems and to ensure biological degradability When running the machine with biodegradable oil the same oil and filter replacement intervals are valid as for mineral oil see chapter 5 14 Maintenance plan overview on page 5 34 Always have the condensation water in the hydraulic oil tank drained by an authorised workshop before the cold season The water content may not exceed 0 1 by weight The instructions in this Operator s Manual concerning environmental protection are also valid for the use of biodegradable oil lf additional hydraulic attachments are mo
94. rear ts Press down the engine cover t Press buckle A forwards and hitch shackle C into the hook at the same time t Press lock A to the rear Locking and unlocking The engine cover can be locked with an external lock in eyelet D DH Notice Do not lock the engine cover during machine operation The emergency switch is located underneath the engine cover ig 39 Engine cover lock 3 22 BA 3001 En Edition 4 0 345001b330 fm WACKER NEUSON Operation 3 12 Working with the machine General safety instructions BA 3001 En Edition 4 0 345001b330 fm Never drive up to the edge of a pit from outside danger of cave in Do not drive underneath projecting earth Stones or the projecting earth can fall onto the machine When working on roofs or similar structures check the resistance and the structure itself before starting work The building can collapse causing severe injury and damage Do not place the machine directly underneath the workplace during demolition otherwise demolished parts can fall onto the machine or the building can collapse Causing severe injury or damage Operation of the machine by unauthorised staff is prohibited The hydraulic system of the machine is still pressurised even when the engine is not running Release the pressure in the sections of the system and hydraulic lines which are to be opened before starting setup or repair work Before dumping out the skip next to an ex
95. rent coolant tank A and on the radiator B t f the coolant level is below the LOW seam or if there is no coolant at the radiator s filler inlet Fill up coolant DH Notice Check the coolant level once a day We recommend checking it before starting the engine Filling up coolant After the engine has cooled down ts Release overpressure in the radiator t Carefully open the cap to the first notch and fully release the pressure t Open filler cap B t Fill in coolant up to the lower edge of the filler inlet radiator t Close filler cap B t Start the engine and let it warm up for about 5 10 minutes t Stop the engine ts Remove the key and carry it with you t Let the engine cool down t Check the coolant level again The coolant level must be between the LOW and FULL tank seams t f necessary fill up coolant and repeat the procedure until the coolant level remains constant AN Caution Do not mix the coolant with other coolants DH Notice Check the antifreeze every year before the cold season sets in 5 11 WACKER Maintenance NEUSON 5 5 Axle mounting 3001 AN Caution Retighten the axle fastening screws every 50 service hours AN Danger Secure the machine with chocks under the wheels to prevent it from rolling away Front axle Proceed as follows t Park the machine on firm and level ground t Prevents the machine from rolling away t Retighten all 4 fastening screws A T
96. res high with skip 10 0 75 x 15 3 4 bar 4 bar dumped out Sound power level 3001 Sound power level Lwa 101 dB A Sound pressure level Lpa 85 dB A DH Notice Measurement of sound power level according to EC Directive 2000 14 EC Noise level at the driver s ear measured according to EC Directives 84 532 EEC 89 514 EEC and 95 27 EEC Measurements carried out on asphalted surface 6 12 Coolant compound table 6 4 Coolant Halvoline XLC based on ethylene glycol Outside tempera Eurolub SF D12 coolant based on ethylene glycol ture Water Anticorrosion agent Antifreeze agent 0 3 Up to C F ee cu in d by volume by volume 37 34 6 50 10 2 6 1 50 Use the 1 1 concentration for warm outside temperatures too e Protection against corrosion cavitation and deposits Do not mix the coolant with other coolants Coolant with specified features is filled in the machine at the factory BA 3001 En Edition 4 0 345001b610 fm WACKER ioe NEUSON Specifications 6 13 Dimensions model 3001 front skip 2610 2220 1475 Fig 47 Machine dimensions model 3001 F Main data Model 3001 F Dead weight 2450 kg Overall height 2670 mm Overall height with rollbar folded down 1870 mm Overall height without rollbar 1870 mm Overall width 1785 mm Ground clearance 280 mm
97. ring refuelling 7 9 Safety instructions for operation of earth moving machines 7 8 7 8 1 7 8 2 7 8 3 7 8 4 7 8 5 7 9 7 9 1 7 9 2 7 10 Monitoring WACKER NEUSON Towing and transporting Tow the earth moving machine only with a towing facility of sufficient size Use the towing points such as eyelets hooks etc prescribed by the manufacturer Move off slowly when towing All persons must stay clear of the towing facility When loading and transporting the earth moving machine secure the machine itself and the auxiliary means against unintentional movements Remove mud snow and ice from the running gear and the undercarriage of the earth moving machine in order to ensure safe driving on ramps with no danger of slipping Place wooden boards on the access ramps of flat bed trailers before driving on them with tracked machines Inspect the planned route before moving off to make sure the roads are sufficiently wide that bridges and clearances are of sufficient size and that the roads paths and bridges have sufficient load bearing capacity Adhere to the prescribed intervals for routine checks Before every work shift the driver must also check the function of the safety drive and work equipment such as the safe load indicator brakes steering system and lights in accordance with the manufacturer s instructions When installing work equipment onto the quickhitch make sure the work equipment is firm
98. rt will take place DH Notice Do not disconnect the battery while the engine is running D Notice Power supply is interrupted directly after the battery by means of a key Before working on the electrical system Interrupting power supply Fig 49 Battery master switch t Turn key A of the battery master switch to position B and remove it Switching on power supply t Insert key A in the battery master switch t Turn the key down to the notched position C 3 32 BA 3001 En Edition 4 0 345001b330 fm WACKER NEUSON 4 Troubleshooting Troubleshooting The information given in this chapter is provided for maintenance staff for fast and reliable detection of malfunctions and their appropriate repair Repairs must be carried out by authorised staff 4 1 Engine trouble Problem Possible causes See Engine does not start or is not easy to start Wrong SAE grade of engine lubrication oil 5 32 Fuel grade does not comply with specifications 5 32 Defective or flat battery 5 29 Loose or oxidised cable connections in starter circuit Defective starter or pinion does not engage Wrong valve clearance Defective fuel injector Engine starts but does not run smoothly or faultless Fuel grade does not comply with specifications 5 32 Wrong valve clearance Injection line leaks Defective fuel injector Engine overheats Temperature
99. sically and mentally suited for this work e Persons have been instructed in driving or servicing the earth moving machine and have proven their qualifications to the contractor e Persons are expected to carry out work reliably Observe statutory minimum age limits Avoid any operational mode that might be prejudicial to safety Do not exceed the authorised load of the earth moving machine Operate the earth moving machine only in a safe and reliable state Follow the instructions given in the Operator s Manual of the manufacturer for all work involving operation maintenance repair assembly and transport If necessary the operator must supplement the safety instructions by specific instructions adapted to the local conditions of the work site The Operator s Manual and safety relevant instructions must be carefully stored in the control stand The manual and the safety instructions can be stored at the work site itself if the earth moving machine has no cab The Operator s Manual and the safety instructions must be complete and legible Do not disable the function of the earth moving machine s safety equipment during Operation Wear protective work clothes during work Avoid wearing rings scarves unzipped or unbuttoned jackets Specific work can require wearing protective goggles safety shoes a hard hat protective gloves reflective vests ear protectors etc Get informed on first aid and rescue possibilities emergency phys
100. ssary t Replace the filter according to the maintenance specifications t Screw the drain plug back in correctly t Fill in clean hydraulic oil through the screen see Filling up hydraulic oil on page 5 20 t Close the hydraulic oil tank correctly t Let the machine run at idling speed without load for some minutes A red telltale on the instrument panel monitors the filter Replace the filter e Ifthe telltale comes on when the hydraulic oil is at operating temperature e According to the maintenance interval In cold weather the telltale can come on immediately when the engine Is started This is caused by increased oil viscosity In this case t Let the engine run at idling speed for about 2 minutes Proceed as follows t Stop the engine t Open cover 1 by about 2 turns and wait until the oil level in the filter housing drops to the oil level in the hydraulic oil tank t Open the cover completely and remove it t Pull filler pipe 2 upwards with a slightly turning movement together with filter element 3 t Remove the filter element from the filler pipe and dispose of it t Slide the filler pipe onto the new filter element and insert it in the filter ts Tighten the cover by hand 5 21 Maintenance WACKER NEUSON Important information for the use of biodegradable oil 5 22 Use only the biodegradable hydraulic fluids which have been tested and approved by Wacker Neuson GmbH Always contact Wacker Neuson GmbH fo
101. sscessessesseseesetssecsseessasatsaseaseateass 3 5 Putting into operation cccceseecsssssssssssssesscseserssessesaessesesseseeseeseesaeseseesesersersansanass 3 6 ell edel 3 6 Putting the machine into operation for the first time ccecceecsesseseeseeeees 3 6 RUNNING IN period oo eceesessecssecsscscssesecsessecsecescessessessesessesseseesaesaesasseseesaesatsates 3 6 ROM MISS E E E oat sasacteeevas uendesen E 3 7 Start up checklist EE 3 7 Acte VIE 3 8 Parking checklist c cccceccssssssssssssssssssrsssssessesseseeessessessessesaeseseseeseesersansansates 3 8 Driving the dumper EE 3 9 Preheating start switch Overview ccccccscssescssesssessesseceecsscsseessesseseseesatsaees 3 9 Accelerator pedal Overview ENEE 3 9 Telltales and warning lights overview 3 10 Before starting the engine 0 cccssessssssssscsscsscsseesssssecessesssseseesseseseesansasees 3 12 Starting the engine general ENEE 3 12 Biel LE 3 12 When the engine has starte 3 13 Engine warm up Aegeegeeerterenbeegesebteg eege 3 13 Jump starting the engine Supply battery ccc cccceccsecececessseteete seers 3 13 Special instructions for driving ON public FOAMS ou eeecceeteeseeeeseeeeeesteseeeees 3 14 MOVING Off APIO 3 14 lee Ciel de EE 3 14 Silent 3 15 Mechanical brake NENNEN 3 15 Li WACKER NEUSON Low high speed WEE 3 15 Hazard Warning E 3 15 DIVING ai e 3 16 Specific safety instructions EE 3 16 Driving on slopes with a loaded skip
102. sssssccsssssssssssscsrsssssseeseseererssvares 5 6 Screw CONNECTIONS cecccssescssssessesessscsesesesscscersesavseeesavaceneesaseess 5 31 Service and maintenance work at regular intervals 5 27 KI 5 24 TE 5 16 N Vie 1 6 BA 3001 En Ausgabe 4 0 Ba345001en4_0SIX fm Index O Operation ccsecesessssessscssscsseesssscessssassecesavsceeeeseseeeecevaseceesaseersesaversetaren 3 1 Selen 3 12 Control Stand OVErVIEW ENEE 3 4 Description of 3001F components overview s s s 3 2 3 3 Instrument Panel Overview cccceccecseessssessecssssssersstrees 3 2 3 3 3 4 Parking the machine cccssscssesssseeesssseeeseseseesenesseetesseeeteneetsens 3 18 Seat belt height adjustment cesssscesesssstseeseeereeseeeeeseeen 3 21 Starting the engine NENNEN 3 12 p Preheating start switch sos onncasnscpedscsonerdsuseduasesasonasnenendemnmouesetensetanenimsonen 3 9 Putting into operation ee eseessesseeerseetseesssessersaeersseereens 3 2 3 3 3 4 Check lists eegene 3 7 Putting the machine into operation for the first time eeeee 3 6 Safety instructions sccscacscnnccassncstessncsneicacanntis caxnebe sdeenepaneniudsdoiersacares 3 6 R KI lte E 5 3 FROME A seis atest ecrtgaeataiecdepecaseas spseedieosaeiere vesnutebcdacd neaseecevpacsanetasse nvedtss 3 26 Running in period s5 o tnabsissacedsasebsasesteaadeuedcceashecadsasanicuahsbnesetebsecehicctcnunns 3 6 S Safety instructions General COMGUCH x aasuss sescetcats
103. ter sales staff This not only increases the operating safety of your machine but also helps to protect the environment e Replace hydraulic hoses every 6 years from the date of manufacture even if they do not seem to be damaged In this respect we recommend that you observe all the relevant safety regulations for hydraulic lines as well as the safety regulations regarding accident prevention and occu pational health and safety in your country Also observe DIN 20066 part 5 9 23 WACKER Maintenance NEUSON 5 9 Tyres Tyre wear can vary according to work and ground conditions A Danger Improper tyre repairs Danger of accidents t All repair work on tyres and rims may only be carried out by authorised workshops t We recommend checking the tyres for wear and the wheel nuts for tightness once a day t Park the machine on firm and level ground to check and carry out maintenance i Notice Checking the tyres at regular intervals increases operational safety and the service life of the tyres and reduces machine downtimes Please refer to Chapter 6 10 Tyres for the authorised tyre types and the correct tyre pressures D Notice Replace tyres with new ones after 6 years irrespective of wear and dispose of them correctly After this period the rubber no longer has its full capability due to various chemical and physical processes Inspection work t Carry out the following maintena
104. test General instructions for air filter maintenance e Store filters in their original packaging and in a dry place Fig 32 Indicator for air filter contamination e Do not knock the filter against other objects as you install it e Check air filter attachments air intake hoses and air filters for damage and immedi ately repair or replace if necessary e Check the screws at the induction manifold and the clamps for tightness 5 14 BA 3001 En Edition 4 0 345001b520 fm WACKER NEUSON Replacing the filter SH Fig 34 Removing the filter element BA 3001 En Edition 4 0 345001b520 fm Maintenance e Replace filter A as follows t Stop the engine t Remove the key and carry it with you t Let the engine cool down t Open the engine cover t Remove dirt and dust from the air filter and the area around the air filter t Fold both bow clips D on lower housing section E to the outside ts Remove lower housing section E t Unscrew wing nut F t Carefully remove filter B with slightly turning movements t Make sure all dirt dust inside the air filter housing has been removed t Clean the parts with a clean lint free cloth do not use compressed air t Check the air filter cartridges for damage only install intact filters t Carefully insert the new filter B in the air filter housing t Position lower housing section E make sure it is properly seated t Close both bow clips D 5 15
105. th a loaded skip Proceed as follows to prevent the machine from tipping over or slipping sideways t When driving on slopes gt 25 with a loaded skip the skip must always face uphill since the heavier part of the machine in this case the load in the skip must face uphill to prevent the machine from tipping over AN Danger Drive on slopes only on firm ground ts When driving on slopes gt 25 with an empty skip the skip must always face downhill since the heavier part of the machine in this case the engine must face uphill to pre vent the machine from tipping over Fig 31 Driving on slopes with an empty skip Driving across slopes t Do not drive across slopes with lateral inclinations steeper than 25 ts When driving across slopes with lateral inclinations up to 25 dump out the skip only uphill for reasons of safety La Danger Pay special attention to the ground when driving across slopes Danger of accidents t Driving across slopes up to 25 steep is allowed only on firm ground BA 3001 En Edition 4 0 345001b330 fm 3 17 WACKER NEUSON Operation Parking the machine AN Danger Always park the machine on firm ground Danger of accidents t Select a level surface t Stop the machine t Move drive lever A to neutral position t Lower the skip ts Apply the parking brake t Switch off ignition t f parking the machine on a slope cannot be avoided
106. the oil level Draining oil WACKER NEUSON AN Danger Some components of the machine and the oil are still very hot after switching off the machine Danger of burns t Wait until the engine has cooled down before taking up work t Slowly open filler plug A to release the pressure inside t Park the machine on firm and level ground t Place the machine so that filler plug A is at the left ts Remove the ignition key t Unscrew screws A The oil must be level with opening A f the oil level is lower t Fill in oil through opening A until it flows out slightly t Screw screws A back in again ts Move the machine a few metres t Park the machine on firm and level ground ts Place the machine so that filler plug A is at the bottom ts Remove the ignition key t Unscrew screws A The oil now flows out of opening A t Use a suitable container to collect the oil as it drains tz Environment Collect the oil with a suitable container and dispose of it in an environmentally friendly manner BA 3001 En Edition 4 0 345001b530 fm WACKER NEUSON 5 11 Electrical system Specific safety instructions Maintenance e The battery contains sulphuric acid This acid must not be allowed to come into contact with the skin the eyes clothing or the machine Therefore when recharging or working near the battery ts Always wear goggles and protective clothing with long sleeves lf acid is spilt t Thoroughly r
107. to prevent it from rolling e Place the access ramps at the smallest possible angle Make sure the grade does not exceed 17 30 Use access ramps with an antiskid surface only e Make sure the loading area is clear and access to it is not obstructed e g by super O E structures Hig 4 Access ramps e Make sure the ramps and the tyres of the dumper are free of oil grease and ice Start the engine of the dumper e Lower the skip of the dumper e Carefully reverse the dumper onto the middle of the transport vehicle Stop and park the machine DH Notice The manufacturer s warranty shall not apply to accidents or damage caused by loading or transporting the excavator BA 3001 En Edition 4 0 345001b330 fm 3 31 WACKER NEUSON Operation Tying down the machine AN Danger The machine must be loaded and transported properly Danger of accidents t t is essential that you read the safety instructions at the beginning of this chapter and follow any other safety instructions relevant in your country e Secure the wheels of the dumper at the front rear and at the sides e Firmly tie down the dumper at the eye hooks H onto the platform with belts or chains of adequate size e Make sure the driver of the transport vehicle knows the overall height width and weight of his vehicle including the dumper before moving off and the legal transport regulations of the country or countries in which transpo
108. ttery or of an insufficient electrolyte level do not try start up with a battery jump cable The battery can burst or explode t Dispose of the battery immediately Repair work on the tyres must be carried out by technical staff or by an authorised workshop only Defective tyres reduce the machine s operational safety Therefore carry out regular checks of the tyres for e Cracks cuts or other damage Check the tyre pressure at regular intervals 2 11 Safety instructions 2 12 WACKER NEUSON BA 3001 En Edition 4 0 345001b210 fm WACKER e NEUSON Operation 3 Operation This chapter describes the controls and contains information on the function and handling of the telltales and controls on the control stand The pages stated in the table refer to the description of the controls A combination of digits or a combination of digits and letters e g 40 18 or 40 A used for identifying the control elements means fig no 40 control element no 18 or position A in fig no 40 Figures carry no numbers if they are placed to the left of the text The symbols used in the description have the following meanings e This symbol stands for a list e Subdivision within lists or an activity Follow the steps in the recommended sequence ts This symbol requires you to carry out the activity described gt Description of the effects or results of an activity n s not shown Opt option Stated whenever controls or oth
109. ty instructions e When driving on public roads follow the legal regulations of your country and equip the machine in compliance with these regulations If the machine is not equipped with lights drive on construction sites only and only in conditions of sufficient visibility BA 3001 En Edition 4 0 345001b210 fm WACKER NEUSON Safety instructions 2 4 General conduct and safety instructions Organisational measures BA 3001 En Edition 4 0 345001b210 fm The machine has been designed and built in accordance with state of the art standards and the recognised safety regulations Nevertheless its use can constitute a risk to life and limb of the user or of third parties or cause damage to the machine and to other material property The machine must only be used in technically perfect condition in accordance with its designated use and the instructions set forth in the Operator s Manual and only by safety conscious persons who are fully aware of the risks involved in operating the machine Any functional disorders especially those affecting the safety of the machine must therefore be rectified immediately Basic rule Before starting up the machine inspect the machine for safety in work and road operation Careful and prudent working is the best way to avoid accidents The Operator s Manual must always be at hand on the machine and must therefore be Stored in the tool kit Immediately complete or replace an inc
110. u have come into contact with is de energised Operation below ground and in enclosed areas When using earth moving machines below ground and in enclosed areas ensure ade quate ventilation and follow the regulations that are in force Breaks work interruptions During breaks and at the end of a shift the driver must park the earth moving machine on firm and level ground and secure the machine against unintentional movements Lower the work equipment to the ground or secure it in order to prevent unintentional movements The driver may not leave the earth moving machine if the work equipment has not been secured or lowered to the ground Park the earth moving machine only in places where it will not pose an obstacle e g to traffic on public roads or construction sites If necessary install warning devices such as warning triangles warning tape flashing or warning lights etc The driver must move all controls to their zero positions and apply the brakes before leaving the control stand The driver must stop the engines and secure them against unauthorised start up if he goes away from the earth moving machine Applications with lifting gear Applications with lifting gear are understood as procedures involving raising trans porting and lowering loads with the help of slings and load securing devices ropes chains etc In doing so the help of persons is necessary for securing and detach ing the load This applies
111. uelling aids funnels or filler pipes with integral microfilter e Keep all refuelling containers clean at all times Use only high grade fuels Grade Use e 2 D ASTM D975 94 e 1 D ASTM D975 94 ES e EN 590 96 EU e ISO 8217 DMX International e BS 2869 A1 Enaland BS 2869 A2 s e Sulphur content below 0 05 e Cetane number over 45 AN Danger lf the fuel as it drains comes into contact with hot engine parts or the exhaust system there is an increased Danger of burns ts Never bleed the fuel system if the engine is hot Bleed the fuel system in the following cases After removing and fitting the fuel filter prefilter or the fuel lines back on again e After running the fuel tank empty After running the engine again after it has been out of service for a longer period of time BA 3001 En Edition 4 0 345001b510 fm WACKER NEUSON Fuel prefilter with water separator Fig 25 Fuel prefilter BA 3001 En Edition 4 0 345001b510 fm Maintenance Bleed the fuel system as follows t Fill the fuel tank t Turn the ignition key to the first position t Wait about 5 minutes while the fuel system bleeds itself automatically t Start the engine lf the engine runs smoothly for a while and then stops or if it does not run smoothly t Stop the engine t Bleed the fuel system again as described above ts Have this checked by authorised staff if necessary Check t
112. un and check for tightness t Dispose of the old fuel filter cartridge by an ecologically safe method 5 6 BA 3001 En Edition 4 0 345001b510 fm WACKER f NEUSON Maintenance 5 3 Engine lubrication system AN Caution If the engine oil level is too low or if an oil change is overdue this can cause Engine damage or loss of output t Have the oil changed by an authorised workshop see chapter 5 14 Maintenance plan overview on page 5 34 Checking the oil level D Notice Check the oil level once a day We recommend checking it before starting the engine After stopping a warm engine wait at least 5 minutes before checking Checking the oil level t Proceed as follows e Park the machine on level ground Stop the engine Let the engine cool down Open the engine cover e Clean the area around the oil dipstick with a lint free cloth e Oil dipstick A t Pull it out t Wipe it with a lint free cloth t Push it back in as far as possible t Withdraw it and read off the oil level t However if necessary fill up oil at the latest when the oil reaches the MIN mark on the oil dipstick A Fig 27 Checking the oil level BA 3001 En Edition 4 0 345001b510 fm 5 7 WACKER Maintenance NEUSON Filling up engine oil AN Caution Filling in the engine oil too fast via filler inlet B can cause engine damage Too much or incorrect engine oil can result in engine damage t Do
113. unted or operated use the same type of biodegradable oil for these attachments to avoid mixtures in the hydraulic system Subsequent change from mineral oil to biodegradable oil must be carried out by an author ised workshop or by your Wacker Neuson partner BA 3001 En Edition 4 0 345001b520 fm WACKER NEUSON Checking hydraulic pressure lines BA 3001 En Edition 4 0 345001b520 fm Maintenance Specific safety instructions AN Danger Caution when checking hydraulic lines especially when searching for leaks Hydraulic oil escaping under high pressure can penetrate the skin and cause serious injuries Danger of personal injury t Always consult a doctor immediately even if the wound seems insignificant otherwise serious infections could set in ts Always observe the following instructions Retighten leaking screwed fittings and hose connections only when the system is not under pressure i e release the pressure before working on pressurised lines Never weld or solder damaged or leaking pressure lines and screw con nections Replace damaged parts with new ones Never search for leaks with your bare hands but wear protective gloves Use paper or wood to check for minor leaks Never use an unprotected light or naked flame Have damaged flexible lines replaced by authorised workshops only e Leaks and damaged pressure lines must be immediately repaired or replaced by an authorised workshop or af
114. ur stop the machine immediately and report the malfunction to the competent authority person Safety relevant damage or malfunctions of the machine must be rectified immediately Never make any modifications additions or conversions to the machine and its super structures as well as to the attachments which might affect safety without the approval of Wacker Neuson This also applies to the installation and the adjustment of safety devices and valves as well as to welding work on load bearing elements Spare parts must comply with the technical requirements specified by Wacker Neuson Original spare parts can be relied to do so Replace hydraulic hoses within stipulated and appropriate intervals even if no safety relevant defects have been detected 2 3 Safety instructions WACKER NEUSON Before working on or with the machine remove jewellery such as rings wristwatches bracelets etc and tie back long hair and do not wear loose fitting garments such as unbuttoned or unzipped jackets ties or scarves Injury can result from being caught up in the machinery or from rings catching on moving parts Keep the machine clean This reduces e Fire hazard e g due to oil soaked rags lying around e Danger of injury e g due to dirt or debris on the footholds and e Danger of accidents e g due to dirt pile up on the drive pedals Observe all safety warning and information signs and labels on the machine Adhere to prescribed int
115. ust the seat before moving the machine DH Notice Adjust the seat suspension correctly to ensure a high level of ride comfort To adjust to a higher weight t Turn the adjusting wheel to the right To adjust to a lower weight t Turn the adjusting wheel to the left The specified weight is indicated by the yellow pointer next to the adjusting wheel t Sit down on the seat t Pull lever 33 upwards and at the same time t Move the seat forwards or backwards t Pull lever up and at the same time press against the backrest to move it to the required position FS Lei lever lock into place BA 3001 En Edition 4 0 345001b330 fm WACKER e NEUSON Operation 3 11 Seat belt AN Danger Do not drive or work with the seat belt unbuckled Danger of personal injury t Buckle up before moving or working with the machine e Always fasten the seat belt if the rollbar is raised e Do not use the seat belt if the rollbar is lowered e Seat belt must not be twisted e The seat belt must run over the hips and not over the stomach Do not place the seat belt over hard edged or fragile items tools meter rule glasses pen carried inside your clothes e Never buckle up 2 persons children with one seat belt e Check seat belts regularly Have damaged parts immediately replaced by an authorised workshop e Always keep the seat belt clean as coarse dirt can impair proper func tioning Seat belt buckle
116. ways fasten the lap belt if the rollbar is raised Fastening the lap belt is prohibited if the rollbar is lowered Location On the engine cover WACKER NEUSON BA 3001 En Edition 4 0 345001b110 fm WACKER NEUSON 2 Safety instructions Safety instructions 2 1 Identification of warnings and dangers 2 2 Warranty BA 3001 En Edition 4 0 345001b210 fm Important indications regarding the safety of the staff and the machine are identified in this Operator s Manual with the following terms and symbols AN Danger Failure to observe the instructions identified by this symbol can result in personal injury or death for the operator or other persons ts Measures for avoiding danger AN Caution Failure to observe the instructions identified by this symbol can result in damage to the machine ts Measures for avoiding danger for the machine DH Notice This symbol identifies instructions for a more efficient and economical use of the machine a Environment Failure to observe the instructions identified by this symbol can result in damage to the environment The environment is in danger if environmentally hazardous material e g waste oil is not subject to proper use or disposal Warranty claims can be brought forward to your Wacker Neuson dealer only Furthermore the instructions in this Operator s Manual must be observed 2 1 Safety instructions 2 3 2 2 WACKER NEUSON Des

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