Wacker Neuson 1001, 1501, 2001 Operator's Manual

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Operator's Manual

1000184998

Dumper

1001, 1501, 2001

Machine type D01-04/D01-05/D05-02

Edition 3.3

Order no 1000184998

Language us

Dokumentationen

Documentations Language Order no

Operator's Manual [us] 1000184998 Spare parts list 1001 [de en fr] 1000164057 Spare parts list 1501 [de en fr] 1000165936 Spare parts list 2001 [de en fr] 1000184835

Legend

Original Operator‘s Manual x Translation of original Operator‘s

Manual

–

Edition 3.3 Date 07/2014 Document BA 1001/1501/2001 us

Copyright © 2014 Wacker Neuson Baumaschinen GmbH, Hörsching Printed in Michigan, USA All rights reserved, in particular the globally applicable copyright, right of reproduction and right of distribution. 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.

No reproduction or translation of this publication, in whole or part, without the written consent of Wacker Neuson Linz GmbH. Violations of legal regulations, in particular of the copyright protection, will be subject to civil and criminal prosecution. Wacker Neuson Linz GmbH keep abreast of the latest technical developments and constantly improve their products. For this reason, we

may from time to time need to make changes to 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.

Technical data, dimensions and weights are given as an indication only. Responsibility for errors or omissions not accepted. Non-metric weights and measurements are approximate.

The cover features machines with possible optional equipment. Pictures and graphics are symbolic representations and can differ from the actual product.

Wacker Neuson Linz GmbH Flughafenstraße 7 A-4063 Hörsching

Table of contents

Introduction 1

Important information on this Operator’s Manual ..................................................... 1-1

Brief description ....................................................................................................... 1-2

Regulations .............................................................................................................. 1-2

EC declaration of conformity 1001 for all machines delivered before 29 December 2009 1-3 EC declaration of conformity 1001 for all machines delivered after 29 December 2009 1-4 EC declaration of conformity 1501 for all machines delivered before 29 December 2009 1-5 EC declaration of conformity 1501 for all machines delivered after 29 December 2009 1-6 EC declaration of conformity 2001 for all machines delivered before 29 December 2009 1-7 EC declaration of conformity 2001 for all machines delivered after 29 December 2009 1-8

Type labels and component numbers ...................................................................... 1-9

Other signs and symbols ....................................................................................... 1-10

Safety Information 2

Safety Symbols Found in this Manual ..................................................................... 2-1

Warranty .................................................................................................................. 2-2

Designated use ........................................................................................................ 2-2

General Conduct and Safety Instructions ................................................................ 2-3

User training and knowledge ............................................................................. 2-3

Preparing for use ............................................................................................... 2-3

Modifications and spare parts ............................................................................ 2-3

General conduct and safety instructions .................................................................. 2-4

Organizational measures ................................................................................... 2-4

Selection and qualification of staff, basic responsibilities .................................. 2-5

Safety instructions regarding operation ................................................................... 2-6

Normal operation ............................................................................................... 2-6

Operation with lowered rollbar ........................................................................... 2-8

Trailer operation ................................................................................................ 2-8

Staff Qualifications and Basic Responsibilities ........................................................ 2-9

User/owner responsibility .................................................................................. 2-9

Repair person qualifications .............................................................................. 2-9

Safety instructions regarding operation ................................................................... 2-9

Preparing for use ............................................................................................... 2-9

Startup and shutdown ........................................................................................ 2-9

Job Site awareness ......................................................................................... 2-10

Danger zone awareness .................................................................................. 2-10

Operating the machine .................................................................................... 2-10

Special operating notes ................................................................................... 2-10

Carrying passengers ....................................................................................... 2-11

Mechanical integrity ......................................................................................... 2-11

Traveling on public roads ................................................................................ 2-11

Trailering and Transport ........................................................................................ 2-12

Trailers ............................................................................................................. 2-12

Transport ......................................................................................................... 2-12

Temperature Range ............................................................................................... 2-12

Safety Guidelines for Maintenance ........................................................................ 2-12

General maintenance notes ............................................................................ 2-12

Personal safety measures ............................................................................... 2-13

Preparing for maintenance and repair work .................................................... 2-13

BA 1001/1501/2001 us - Edition 3.3 * Ba12001us3_3IVZ.fm I-1

Table of contents

Performing maintenance and repairs ............................................................... 2-13

Special hazards ..................................................................................................... 2-14

Battery ............................................................................................................. 2-14

Tracks (track dumpers) .................................................................................... 2-14

Electric energy ................................................................................................. 2-14

Gas, dust, steam, smoke ................................................................................. 2-15

Hydraulics ........................................................................................................ 2-15

Noise ................................................................................................................ 2-15

Oil, grease and other chemical substances ..................................................... 2-15

MSDS .............................................................................................................. 2-15

Tires (wheel dumpers) ..................................................................................... 2-16

Safety Guidelines while using Internal Combustion Engines ................................. 2-16

Guidelines for running the engine .................................................................... 2-16

Guidelines for fueling the engine ..................................................................... 2-17

Operation 3

Description of 2001S components (overview) ......................................................... 3-4

Description of 2001 SLE components ...................................................................... 3-5

1001/1501/1501S operating equipment up to serial no. AB ... ................................ 3-6

1001/1501/1501S operating equipment from serial no. AB ... ................................. 3-7

2001/2001SLE operating equipment ....................................................................... 3-8

Putting into operation ............................................................................................... 3-9

Safety instructions ............................................................................................. 3-9

Putting into operation for the first time ............................................................... 3-9

Running-in period .............................................................................................. 3-9

Check lists ....................................................................................................... 3-10

Start-up checklist ............................................................................................. 3-10

Operation checklist .......................................................................................... 3-11

“Parking” checklist ........................................................................................... 3-11

Machine travel ........................................................................................................ 3-12

Preheating start switch (overview) ................................................................... 3-12

Accelerator pedal (overview) ........................................................................... 3-12

Indicator lights and warning lights (overview) ................................................. 3-13

Mirrors (option) ................................................................................................ 3-15

Adjusting the outside rearview mirrors on left and right ................................... 3-15

StVO accessories (option) ............................................................................... 3-16

Reversing signal (option) ................................................................................. 3-16

Before starting the engine ................................................................................ 3-16

General information on starting the engine ...................................................... 3-16

Procedure ........................................................................................................ 3-17

Travel interlock ....................................................................................................... 3-18

When the engine has started ... ....................................................................... 3-19

Engine warm-up ............................................................................................... 3-19

Jump-starting the engine (supply battery) ....................................................... 3-19

Special instructions for traveling on public roads ............................................. 3-20

Checks before traveling on public roads .......................................................... 3-20

Starting machine travel .................................................................................... 3-20

Brake pedal (standard for 1001 + 1501, option for 2001) ................................ 3-21

Parking brake ................................................................................................... 3-22

Hazard warning system ......................................................................................... 3-23

Rotating beacon (option) ................................................................................. 3-23

Machine travel on slopes ....................................................................................... 3-23

Specific safety instructions .............................................................................. 3-23

Driving on slopes with a loaded skip ................................................................ 3-24

Machine travel on slopes with an empty skip .................................................. 3-24

Machine travel across slopes .......................................................................... 3-24

Parking the machine ........................................................................................ 3-25

I-2 BA 1001/1501/2001 us - Edition 3.3 * * Ba12001us3_3IVZ.fm

Table of contents

Loading the machine ....................................................................................... 3-26

Seat adjustment ..................................................................................................... 3-27

Weight adjustment ........................................................................................... 3-27

Horizontal adjustment ...................................................................................... 3-27

Backrest adjustment ........................................................................................ 3-27

Seat belt ................................................................................................................. 3-28

Engine cover .................................................................................................... 3-29

Working with the machine ...................................................................................... 3-30

General safety instructions .............................................................................. 3-30

Skip operation ........................................................................................................ 3-31

Operation of high-tip skip (1001/1501H) .......................................................... 3-31

Swivel skip operation (1501S/option) .............................................................. 3-31

Swivel skip operation (2001S) ......................................................................... 3-31

Swivel skip and loader unit operation (2001SLE) ............................................ 3-32

Loader unit (option 2001) ....................................................................................... 3-33

Rollbar ................................................................................................................... 3-34

Towing 1001/1501/2001 ........................................................................................ 3-35

Opening the high-pressure circuit 1001/1501 .................................................. 3-35

Releasing the hydraulic parking brake 1001/1501 ................................................. 3-36

Opening the high-pressure circuit 2001 ................................................................. 3-36

Releasing the hydraulic parking brake 2001 .......................................................... 3-37

Center-pivot prop ................................................................................................... 3-38

Locking the control levers ...................................................................................... 3-38

Locking the control levers (1001/1501) ........................................................... 3-38

Locking the control levers (2001) .................................................................... 3-39

Lifting the machine ................................................................................................. 3-40

Loading and transporting the machine ............................................................ 3-41

Tying down the machine .................................................................................. 3-42

Battery master switch 1001 – 1501 ....................................................................... 3-42

Malfunctions 4

Engine trouble .......................................................................................................... 4-1

Maintenance 5

Introduction .............................................................................................................. 5-1

Brake test ................................................................................................................. 5-2

High-tip skip maintenance prop (1001/1501H) .................................................. 5-3

Swivel skip maintenance prop (1501S/option) .................................................. 5-3

Swivel skip maintenance prop 2001S ................................................................ 5-4

Fuel system ............................................................................................................. 5-5

Specific safety instructions ................................................................................ 5-5

Refueling ........................................................................................................... 5-5

Stationary fuel pumps ........................................................................................ 5-7

Diesel fuel specification ..................................................................................... 5-7

Bleeding the fuel system ................................................................................... 5-7

Fuel prefilter with water separator ..................................................................... 5-8

Replacing the fuel filter ...................................................................................... 5-9

Engine lubrication system ...................................................................................... 5-10

Checking the oil level ....................................................................................... 5-10

Adding engine oil ............................................................................................. 5-11

Engine and hydraulics cooling system ................................................................... 5-12

Specific safety instructions .............................................................................. 5-12

Checking the coolant level/adding coolant ...................................................... 5-13

Air filter (1001/1501: up to serial no. EA01742) ..................................................... 5-15

Replacing the filter ........................................................................................... 5-16

Air filter (1001/1501: from serial no. EA01743) ...................................................... 5-17

Replacing the air filter ...................................................................................... 5-17

V-belt ..................................................................................................................... 5-18

BA 1001/1501/2001 us - Edition 3.3 * Ba12001us3_3IVZ.fm I-3

Table of contents

Checking V-belt tension ................................................................................... 5-18

Retightening the V-belt .................................................................................... 5-19

Hydraulic system .................................................................................................... 5-20

Specific safety instructions .............................................................................. 5-20

Checking the hydraulic oil level ....................................................................... 5-21

Adding hydraulic oil .......................................................................................... 5-22

Changing hydraulic oil ..................................................................................... 5-23

Dirt indicator for hydraulic oil filter .................................................................... 5-23

Replacing the hydraulic oil filter element ......................................................... 5-23

Important information on the use of biodegradable oil ..................................... 5-24

Checking hydraulic pressure lines ................................................................... 5-25

Tires ....................................................................................................................... 5-26

Inspection work ................................................................................................ 5-26

Wheel change .................................................................................................. 5-27

Electrical system .................................................................................................... 5-28

Specific safety instructions .............................................................................. 5-28

Servicing and maintenance at regular intervals ............................................... 5-28

Instructions concerning specific components .................................................. 5-29

Alternator ......................................................................................................... 5-29

Battery ............................................................................................................. 5-29

General maintenance ............................................................................................. 5-30

Cleaning ........................................................................................................... 5-30

General instructions for all areas of the machine ............................................ 5-30

Exterior of the machine .................................................................................... 5-31

Engine compartment ........................................................................................ 5-31

Threaded fittings and attachments .................................................................. 5-31

Pivots and hinges ............................................................................................ 5-31

Engine/machine fluids and lubricants (1001 and 1501) ......................................... 5-32

Engine/machine fluids and lubricants (2001) ......................................................... 5-34

Maintenance plan 1001 – 1501 (overview) ............................................................ 5-36

Maintenance plan 2001 (overview) ........................................................................ 5-39

Lubrication plan 1001/1501H (high-tip skip) .......................................................... 5-42

Lubrication plan 1501S (swivel skip) ...................................................................... 5-44

Lubrication plan 2001 (swivel skip) ........................................................................ 5-46

Technical data (1001 – 1501) 6

Chassis .................................................................................................................... 6-1

Engine ...................................................................................................................... 6-1

Traveling drive 1001 ................................................................................................ 6-2

Traveling drive 1501 ................................................................................................ 6-2

Brakes ...................................................................................................................... 6-2

Steering system ....................................................................................................... 6-2

Operating hydraulics ................................................................................................ 6-3

Loader unit............................................................................................................... 6-3

Travel specifications ................................................................................................ 6-3

Electrical system ...................................................................................................... 6-4

Fuse box (up to AC000101) ............................................................................... 6-4

Relays (up to AC000101) .................................................................................. 6-4

Fuse box (from AB150001H/150002D) ............................................................. 6-4

Relays (from AB150001H/150002D) ................................................................. 6-5

Tires 1001/1501 ....................................................................................................... 6-6

Noise levels ............................................................................................................. 6-6

Coolant compound table .......................................................................................... 6-6

Vibration ................................................................................................................... 6-6

Dimensions model 1001 .......................................................................................... 6-9

Dimensions model 1501 ........................................................................................ 6-10

Dimensions model 1501S ...................................................................................... 6-11

I-4 BA 1001/1501/2001 us - Edition 3.3 * * Ba12001us3_3IVZ.fm

Table of contents

Technical data (2001) 6

Chassis .................................................................................................................. 6-12

Engine .................................................................................................................... 6-12

Traveling drive ....................................................................................................... 6-13

Brakes .................................................................................................................... 6-13

Steering system ..................................................................................................... 6-13

Operating hydraulics .............................................................................................. 6-13

Loader unit ............................................................................................................. 6-14

Travel specifications .............................................................................................. 6-14

Electrical system .................................................................................................... 6-14

Fuse box .......................................................................................................... 6-14

Relays .............................................................................................................. 6-15

Tires ....................................................................................................................... 6-16

Coolant compound table ........................................................................................ 6-16

Noise levels ........................................................................................................... 6-16

Vibration ................................................................................................................. 6-16

Dimensions model 2001 ........................................................................................ 6-19

Safety instructions for operation of earth moving machines 7

Preliminary remark ................................................................................................... 7-1

Designated use ........................................................................................................ 7-1

General .................................................................................................................... 7-2

Danger zone ............................................................................................................ 7-3

Stability .................................................................................................................... 7-3

Operation ................................................................................................................. 7-4

Assembly, maintenance, repair ............................................................................... 7-8

Towing and transporting ........................................................................................ 7-10

Monitoring .............................................................................................................. 7-10

BA 1001/1501/2001 us - Edition 3.3 * Ba12001us3_3IVZ.fm I-5

Index

Numerisch

14 .......................................................................................................... 3-8

Abbreviations .........................................................................................1-1

Air filter ................................................................................................5-15

Biodegradable oil .................................................................................5-24

Check lists ...........................................................................................3-10

Driving on public roads ........................................................................ 3-20

Driving the dumper ..............................................................................3-12

Fastening the seat belt ........................................................................3-28

Fluids and lubricants ..................................................................5-32, 5-34

Important information

On this Operator’s Manual

Indicator lights and warning lights .......................................................3-13

Instrument panel overview ..............................................3-2, 3-3, 3-4, 3-5

............................................................. 1-1

Legal regulations ...................................................................................1-2

Lifting the machine .............................................................................. 3-40

Machine

Brief description

Loading and transporting ..............................................................3-41

Maintenance

Adding coolant

Adding engine oil ..........................................................................5-11

Adding hydraulic oil ......................................................................5-22

Air filter

Biodegradable oil ..........................................................................5-24

Checking the coolant level ........................................................... 5-13

Checking the engine oil level

Checking the hydraulic oil level ....................................................5-21

Cleaning ....................................................................................... 5-30

Electrical system

Engine and hydraulics cooling system ......................................... 5-12

Engine lubrication system

Fluids and lubricants ...........................................................5-32, 5-34

Fuel system ....................................................................................5-5

General maintenance

Hydraulic pressure lines ...............................................................5-25

Hydraulic system ..........................................................................5-20

Instructions concerning specific components

Maintenance plan ................................................................5-36, 5-39

Pivots and hinges .........................................................................5-31

Replacing the fuel filter

Servicing and maintenance at regular intervals ...........................5-28

Threaded fittings ...........................................................................5-31

............................................................................................. 5-26

Tires

V-belt ............................................................................................5-18

..............................................................................1-2

..............................................................................5-13

.........................................................................................5-16

........................................................5-10

.......................................................................... 5-28

............................................................ 5-10

................................................................... 5-30

...............................5-29

................................................................... 5-9

Operation .............................................................................................. 3-1

Before starting the engine

Control stand overview .................................................................. 3-5

Description of 1001/1501 components (overview) ......................... 3-2

Description of 1501S components (overview)

Description of 2001S components (overview) ............................... 3-4

Instrument panel overview ....................................... 3-2, 3-3, 3-4, 3-5

Parking the machine

Seat belt height adjustment ......................................................... 3-28

Starting the engine ....................................................................... 3-16

............................................................ 3-15

............................... 3-3

.................................................................... 3-25

Preheating start switch ....................................................................... 3-12

Putting into operation ...................................................... 3-2, 3-3, 3-4, 3-5

Check lists .................................................................................... 3-10

Putting into operation for the first time

Safety instructions .......................................................................... 3-9

........................................... 3-9

Refueling ............................................................................................... 5-5

................................................................................................ 3-34

Rollbar

Rotating beacon (option) .................................................................... 3-23

Running-in period ................................................................................. 3-9

Safety instructions

Operation ....................................................................................... 2-6

Trailers and attachments ............................................................... 2-8

Seat adjustment

Backrest adjustment .................................................................... 3-27

Horizontal adjustment .................................................................. 3-27

Weight adjustment

Seat belt .............................................................................................. 3-28

Signs and symbols .............................................................................. 1-10

Starting aid

.................................................................................. 3-27

....................................................................... 3-27

.......................................................................................... 3-19

Technical data ............................................................................. 6-1, 6-12

Chassis .......................................................................................... 6-1

Coolant compound table

Dimensions ........................................................6-9, 6-10, 6-11, 6-19

Electrical system ................................................................... 6-4, 6-14

................................................................................... 6-1, 6-12

Engine

Noise levels ...........................................................................6-6, 6-16

.................................................................................................... 5-26

Tires

....................................................... 6-8, 6-19

I-6 BA 1001/1501/2001 us - Edition 3.3 * * Ba12001us3_3SIX.fm

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 hazardous 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 in the machine.

Your own safety, as well as the safety of others, depends to a great extent 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 familiarize 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 servicing is absolutely necessary. Extensive maintenance and repair work must always be performed by an expert with appropriate training. Insist on using original spare parts when performing maintenance and repair work. This ensures operational safety and readiness of your machine, and maintains its value.

Your Wacker Neuson dealer will be happy to answer any further questions regarding the machine or the Operator’s Manual.

Introduction

Abbreviations/symbols

• Identifies a list

• Subdivision within lists or an activity. Follow the steps in the recommended order

☞Identifies an activity ➥Description of the effects or results of an activity

n. s. = not shown “Opt” = option Stated whenever controls or other components of the machine are installed as an option.

BA 1001/1501/2001 us – Edition 3.3 * 12001b110.fm 1-1

Introduction

Important

1.2 Brief description

1.3 Regulations

The model 1001/1501/2001 dumpers are self-propelled work machines. 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 construction sites and elsewhere. The main components of the machine are:

• Rollbar

• Hydraulic swivel skip or front skip

• Yanmar three cylinder diesel engine

• Sturdy steel sheet chassis

The machine can be equipped with the “Telematic” option (for transmitting

operating data, location, etc. via satellite).

Requirements to be met by the operator

Earth moving machines may be traveled and serviced only by persons who meet the following requirements:

• 18 years or older

• Physically and mentally suited for this work

• Persons have been instructed in driving and servicing the earth moving machine and have proven their qualifications to the contractor

• Persons are expected to perform 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.

1-2 BA 1001/1501/2001 us – Edition 3.3 * * 12001b110.fm

Introduction

EG-Konformitätserklärung

Gemäß Maschinen-Richtlinie 98/37/EG, Anhang II A

Der Unterzeichnende Wacker Neuson Linz GmbH

Haidfeldstraße 37 A-4060 Leonding

bescheinigt, daß die Baumaschine,

Firmenstempel

1. Art Kompakt-Dumper

2. Fabrikmarke WACKER NEUSON

3. Typ

1001

4. Nummer innerhalb der Typenserie des Geräts

folgenden einschlägigen Bestimmungen entspricht 98/37/EG

2004/108/EG 2000/14/EG 2005/88/EG

Angewandte harmonisierte Normen EN 474-1, EN 474-6

EN ISO 12100-1, EN ISO 12100-2 EN 982

Nationale Normen und technische Spezifikationen

Gemessener Schalleistungspegel 91,7

Garantierter Schalleistungspegel

93 dB

Zertifikat-Nr.: OR/150012/013

Einbezogene Prüfstelle TÜV Anlagen und Umwelt GmbH

Westendstraße 199 D-80686 München

Die gemeldete Stelle nach Anhang VII

Fachausschuß Tiefbau Landsbergerstr. 309 D - 80687 München

Wurde (wird) eingeschaltet zur

Freiwilligen Baumusterprüfung Baumusterprüfbescheinigungs-Nr.: 08003-E

Leonding, . . .

Ort, Datum Josef Erlinger, Geschäftsführer

Unterschrift

1.4 EC declaration of conformity 1001 for all machines delivered before 29 December 2009

NEUSON

BA 1001/1501/2001 us – Edition 3.3 * 12001b110.fm 1-3

Introduction

EC Declaration of Conformity

According to Machine Directive 2006/42/EC, appendix II A

Manufacturer

Wacker Neuson Linz GmbH Haidfeldstr. 37 4060 Linz-Leonding

Product

Machine designation: Compact dumper Machine model: 1001 Serial no.: ______________ Output (kW): 17 kW Measured sound power level: 100.6 dB (A) Guaranteed sound power level: 101 dB (A)

Conformity assessment procedure

Notified body according to Directive 2006/42/EC, appendix XI: Fachausschüsse Bau und Tiefbau Prüf- und Zertifizierungsstelle im BG-PRÜFZERT Landsberger Str. 309 D-80687 Munich Distinguishing EU number 0036

Notified body according to Directive 2000/14/EC, appendix VI: TÜV SÜD 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

Leonding,

1.5 EC declaration of conformity 1001 for all machines delivered after 29 December 2009

1-4 BA 1001/1501/2001 us – Edition 3.3 * * 12001b110.fm

Introduction

EG-Konformitätserklärung

Gemäß Maschinen-Richtlinie 98/37/EG, Anhang II A

Der Unterzeichnende Wacker Neuson Linz GmbH

Haidfeldstraße 37 A-4060 Leonding

bescheinigt, daß die Baumaschine,

Firmenstempel

1. Art Kompakt-Dumper

2. Fabrikmarke WACKER NEUSON

3. Typ

1501

4. Nummer innerhalb der Typenserie des Geräts

folgenden einschlägigen Bestimmungen entspricht 98/37/EG

2004/108/EG 2000/14/EG 2005/88/EG

Angewandte harmonisierte Normen EN 474-1, EN 474-6

EN ISO 12100-1, EN ISO 12100-2 EN 982

Nationale Normen und technische Spezifikationen

Gemessener Schalleistungspegel 92,8

Garantierter Schalleistungspegel

93 dB

Zertifikat-Nr.: OR/01589

Einbezogene Prüfstelle TÜV Anlagen und Umwelt GmbH

Westendstraße 199 D-80686 München

Die gemeldete Stelle nach Anhang VII

Fachausschuß Tiefbau Landsbergerstr. 309 D - 80687 München

Wurde (wird) eingeschaltet zur Freiwilligen Baumusterprüfung Baumusterprüfbescheinigungs-Nr.: 03154-E

Leonding, . . .

Ort, Datum Josef Erlinger, Geschäftsführer

Unterschrift

1.6 EC declaration of conformity 1501 for all machines delivered before 29 December 2009

NEUSON

BA 1001/1501/2001 us – Edition 3.3 * 12001b110.fm 1-5

Introduction

EC Declaration of Conformity

According to Machine Directive 2006/42/EC, appendix II A

Manufacturer

Wacker Neuson Linz GmbH Haidfeldstr. 37 4060 Linz-Leonding

Product

Machine designation: Compact dumper Machine model: 1501 Serial no.: ______________ Output (kW): 17 kW Measured sound power level: 101 dB (A) Guaranteed sound power level: 101 dB (A)

Conformity assessment procedure

Notified body according to Directive 2000/14/EC, appendix VI: TÜV SÜD Industrie Service GmbH Westendstr. 199 D-80686 Munich

Directives and standards

Josef Erlinger,Thomas Köck,

Leonding, Place, date

1.7 EC declaration of conformity 1501 for all machines delivered after 29 December 2009

1-6 BA 1001/1501/2001 us – Edition 3.3 * * 12001b110.fm

Introduction

EG-Konformitätserklärung

Gemäß Maschinen-Richtlinie 98/37/EG, Anhang II A

Der Unterzeichnende Wacker Neuson Linz GmbH

Haidfeldstraße 37 A-4060 Leonding

bescheinigt, daß die Baumaschine,

Firmenstempel

1. Art Kompakt-Dumper

2. Fabrikmarke WACKER NEUSON

3. Typ

2001

4. Nummer innerhalb der Typenserie des Geräts

folgenden einschlägigen Bestimmungen entspricht 98/37/EG

2004/108/EG 2000/14/EG 2005/88/EG

Angewandte harmonisierte Normen EN 474-1, EN 474-6

EN ISO 12100-1, EN ISO 12100-2 EN 982 EN 13510

Nationale Normen und technische Spezifikationen

Gemessener Schalleistungspegel 92,5

Garantierter Schalleistungspegel

93 dB

Zertifikat-Nr.: OR/150012/015

Einbezogene Prüfstelle TÜV Anlagen und Umwelt GmbH

Westendstraße 199 D-80686 München

Die gemeldete Stelle nach Anhang VII

Fachausschuß Tiefbau Landsbergerstr. 309 D - 80687 München

Wurde (wird) eingeschaltet zur

Freiwilligen Baumusterprüfung Baumusterprüfbescheinigungs-Nr.: 03155-E

Leonding, . . .

Ort, Datum Josef Erlinger, Geschäftsführer

1.8 EC declaration of conformity 2001 for all machines delivered before 29 December 2009

NEUSON

BA 1001/1501/2001 us – Edition 3.3 * 12001b110.fm 1-7

Introduction

EC Declaration of Conformity

According to Machine Directive 2006/42/EC, appendix II A

Manufacturer

Wacker Neuson Linz GmbH Haidfeldstr. 37 4060 Linz-Leonding

Product

Machine designation: Compact dumper Machine model: 2001 Serial no.: ______________ Output (kW): 22.5 kW Measured sound power level: 101.1 dB (A) Guaranteed sound power level: 101 dB (A)

Conformity assessment procedure

Notified body according to Directive 2000/14/EC, appendix VI: TÜV SÜD Industrie Service GmbH Westendstr. 199 D-80686 Munich

Directives and standards

Josef Erlinger,Thomas Köck,

Leonding, Place, date

1.9 EC declaration of conformity 2001 for all machines delivered after 29 December 2009

1-8 BA 1001/1501/2001 us – Edition 3.3 * * 12001b110.fm

1.10 Type labels and component numbers

Fig. 1: Type label: location

Fig. 2: Type label (symbolic representation)

Fig. 3: Yanmar diesel engine number

Fig. 4: Number of variable displacement pump

Fig. 5: Rollbar type label

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: 1001

Model: 1001 Year: --------------PIN: (serial number) AB1001 ... Power: --------------Mass: --------------Load: --------------Other information – see chapter 6 Technical data (1001 – 1501) on page 6-1

Introduction

Engine number

The type label (arrow) is located on the cylinder-head cover of the engine.

Example: Yanmar 46557

Hydraulic pump number

The type label (arrow) is located on the hydraulic pump housing

BA 1001/1501/2001 us – Edition 3.3 * 12001b110.fm 1-9

Rollbar number

The type label is located on the left on the rollbar

Introduction

Important

Fig. 6: Lifting eye

Fig. 7: Fuel tank

Fig. 8: Hydraulic oil reservoir

1.11 Other signs and symbols

The following states signs and symbols that do not contain explanatory text and that are not explained in the following chapters.

Short model designations

☞1501 swivel skip = 1501S ☞1501 high-tip skip = 1501H

Meaning

Raise the machine or machine parts only by means of these eyelets.

Position

At the lifting eyes.

Type, quantity and position of the labels depend on options, country and machine.

Meaning

Machine runs with diesel fuel. Add diesel fuel only!

Position

On the fuel tank

Meaning

Reservoir contains hydraulic oil

Position

On the hydraulic oil reservoir

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Meaning

Fig. 9: Tilting out the skip

Fig. 10: Serial number

Fig. 11: Sound power level

Fig. 12: Seat belt (label version 1)

Shows how the skip can be tilted out.

Position

On the engine cover

Meaning

This label includes the serial number of the machine

Position

At the front right of the chassis

Meaning

Value of sound power level according to the 2000/14/EC standard.

Position

On the engine cover

Introduction

Meaning

Machine operation is only allowed if the rollbar is raised and locked, and if the seat belt is fastened.

Position

On the engine cover

BA 1001/1501/2001 us – Edition 3.3 * 12001b110.fm 1-11

Introduction

Fig. 13: Seat belt (label version 2) Fig. 14: Rotating and hot parts

Fig. 15: Distance from machine

Fig. 16: Towing

Meaning

Machine operation is only allowed if the rollbar is raised and locked, and if the seat belt is fastened.

Position

On the ROPS rollbar on the left in travel direction.

Meaning

Caution – rotating or hot parts! Read the Operator’s Manual

Position

On the engine cover

Meaning

Indicates that persons other than the operator must keep a safe distance from the machine during operation!

Position

On the skip

Meaning

Machine must be towed away only by trained personnel. Follow the instructions in the Operator’s Manual!

Position

On the engine cover

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Introduction

Fig. 17: Parking brake

Fig. 18: Raising and lowering the skip

Fig. 19: Angle of inclination

Fig. 20: Angle of inclination

Fig. 21: Angle of inclination

Fig. 22: Skip swivel

Label only with parking brake switch without lock

Meaning

Parking brake

Position (1501H-S, 1001)

Control stand

Meaning

Information on raising/lowering the skip

Position (1501H, 1001)

On the engine cover

Meaning

This label shows the following information/regulations:

• Maximum payload of machine.

• Tilt out the raised skip only on horizontal ground.

• Tilt out only in straight machine position.

• Maximum slope inclination allowed for tilting out downhill.

Position (1001)

On the skip

Meaning

This label shows the following information/regulations:

• Maximum payload of machine.

• Do not tilt out the skip if material is stuck in the skip.

Position (1501S)

On the skip

Meaning

This label indicates the maximum authorized angle of inclination for traveling on slopes, whatever the position of the machine.

Position (2001)

On the skip

Meaning

Skip swivel

Position (1501S, 2001)

On the engine cover

BA 1001/1501/2001 us – Edition 3.3 * 12001b110.fm 1-13

Introduction

Fig. 23: Loading the dumper

Fig. 24: Maintenance prop

Fig. 25: (symbolic representation)

Meaning

Loading the dumper

Position (2001)

At the rear right on the chassis

Meaning

Maintenance prop

Position

On the front chassis (1001, 1501) and on the swiveling console (2001)

Meaning

Identifies the design-specific machine speed.

Position

At the rear of the machine (left, right and rear).

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2 Safety Information

WARNUNG

DANGER

WARNUNG

WARNINGW

WARNUNG

CAUTION

NOTICE

Important

Environment

2.1 Safety Symbols Found in this Manual

This is the safety alert symbol. It is used to alert you to potential personal hazards.

• Obey all safety messages that follow this symbol.

DANGER indicates a hazardous situation which, if not avoided, will result in death or severe injury.

Consequences in case of non-observance.

• Obey all safety messages that follow this symbol to avoid injury or death

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Safety Information

Consequences in case of non-observance.

• Obey all safety messages that follow this symbol to avoid possible injury or death

CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Consequences in case of non-observance.

• Obey all safety messages that follow this symbol to avoid possible minor or moderate injury

Used without the safety alert symbol. NOTICE indicates a situation which, if not avoided, could result in property damage.

Identifies an instruction that, when followed, provides for a more efficient and economical use of the machine.

Failure to observe the instructions identified by this symbol can result in damage to the environment. The environment is endangered if environmentally hazardous material, such as waste oil, is not properly used or disposed of.

BA 1001/1501/2001 us – Edition 3.3 * 12001b210_us.fm 2-1

Safety Information

2.2 Warranty

2.3 Designated use

Warranty claims must be submitted to your Wacker Neuson dealer only. This requires, among other things, following the instructions in this Operator's Manual.

• The machine is intended for:

• 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 this Operator's Manual and observing the maintenance schedule.

• Machine safety can be negatively affected by performing machine modifications without proper authority and by using spare parts, equipment, attachments and optional equipment which have not been checked and released by Wacker Neuson. Wacker Neuson will not be liable for damage resulting from unapproved parts or unauthorized modifications.

• Wacker Neuson shall not be liable for personal injury and/or damage to property caused by failure to observe the safety instructions on labels and in this Operator's Manual, and by the negligence of the duty to exercise due care when:

• handling the machine

• operating the machine

• servicing the machine and performing maintenance on or with the machine

• repairing the machine

☞This is also applicable when special attention has not been drawn to the duty to

exercise due care.

• Read and understand this Operator's Manual before starting up, servicing or repairing the machine. Observe all safety instructions.

• The machine may not be used for transport jobs on public roads!

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2.4 General Conduct and Safety Instructions

Safety Information

Conditions for use

User training and knowledge

• The machine has been designed and built in accordance with state-of-the-art standards and recognized 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.

• Read and follow this Operator's Manual and other manuals that accompany the machine.

• The machine must only be used in accordance with its designated use and the instructions set forth in this Operator's Manual.

• The machine must only be used by safety-conscious persons who are fully aware of the risks involved in operating the machine.

• The machine must only be used when it is in serviceable condition. Any mechanical dysfunctions, especially those affecting the safety of the machine, must be repaired immediately.

• 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 and safety equipment.

• Always keep this Operator's Manual and other manuals that accompany the machine on hand in their storage bin at the place of use of the machine. Immediately replace an incomplete or illegible Operator's Manual.

• All persons working on or with the machine must read and understand the safety information in this Manual before beginning machine operation. This applies especially to persons working only occasionally on the machine, such as performing set-up or maintenance tasks.

• Follow and instruct the operator in legal and other mandatory regulations relevant to accident prevention and environmental protection. These may include handling hazardous substances, issuing and/or wearing personal protective equipment, or obeying traffic regulations.

• The user/owner must regularly ensure that all persons entrusted with operation or maintenance of the machine are working in compliance with this Operator's Manual and are aware of the risks and safety factors of the machine.

Preparing for use

• Before starting up the machine, always inspect the machine to make sure that it is ready for safe machine operation and traveling.

• Wear close-fitting work clothes that do not hinder movement. Tie back long hair and remove all jewelry (including rings).

Modifications and spare parts

• Never make any modifications, additions or conversions to the machine and its superstructures (for example, cab, etc.), or the machine's attachments, without the approval of Wacker Neuson! Such modifications may affect safety and/or machine performance. This also applies to the installation and 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. Contact your Wacker Neuson dealer for assistance.

BA 1001/1501/2001 us – Edition 3.3 * 12001b210_us.fm 2-3

Safety Information

2.5 General conduct and safety instructions

Organizational measures

• The machine has been designed and built in accordance with state-of-the-art standards and the recognized 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 the machine ensure that:

• All safety devices and guards are in place and in working order.

• All controls operate correctly.

• The machine is set up correctly according to the instructions in the Operator's

Manual.

• The machines is clean.

• The machine's labels are legible.

• No safety devices or guards are missing or inoperative.

• Careful and prudent machine operation 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 replace an incomplete 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 organization, task sequences or the persons entrusted with the task, supplement the Operator's Manual by corresponding instructions, including those relevant to supervising and reporting duties

• Persons entrusted with service/maintenance on the machine must have read and understood the Operator's Manual and in particular, the chapter “Safety Instructions”, before beginning service/maintenance. 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 operator or service technician must wear personal protective equipment as specified by local regulations.

• In the event of safety-relevant modifications or changes on the machine or of its behavior, 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 superstructures, 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

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• 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 safetyrelevant defects have been detected.

• Before servicing the machine, remove jewelry, 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

• Fire hazard e.g. due to oil-soaked rags lying around

• Injury hazard e.g. due to dirt or debris on the footholds, and

• Accident hazard e.g. due to dirt pile-up on the travel pedals

• Observe all safety, warning and information signs and labels on the machine

• Adhere to prescribed intervals or those specified in the Operator's Manual for routine checks/inspections and maintenance on or with the machine!

• For service, inspection, maintenance or repair tools and workshop equipment adapted to the task on hand are absolutely indispensable

Selection and qualification of staff, basic responsibilities

• Any maintenance on or with the machine must be performed by reliable staff only. Do not let unauthorized persons travel or operate 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 performed only by skilled staff which has been specially trained for such work. Work on the hydraulic system of the machine must be performed only by staff with special knowledge and experience in hydraulic equipment!

• Seal off the danger zone should it not be possible to keep a safe distance. Stop operation if persons do not leave the danger zone in spite of warning!

• Keep out of the danger zone!

Danger zone:

The danger zone is the area in which persons are endangered due to the movements of the:

• machine

• work equipment

• additional equipment or

• material

• This also includes the area affected by falling material, equipment or by debris which

are thrown out. The danger zone must be extended by 0.5 m in the immediate vicinity of

• buildings

• scaffolds or

• other elements of construction

Safety Information

BA 1001/1501/2001 us – Edition 3.3 * 12001b210_us.fm 2-5

Safety Information

2.6 Safety instructions regarding operation

Normal operation

• Avoid any operational mode that might be prejudicial to safety!

• Before beginning machine operation, familiarize yourself with the surroundings and circumstances of the work site. These are e.g. obstacles in the traveling area or the job site, the soil bearing capacity and any necessary barriers separating the work site from public roads

• 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 mufflers etc., are in place and fully functional!

• 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 operational behavior) to the competent organization/person immediately! If necessary, stop the machine immediately and lock it!

• In the event of malfunctions, stop the machine immediately and lock it! Have any defects rectified immediately!

• Start and operate the machine from the operator‘s seat only!

• Perform start-up and shut-down procedures in accordance with the Operator's Manual, and observe the indicators!

• Before putting the machine into operation (start-up/moving), make sure no one is at risk by putting the machine into operation!

• Before machine travel, and also after interrupting operation, 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!

• When traveling 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!

• Always switch on the lights in conditions of poor visibility and after dark.

• Do not carry any other persons apart from the operator!

• When crossing underpasses, bridges and tunnels, or when passing under overhead lines always make sure there is enough clearance!

• Always keep at a safe distance from the edges of building pits and slopes!

• When working in buildings or in enclosed areas, look out for:

• Height of the ceiling/clearances

• Width of entrances

• Maximum load of ceilings and floors

• Sufficient room ventilation – poisoning hazard! (exhaust)

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Safety Information

• Avoid any operation that might be a risk to machine stability!

• On sloping terrain always adapt your travel 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 unauthorized use!

• Before starting work check whether

• all safety devices are properly installed and functional.

• dirt has been removed from all footholds.

• Before starting machine travel or operation:

• Make sure visibility is sufficient!

• Adjust your correct seat position, never adjust the seat when traveling or operating!

• Always fasten the seat belt if the rollbar is raised!

• Inspect the immediate area and ensure no one is in the danger zone.

• On the job site the operator is responsible for third parties!

• Caution when handling fuel – increased fire hazard!

• Make sure fuel does not come into contact with hot parts!

Stop the engine before refueling, do not smoke and avoid open flames or sparks.

• Never get on or off during travel or operation! Never jump off the machine!

• Should it be too dark for performing work safely, provide additional lighting on the job site.

• Installed work lights must not be switched on for travel on public roads. They can be switched on in work operation if users of public roads are not blinded.

• Adjust the travel speed to your abilities and the circumstances.

• Always adapt your travel 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 avoid tipping over the dumper by traveling 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 traveling off-road (turtle indicator light on the instrument panel).

• Proceed with extreme care when working on slopes. The dumper can be traveled on firm ground in all positions on slopes up to 25 % steep. On slopes that are less steep if you expect the wheels on one side to sink in. When traveling on slopes steeper than 25 %, travel the loaded dumper only with the skip facing uphill, i.e. travel downhill reversing. When traveling 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 traveling downhill with a full skip, travel 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 center 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 machine. 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 during machine travel.

• 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. Tilt 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 1001/1501/2001 us – Edition 3.3 * 12001b210_us.fm 2-7

Safety Information

WARNUNG

WARNINGW

Operation with lowered rollbar

• Never travel 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 travel closer to edges of pits, precipices, etc.

• Never tilt out material into trenches in which there are persons. If the operator cannot see into the trench, he must be instructed by a person who can see into the trench.

• Always make sure the brakes are in a perfect condition.

Crushing hazard during machine travel with lowered rollbar!

Can cause severe injuries or death.

• Depending on the situation, travelling over very short distances with a lowered rollbar is allowed (in case of low clearance heights, for example), however only if the following conditions are fulfilled:

• Obtain the approval of the competent national authority.

• Machine operation with a lowered rollbar is prohibited.

• Machine travel is only allowed on absolutely level ground.

• Avoid tipping movements of the machine under all circumstances.

• Operation in areas involving a risk of falling objects or fragments flying around is prohibited.

• Do not fasten the seat belt in order to be able to leave the machine immediately in an emergency.

• Wear protective equipment (protective clothing, safety glasses, for example).

Trailer operation

In spite of being equipped with towing gear, the dumper is not a tractor and may not be used as such in difficult terrain. If the dumper is used on construction sites for towing trailers, weight down the skip with 25 % of the payload. However, the towed equipment including the weight in the skip may not exceed the dumper's payload. Secure the towing pin of the towing gear with a split pin!

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2.7 Staff Qualifications and Basic Responsibilities

User/owner responsibility

• Only allow trained and experienced individuals to travel, maintain or repair the machine. Never let unauthorized or underaged persons travel or operate the machine.

• Clearly and unequivocally define the individual responsibilities of the staff for operation, maintenance and repair.

• Define the machine operator's responsibilities on the job site and for 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 by anyone other than an experienced person. Also, Never allow persons taking part in a general training course to operate the machine without being permanently supervised by an experienced person.

Repair person qualifications

• Service on the electric system and equipment, on the undercarriage and the steering and brake systems may be performed only by skilled individuals who have been specially trained for such work.

• Service on the hydraulic system of the machine must be performed only by staff with special knowledge and experience in hydraulic equipment.

Safety Information

2.8 Safety instructions regarding operation

Preparing for use

• Keep the machine clean. This reduces the risk of fire hazards (such as from combustible materials like rags)and reduces the risk of injury or operational accidents that may be caused by dirt build-up on the travel pedals or footholds.

• Observe all safety, warning and informational signs and labels on the machine.

• Start and operate the machine from the operator‘s seat only.

• The operator must sit in the seat, fasten and tighten the seat belt before putting the machine into operation.

• Always adjust the seat position before starting machine operation. Never change the seat position during machine travel or operation.

• Make sure that all safety devices are properly installed and functional before starting machine operation.

• Before putting the machine/attachment into operation (startup/moving), make sure that no one in the immediate vicinity will be at risk.

Startup and shutdown

• Perform startup and shutdown procedures according to this Operator's Manual.

• Observe all indicator lights.

• Do not use starting fluid (for example, ether), especially in those cases in which a heater plug (intake air pre-heating) is used at the same time.

• Make sure the travel levers, the signaling and the light systems are functional before operating the machine, and also before restarting after a interruption of machine operation.

• Make sure that the service brake and the parking brake are functional before operating the machine, and also after an interruption of machine operation. The machine will not start unless the parking brake is applied. The drive must be switched off if the parking brake is applied

BA 1001/1501/2001 us – Edition 3.3 * 12001b210_us.fm 2-9

Safety Information

Job Site awareness

• Familiarize yourself with the surroundings and circumstances of the job site before beginning machine operation. Be aware of:

• obstacles in the working and traveling area

• the soil weight-bearing capacity

• any necessary barriers separating the job site from public roads

• Always keep a safe distance from the edges of building pits and slopes.

• Look out for the following when working in buildings or in enclosed areas:

• Height of the ceiling/clearances

• Width of entrances

• Maximum load of ceilings and floors

• Sufficient room ventilation—carbon monoxide poisoning hazard!

• Observe the danger zone. See “Danger zone awareness”.

• Use the rearview mirror to stay aware of job site obstacles and personnel.

• Always switch on the work lights in conditions of poor visibility and after dark. However, make sure that users of public roads will not be temporarily blinded by the work lights.

• Provide additional lighting on the job site if the lights of the machine are not sufficient for performing safe operation.

• Travel slowly on meadows, on leaves or wet steel plates. The machine can slip even if the ground is level.

Danger zone awareness

Operating the machine

Special operating notes

• The danger zone is the area in which persons are endangered due to the movements of the machine, work equipment, additional equipment, or material.

• The danger zone also includes the area affected by falling material, equipment or construction debris. The danger zone must be extended by 0.5 m (20”) in the immediate vicinity of buildings, scaffolds, or other elements of construction.

• Seal off the danger zone if it is not possible to keep a safe distance. Stop operating immediately if persons do not leave the danger zone in spite of warnings!

• Never operate the machine if you are standing on the ground.

• Operate the machine only when you are seated and you have fastened your seat belt. Stop the engine before releasing the seat belt.

• On sloping terrain, adapt your travel speed to the prevailing ground conditions.

• Never get on or off a machine during travel or operation, and never jump off the machine.

• Always adapt your travel speed to the road and ground conditions, and to the visibility conditions. Ask for help in navigating difficult passages or obstacles. To avoid tipping the dumper, travel appropriately and slowly as conditions dictate. This applies in particular to rough terrain, the edges of trenches, curves and emergency braking. Use only the low speed range when traveling off-road (see the turtle indicator light on the instrument panel).

• Make sure the engine cover is closed and locked before starting the dumper.

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Carrying passengers

Mechanical integrity

Safety Information

• 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.

• Never travel too close to the edges of unsecured pits, precipices, etc. The pressure of the wheels on the ground may cause the edge to give way.

• Never tilt out material into trenches where people are working. If the operator cannot see into the trench, he or she must be guided by someone who can see into the trench.

• Always make sure the brakes are in perfect condition.

• Apart from the operator, do not allow anyone to ride on the machine.

• Never lift, lower, or carry persons in the work equipment or attachments.

• Never install a man basket or a working platform to the machine.

• 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 (ROPS, removable safety devices, soundproofing elements, mufflers, etc.) are in place and fully functional.

• Check the machine at least once a day/per machine operation shift for visible damage and defects. Report any changes, including changes in the machine's operational behavior, to your supervisor immediately!

• If the machine is behaving unpredictably, stop the machine immediately, lock it and report the malfunction to the competent authority/person. Safety-relevant damage or malfunctions of the machine must be rectified immediately.

Traveling on public roads

• When traveling on public roads, ways and places, observe all applicable traffic regulations. If necessary, make sure that the machine is in compliance with these regulations.

• When crossing underpasses, gates, bridges and tunnels, or when passing under overhead lines, make sure the clearance height and width are sufficient.

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Safety Information

2.9 Trailering and Transport

Trailers

Transport

• Even though the dumper is equipped with towing gear, it is not a tractor and may not be used as such in difficult terrain.

• If the dumper is used on construction sites for towing trailers, weight the skip with 25 % of the payload. However, do not exceed the dumper's maximum payload with the combination of towed equipment and the weight in the skip!

• Secure the towing pin of the towing gear with a split pin.

• Use special care when coupling trailers, and couple them with the specially required devices only.

• Always secure trailers against unintentional movement.

• If optional equipment such as a trailer is installed, make sure that all lights and associated indicator lights are installed and functional.

• The machine must be towed, loaded and transported only in accordance with procedures described in this Operator's Manual.

• For towing the machine, observe the prescribed transport position, admissible speed and itinerary.

• Make sure that the vehicle transporting the machine has a sufficient capacity and payload.

• Safely secure the machine on the transporting vehicle. Use the specified tie-down points.

2.10 Temperature Range

The machine may only be used between a maximum +45°C (113°F) and minimum -15°C (5°F). Contact your Wacker Neuson dealer if you intend to use the machine in other temperature ranges. Store the machine in a dry place at room temperature (about 15°C, or 59°F). Observing these temperature ranges will help to prolong the machine's service life.

2.11 Safety Guidelines for Maintenance

General maintenance notes

• Adhere to prescribed intervals or those specified in this Operator's Manual for routine checks/inspections and maintenance.

• For inspection and maintenance, ensure that all tools and workshop equipment are adapted to the task that must be performed.

• Replace hydraulic hoses within stipulated and appropriate intervals even if no safety-relevant defects have been detected.

• Make sure all consumables and replaced parts are disposed of safely and with minimum environmental impact.

• Always tighten any screws, electrical connections, or hose connections that may have been loosened during maintenance.

• Upon completion of the maintenance on or with the machine, immediately refit and check any safety devices removed for set-up or maintenance purposes.

2-12 BA 1001/1501/2001 us – Edition 3.3 * * 12001b210_us.fm

Personal safety measures

Safety Information

• Brief the staff and the operator before beginning maintenance or repair. Appoint someone to supervise the activities.

• Always work in groups of two. Both persons must be trained on the machine—one person must be seated on the seat and maintain visual contact with the other person.

• Observe the specific safety instructions in the Maintenance section of this Operator's Manual.

• Always keep a safe distance from all rotating and moving parts, for example, fan blades, V-belt drives, PTO shaft drives, fans, etc.

• Before starting to work on hazardous machine parts, always ensure safety devices and guards are in place.

• Use extreme caution when working on the fuel system due to the increased fire hazard.

• Engine and muffler system become very hot during operation and require cool-down time after machine is shut off. Avoid contact with hot parts. Wait for the machine to cool before touching components.

• Retainer pins can fly out or splinter when struck with force. Avoid striking the pins during operation, repair, or maintenance.

• Do not use starting fluid (for example, ether), especially in those cases in which a heater plug (intake air pre-heating) is used at the same time.

Preparing for maintenance and repair work

• Prior to performing repair and maintenance, always attach a warning label such as “Repair work—do not start machine!” to the control elements as a precautionary measure.

• Observe the startup and shutdown procedures set forth in this Operator's Manual. This applies to any task concerning the operation, conversion or adjustment of the machine and its safety-oriented devices, or any work related to inspection and maintenance.

• Prior to performing assembly maintenance on the machine, make sure no movable parts will roll away or start moving.

• Perform maintenance only if:

• the machine is positioned on firm and level ground

• secured against unintentional movement

• all hydraulically movable attachments and working equipment have been lowered to

the ground

• the engine is switched off

• the starter key has been removed

• Perform maintenance beneath a raised machine, attachments or additional equipment only if a safe and secure support has been provided. The use of hydraulic hydraulic cylinders or jacks as the sole method of support does NOT sufficiently secure raised machines or equipment/attachments!

Performing maintenance and repairs

• Observe the adjustment, maintenance and inspection activities and intervals set forth in this Operator's Manual, including information on the replacement of parts and partial equipment. These activities must be performed only by qualified personnel.

• Disconnect the negative battery terminal when working on the electric system.

• Do not allow the machine to be serviced, repaired, or test-traveled by unauthorized staff.

• If maintenance with the engine running cannot be avoided, lower the skip and apply the parking brake.

BA 1001/1501/2001 us – Edition 3.3 * 12001b210_us.fm 2-13

Safety Information

2.12 Special hazards

Battery

• Wear a safety harness when performing elevated maintenance. Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow and ice.

• Always use specially designed or otherwise safety-oriented ladders and working platforms to perform overhead assembly maintenance. Never use machine parts or attachments/superstructures as a climbing aid!

• Do not use the work equipment as lifting platforms for persons.

• In accordance with this Operator's Manual and instructions for the respective assembly, release the pressure in all system sections and pressure lines (hydraulic system) before performing any maintenance.

• In case of a frozen battery or of an insufficient electrolyte level, do not try starting the machine with battery jumper cables. The battery can burst or explode.

• Batteries contain caustic sulphuric acid. When handling the battery, observe the specific safety instructions and regulations relative to accident prevention.

• A volatile oxyhydrogen mixture forms in batteries during normal operation and especially when charging. Always wear gloves and eye protection when working with batteries.

• Starting the machine with a battery jumper cable can be hazardous if performed improperly. Observe the safety instructions regarding the battery.

Tracks (track dumpers)

Electric energy

• Repair on the tracks must be performed only by trained technical staff or by a Wacker Neuson service center.

• Malfunctioning tracks reduce the machine's operational safety. Therefore, check the tracks regularly for cracks, cuts or other damage.

• Check track tension at regular intervals.

• Use only original fuses with the specified current rating.

• In case of electric system malfunctions, stop the machine immediately, disconnect the battery (by using the battery master switch)and perform troubleshooting procedures.

• During machine operation, maintain a safe distance from overhead electric lines! If machine operation must be performed close to overhead lines, the equipment and attachments must be kept well away from them.

• If the machine comes into contact with a live wire:

• Immediately travel the machine out of the danger zone.

• Warn others against approaching and touching the machine.

• Do not leave the machine until the line that has been touched or damaged has been

safely de-energized!

• Make sure that service on the electric system is performed only by a technician with appropriate training, in accordance with applicable electrical engineering codes.

• Inspect and check the electric equipment of the machine at regular intervals. Defects such as loose connections or scorched cables must be repaired immediately.

• Observe the operating voltage of the machine/attachments.

• Always remove the grounding strap from the battery when working on the electric system.

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Gas, dust, steam, smoke

Hydraulics

Safety Information

• 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!

• Perform welding, flame-cutting and grinding work on the machine only if this has been expressly authorized. There can be a risk of explosion and fire, for example!

• Before performing 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 – explosion hazard!

• Service on the hydraulic equipment of the machine must be performed 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 performing any maintenance/repairs!

• 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

• Check all lines, hoses and threaded fittings regularly for leaks and obvious damage! Repair any damage and leaks immediately. Leaking oil may cause injury and fire!

Noise

Oil, grease and other chemical substances

MSDS

• Close all sound baffles during operation.

• Wear ear protection. This is especially important when performing hammer operations or working in enclosed areas.

• 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 – burn hazard!

• When handling oil, grease and other chemical substances such as battery electrolyte or hydraulic fluid, observe the product-related safety regulations (Material Safety Data Sheet: MSDS).

BA 1001/1501/2001 us – Edition 3.3 * 12001b210_us.fm 2-15

Safety Information

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Tires (wheel dumpers)

• Repair on the tires must be performed only by trained technical staff or by a Wacker Neuson service center.

• Malfunctioning tires reduce the machine's operational safety. Therefore, check the tires regularly for cracks, cuts or other damage.

• Check the tire pressure at regular intervals.

2.13 Safety Guidelines while using Internal Combustion Engines

Internal combustion engines present special hazards during operation and fueling. Failure to follow the warnings and safety guidelines could result in severe injury or death.

• Read and follow the warning instructions in the engine owner's manual and the safety guidelines below.

Guidelines for running the engine

CALIFORNIA Proposition 65 Warning

Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

• Keep the area around muffler pipe free of flammable materials.

• Check the fuel lines and the fuel tank for leaks and cracks before starting the engine. Do not run the machine if fuel leaks are present or the fuel lines are loose.

• Engine exhaust can kill you in minutes! Engine exhaust contains carbon monoxide. This is a poison you cannot see or smell. Never run the machine indoors or in an enclosed area such as a deep trench unless adequate ventilation, through such items as exhaust fans or hoses, is provided.

• Do not smoke while operating the machine.

• Do not run the engine near open flames.

• Do not touch the engine or muffler while the engine is running or immediately after it has been turned off.

• Do not operate a machine when its fuel cap is loose or missing.

• Do not remove the radiator cap when the engine is running or hot. The radiator fluid is hot and under pressure, and may cause severe burns!

2-16 BA 1001/1501/2001 us – Edition 3.3 * * 12001b210_us.fm

Guidelines for fueling the engine

Safety Information

When fueling the engine:

• Clean up any spilled fuel immediately.

• Refill the fuel tank in a well-ventilated area.

• Replace the fuel tank cap after refueling.

When fueling the engine:

• Do not smoke.

• Do not refuel a hot or running engine.

• Do not refuel the engine near an open flame.

BA 1001/1501/2001 us – Edition 3.3 * 12001b210_us.fm 2-17

Safety Information

2-18 BA 1001/1501/2001 us – Edition 3.3 * * 12001b210_us.fm

3Operation

Operation

This chapter describes the controls, and contains information on the function and handling of the indicator lights 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 (for example 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:

• Identifies a list

• Subdivision within lists or an activity. Follow the steps in the recommended order

☞Identifies an activity

➥Description of the effects or results of an activity

n. s. = not shown Opt = option Stated whenever controls or other components of the machine are installed as an option.

BA 1001/1501/2001 us – Edition 3.3 * 12001b320.fm 3-1

Operation

Description of 1001/1501 components (overview)

Pos.

3-2 BA 1001/1501/2001 us – Edition 3.3 * * 12001b320.fm

Designation

1 Rear chassis 2Front chassis 3 Lift frame 4 Articulated joint 5 Operator seat 6 Control stand 7 Tilt console 8 Engine cover

9 Parallel lift 10 Skip 11

Lift cylinder

Tilt cylinder (not shown)

Steering cylinder

Operation

Description of 1501S components (overview)

Pos.

BA 1001/1501/2001 us – Edition 3.3 * 12001b320.fm 3-3

Designation

1 Operator seat 2 Control stand 3Skip 4 Swivel centring 5 Swiveling console 6 Tilt cylinder 7 Articulated joint 8 Steering cylinder 9 Rear chassis

10 Engine cover

Operation

3.1 Description of 2001S components (overview)

Pos.

3-4 BA 1001/1501/2001 us – Edition 3.3 * * 12001b320.fm

Designation

1 Rear chassis

2Front chassis

3 Swiveling console

4 Articulated joint

5 Operator seat

6 Control stand

7 Mudguard

8 Engine cover

9 Swivel centring 10 Skip 11 Swiveling cylinder 12 Tilt cylinder 13 Steering cylinder 14 Rollbar

Operation

3.2 Description of 2001 SLE components

Pos.

BA 1001/1501/2001 us – Edition 3.3 * 12001b320.fm 3-5

Designation

1 Lift frame 2 Lift cylinder 3 Bucket cylinder 4Bucket 5 Fastening mount 6 Articulation (large) 7 Articulation (small)

Operation

3.3 1001/1501/1501S operating equipment up to serial no. AB ...

Driving direction lever

Pos.

Designation

1 Accelerator pedal 14 Hour meter

2 Parking brake 15 Fuel level indicator 3 Preheating start switch 16 Lever “Tilting out/lowering the skip” 4 Travel direction lever 17 Lever “Raising/lowering the skip” 5 Horn 18 Bar for horizontal seat adjustment 6 Alternator charge indicator light 7 Engine oil pressure indicator light 8 Parking brake indicator light

9 Engine temperature indicator light 10 Spare fuel indicator light 11 Not assigned 12 Hydraulic oil filter indicator light 13 Preheating indicator light

3-6 BA 1001/1501/2001 us – Edition 3.3 * * 12001b320.fm

Operation

3.4 1001/1501/1501S operating equipment from serial no. AB ...

Pos.

Designation

1 Accelerator pedal 14 Hydraulic oil filter indicator light

2 Service brake 15 Preheating indicator light 3 Parking brake 16 Hour meter 4 Preheating start switch 17 Fuel level indicator 5 Travel direction lever 18 Lever “Tilting out/lowering the skip” 6 Horn 19 Lever “Raising/lowering the skip” 7 Display element 20 Bar for horizontal seat adjustment 8 Alternator charge indicator light

9 Engine oil pressure indicator light 10 Parking brake indicator light 11 Engine temperature indicator light 12 Turn indicator light 13 Not assigned

BA 1001/1501/2001 us – Edition 3.3 * 12001b320.fm 3-7

Operation

9 10

1st row of indicator lights 2nd row of indicator lights

3rd row of indicator lights

3.5 2001/2001SLE operating equipment

Pos. Designation Pos. Designation

Accelerator pedal

Parking brake

Preheating start switch

Travel direction lever

Horn

Alternator charge function indicator light

Engine oil pressure indicator light

Parking brake indicator light

Engine temperature indicator light

Spare fuel indicator light

Not assigned

Hydraulic oil filter indicator light

Not assigned

High beam indicator light Not assigned Preheating indicator light Turn indicator light Hour meter Fuel level indicator Lever for tilting/lowering the skip Lever: swivel skip Hydrostatic brake pedal Light switch Seat adjustment lever Skip/loader unit switch (option 2001)

14 15 16 17 18 19 20 21 22 23 24 25

3-8 BA 1001/1501/2001 us – Edition 3.3 * * 12001b320.fm

3.6 Putting into operation

Safety instructions

Putting into operation for the first time

Operation

• Use footholds and handles to access and leave the machine

• Never use control elements as handles

• Never get on a moving machine. Never jump off the machine

Important information

• The machine may only be put into operation by authorized personnel – see chapter Selection and qualification of personnel, basic responsibilities on page 2-4 and –

see chapter 2.5 Safety instructions regarding operation on page 2-5 of this

Operator’s Manual.

• The personnel 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, and only by safetyconscious persons who are fully aware of the risks involved in operating the machine.

• Go through the “Start-up” checklist in the following chapter.

Running-in period

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 travel 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 while varying the engine speed

• Strictly observe the maintenance schedules in the appendix

– see chapter 5.16 Maintenance plan 2001 (overview) on page 5-39

BA 1001/1501/2001 us – Edition 3.3 * 12001b320.fm 3-9

Operation

Check lists

Start-up checklist

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 work listed below is described in greater detail in the following chapters.

If the answer to one of the following questions is NO, first rectify the cause of the fault before starting or continuing work.

Check the following points before putting the machine into operation or starting the engine:

No.

Question

Enough fuel in the tank? (➠ 5-5)

Coolant level OK? (➠ 5-13)

Remove water in the diesel fuel prefilter (➠ 5-7)

Engine oil level OK? (➠ 5-10)

Oil level in hydraulic oil reservoir OK? (➠ 5-21)

V-belt condition and tension checked? (➠ 5-18)

Lubrication points greased?

Check hydraulic hoses, connections and cylinder seals for leaks

Firm position of battery terminals

Tires checked for cracks, cuts, etc. ? (➠ 5-26)

Footholds clean?

Engine cover locked with the buckle? (➠ 3-29) Especially after cleaning, maintenance or repair work:

➥Rags, tools and other loose objects removed?

Seating position adjusted correctly? (➠ 3-27)

Rollbar raised and locked?

Seat belt fastened? (➠ 3-28)

✔

3-10 BA 1001/1501/2001 us – Edition 3.3 * * 12001b320.fm

Operation checklist

Operation

After starting the engine and during operation, check and observe the following points:

“Parking” checklist

No. Question

Anyone in the danger zone of the machine? Indicator lights for engine oil pressure and alternator charge function gone

out? (➠ 3-13)

Temperature indicators for engine coolant do not illuminate? (➠ 3-13)

Accelerator and brake pedals working correctly? (➠ 3-20)

Check and observe the following points when parking the machine:

No. Question

Skip lowered?

Travel lever in neutral position?

Parking brake applied?

Starting key removed?

When parking on public roads:

Machine adequately secured?

When parking on slopes:

Machine additionally secured with chocks under the wheels to prevent it from

rolling away?

✔

BA 1001/1501/2001 us – Edition 3.3 * 12001b320.fm 3-11

Operation

Fig. 26: Preheating start switch

Fig. 27: Accelerator pedal (symbolic representation)

3.7 Machine travel

Preheating start switch (overview)

Accelerator pedal (overview)

Position

Function Power consumer

Insert or remove the starting key None

All functions are operational

ON/travel position

➥Indicator lights illuminate ➥Rotating beacon illuminates

(option)

Preheats the engine (10 – 15 seconds)

Starts the engine

The accelerator pedal controls the engine speed as follows:

• Speed can be set continuously with accelerator pedal 25

➥Until the preheating indicator

light goes out

➥Starter is actuated ➥Indicator lights must go out

☞Press down the accelerator pedal:

➥Engine speed rises

☞Reduce the pressure on the accelerator pedal:

➥Engine speed is reduced

3-12 BA 1001/1501/2001 us – Edition 3.3 * * 12001b320.fm

Indicator lights and warning lights (overview)

NOTICE

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14 Indicator light (red) – hydraulic oil filter

Indicates inadmissibly high pressure in the hydraulic return line to the reservoir. In this case:

☞Have the hydraulic oil return filter checked and, if necessary, replaced by a Wacker

☞The indicator light can illuminate briefly if the hydraulic oil is cold, but goes out again

8 Indicator light (red) – alternator charge function

The V-belt is malfunctioning or there is an error in the charging circuit of the alternator if the indicator light illuminates with the engine running. The battery is no longer charged.

Operation

Neuson service center

once operating temperature is reached.

The coolant pump no longer runs if the V-belt is faulty. Danger of engine overheating or breakdown! If the indicator light illuminates with the engine running:

☞Stop the engine immediately and ☞Have the cause repaired by a Wacker Neuson service center

9 Indicator light (red) – engine oil pressure

Illuminates if the engine oil pressure is too low. In this case:

☞Stop the machine ☞Stop the engine immediately and check the oil level

The indicator light illuminates when the starter is turned on and goes out as soon as the engine runs.

11 Indicator light (red) – coolant temperature

Burn hazard! The engine coolant is under pressure at high temperature.

Can cause severe injury or death.

• Wait at least 10 minutes after stopping the engine.

• Wear protective gloves and clothing.

• Open the cap to the first notch and release the pressure.

15 Indicator light (yellow) – preheating

Illuminates 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 indicator light goes out as soon as preheating temperature is reached (15 – 20 sec)

BA 1001/1501/2001 us – Edition 3.3 * 12001b320.fm 3-13

Operation

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13 Not assigned

10 Indicator light (red) – parking brake

Illuminates if the parking brake is applied! In this case:

☞Actuate lever 2 to release the parking brake

Indicator light (blue) – high beam

Illuminates if high beam is on.

Accident hazard! Motorists can be blinded by bright lights on the job site.

Can cause severe injuries or death.

• Switch on low beam when other motorists are nearby.

• If this is not possible, stop machine operation and only resume it if sufficient illumination of the job site can be ensured without blinding other motorists.

12 Indicator light (green) – turn indicators

Flashes if the turn indicators are switched on.

16 Hour meter

Counts the engine operating hours with the engine running.

17 Fuel level indicator

Refuel immediately if the fuel level indicator reaches minimum. Otherwise the fuel system must be bled if it is run dry.

3-14 BA 1001/1501/2001 us – Edition 3.3 * * 12001b320.fm

WARNUNG

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Important

Fig. 26: Mirrors (symbolic representation)

Operation

Mirrors (option)

Operation

Accident hazard if mirrors are adjusted incorrectly!

Can cause severe injury or death.

• Use safety-oriented ladders and work platforms for adjustment work on the

machine.

• Never use machine parts or attachments/superstructures as a climbing aid.

• Do not adjust the mirrors during machine travel.

• Immediately replace damaged or broken mirrors.

• Additional equipment or attachments must not impair visibility.

• Convex mirrors enlarge, reduce or distort the field of view. Bear this in mind

when adjusting and using such mirrors.

Injury hazard to persons in the danger zone!

Can cause severe injury or death.

• Follow the safety instructions.

• Check the surroundings constantly.

• Put the machine into operation/machine travel only if visibility is sufficient

(have another person guide you if necessary).

Adjusting the outside rearview mirrors on left and right

We recommend having the mirrors adjusted by a second person.

Adjust the mirrors in order to:

• Ensure sufficient visibility from the operator seat onto the job site.

• Ensure maximum visibility to the rear.

• Ensure visibility of the rear edges of the machine in the mirrors.

BA 1001/1501/2001 us – Edition 3.3 * 12001b330.fm 3-15

Operation

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Important

StVO accessories (option)

Reversing signal (option)

Scope of delivery of StVO accessories:

• Headlights and rear lights

• Turn indicators and clearance lights

• Reversing light and reflectors

• Numberplate console and light

• Wheel chock

• Control lever lock

The reversing signal sounds during backward machine travel.

Accident hazard when traveling forward/backward!

Crushing hazard causing death or severe injury.

• Do not allow anyone to stay in the danger zone.

• Do not rely on the reversing signal under any circumstances.

• If the reversing signal does not sound, stop machine operation immediately and get in touch with a Wacker Neuson service center (observe the relevant national regulations).

Before starting the engine

General information on starting the engine

☞Adjust your seating position – see Seat adjustment on page 3-27

All controls must be within easy reach. You must be able to press the accelerator and brake pedals to their limit positions!

☞Fasten your seat belt – see Seat belt on page 3-28 ☞Check whether all levers and pedals are in neutral position ☞Press the accelerator pedal to the center position (between minimum and maximum) if

the engine is cold

The model 1001 and 1501 engine will not start unless the parking brake is applied and the brake pedal is pressed at the same time.

• 1001: from serial no. EA03289.

• 1501: from serial no. WNCD0105TPAL00166.

• Besides, the starter cannot be actuated if:

• the engine is already running (start repeat interlock),

• the travel lever is not in neutral position,

• the parking brake is not applied.

➥1001: up to serial no. EA03288. ➥1501: up to serial no. WNCD0105TPAL00165.

• the parking brake is not applied (2001).

3-16 BA 1001/1501/2001 us – Edition 3.3 * * 12001b330.fm

Procedure

Fig. 27: Preheating start switch

Fig. 28: Indicator lights

Operation

• Do not run the starter for more than 10 seconds

• Wait about 1 minute so the battery can recover before trying again

After you have completed the starting preparations:

☞Insert the starting key in preheating start switch 3 ☞Turn the starting key to position “1” ☞Check whether the following indicator lights illuminate:

➥Indicator light 9 for engine oil pressure

➥Indicator light 13 for alternator charge function ☞Replace malfunctioning indicator lights immediately. ☞Turn the starting key to position “2” and hold it in this position until the preheating indi-

cator light goes out

☞Turn the starting key to position “3” and hold it in this position until the engine starts

➥If the engine does not start after 10 seconds

☞Interrupt the start procedure and try again after 1 minute

➥If the engine still does not start after the second try

☞Contact a Wacker Neuson service center for troubleshooting. ➥As soon as the engine runs: ☞Release the starting key

When the engine runs smoothly (increased engine speed):

BA 1001/1501/2001 us – Edition 3.3 * 12001b330.fm 3-17

Operation

Important

Fig. 29: Travel interlock key

Fig. 30: Travel interlock key

3.14 Travel interlock

Scope of delivery A: starting key (blue, 2 pieces)

B: master key (red)

Keys can be coded or deleted only with the master key. A new travel interlock must be installed if the master key is lost.

Coding keys

1 Insert the master key in the starter and turn it to position 1 for a maximum 5 seconds. 2 Remove the master key. 3 Turn the keys requiring coding to position 1 within 15 seconds, for at least one second.

➥The key is registered.

Coding is automatically interrupted if no key is coded within 15 seconds. Coding can be performed for a maximum 10 keys.

Deleting a key

If a coded key is lost, all keys have to be deleted and recoded. 1 Insert the master key in the starter and turn it to position 1 for at least 20 seconds.

➥The coded keys are deleted now. New or existing keys have to be recoded.

3-18 BA 1001/1501/2001 us – Edition 3.3 * * 12001b330.fm

When the engine has started ...

12 V

34001b710_05.eps

Fig. 31: Starting aid with battery jumper cables

Empty battery

Starting battery

Engine warm-up

Jump-starting the engine (supply battery)

Operation

☞Check whether all indicator lights have gone out: ☞Let the engine warm up

At cold temperatures:

☞Increase the engine speed slowly ☞Do not run the engine at full load until it has reached its operating temperature

Once it has started, let the engine warm up at slightly increased idling speed. Run the engine without load during the warm-up phase (travel lever in neutral position). During the warm-up phase, check for unusual noise, exhaust color, 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.

Safety instructions

• Never jump-start the engine if the battery of the machine is frozen – explosion hazard!

☞Dispose of a frozen battery!

• The excavator must not touch the jump-starting vehicle when connected with jump leads – sparking hazard!

• The external power source must deliver 12 V; higher supply voltages will damage the electrical system of the vehicles!

• Use only authorized battery jumper cables which conform to the safety requirements and which are in perfect condition!

• The jump lead connected to the positive + terminal of the starting battery must never be brought into connection with electrically conductive vehicle parts – risk of short

circuit!

• Route the battery jumper cables so they cannot catch on rotating components in the engine compartment!

Procedure

☞Travel the jump-starting vehicle close enough to the machine so that the jump leads

can reach to connect the two batteries

☞Let the engine of the jump-starting vehicle run ☞First connect one end of the red jump lead (+) to the + terminal of the empty battery,

then connect the other end to the + terminal of the starting battery

☞Connect one end of the black jump lead (–) to the – terminal of the starting battery ☞Connect the other end of the black cable (–) to a solid metal component fimly screwed

on the engine block or onto the engine block itself. Do not connect it to the negative terminal of the empty battery, as otherwise explosive gas emerging from the battery can ignite if sparks are formed!

☞Start the engine of the machine with the empty battery

Once the engine has started:

☞With the engine running, disconnect both jump leads in exactly the reverse order (first

remove the

– terminal, then the + terminal) – this prevents sparking near the battery!

BA 1001/1501/2001 us – Edition 3.3 * 12001b330.fm 3-19

Operation

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Special instructions for traveling on public roads

• The machine is subject to the applicable legal regulations of your country.

• Also observe the applicable regulations for accident prevention of your country.

Checks before traveling on public roads

• Stop the engine.

• Apply the parking brake.

• Check the operator seat for correct adjustment.

• Check the StVO accessories (option) for completeness and correct function.

• Check the mirrors (option) for correct adjustment.

• Check the brake system for correct function.

• Check the tires for correct inflation pressure.

• Move the travel direction lever to neutral.

• Let the skip lock in the straight position.

• Lock the control lever for skip operation.

• Secure the load adequately.

• Remove dirt from the controls and loose material.

Starting machine travel

Accident hazard due to incorrectly adjusted traveling direction lever!

Can cause severe injury or death.

• Ensure that the surrounding area is clear.

• Press the brake pedal or apply the parking brake.

• Set the travel direction lever to the correct position before starting machine travel.

• Press the accelerator pedal to start machine travel.

Accident hazard! The machine can travel when the brake is not activated.

Can cause severe injury or death.

• Stop the machine and activate the brake during travel direction changeover.

Accident hazard due to traveling direction changeover during machine travel!

Can cause severe injury or death.

• Stop the machine and activate the brake during travel direction changeover.

3-20 BA 1001/1501/2001 us – Edition 3.3 * * 12001b330.fm

Operation

Fig. 32: Starting machine travel

Fig. 33: Accelerator pedal (symbolic representation)

Fig. 34: Brake pedal 1001/1501

Fig. 35: Brake pedal 2001

☞Selection of travel direction ☞Stop the machine. ☞Press brake pedal 2 or apply the parking brake – see chapter Parking brake on

page 3-22.

☞Set travel direction lever B to the required position. ☞Release the brake and press accelerator pedal 1 to start machine travel.

Accelerator pedal 1 sets the engine speed and travel speed.

Function

Press the pedal The machine accelerates Reduce the pressure on the pedal The machine is braked Release the pedal Idling speed

The speed with which the skip moves also depends on the position of the accelerator pedal.

Brake pedal (standard for 1001 + 1501, option for 2001)

The machine brakes automatically to a standstill when releasing the accelerator pedal. Press and release the accelerator pedal slowly to avoid jerky movements of the dumper.

Press brake pedal 2 for faster deceleration, or during downhill machine travel, for example.

Press brake pedal 2 to brake the machine. 1001:

• Option up to serial no. EA03288

• Standard from serial no. EA03289

1501:

• Option up to serial no. WNCD0105TPAL00165

• Standard from serial no. WNCD0105TPAL00166

BA 1001/1501/2001 us – Edition 3.3 * 12001b330.fm 3-21

Operation

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Fig. 36: Parking brake 1001/1501 (symbolic representation)

Fig. 36: Parking brake 1001/1501

Fig. 37: Parking brake 2001

Parking brake

Accident hazard! Do not apply the parking brake during machine travel.

Can cause severe injury or death.

• Apply the parking brake only at machine standstill.

1001/1505 (switch without lock):

To apply: press switch 3 to position A. To release: press switch 3 to position B.

1001/1501 (switch with lock):

To apply: Pull lock C downward and press switch 3 to position B. To release: Pull lock C downward and press switch 3 to position A.

2001:

To apply: pull lever 10 upward. To release: press and hold button 21, then lower lever 10 completely.

3-22 BA 1001/1501/2001 us – Edition 3.3 * * 12001b330.fm

3.15 Hazard warning system

Important

Fig. 38: Hazard warning system

Fig. 39: Rotating beacon on the rollbar

Rotating beacon (option)

Operation

Pressing switch 39 switches the hazard warning system on and off.

The rotating beacon is switched on as soon as the starting key is in position 1.

Observe the legal regulations of your country for operating the rotating beacon.

3.16 Machine travel on slopes

Follow these safety instructions carefully when traveling on slopes, in order to avoid accidents.

Specific safety instructions

☞Tilt in the skip during machine travel. ☞Always travel in low speed on slopes! ☞During machine travel, ensure that you can stop safely any time if the machine starts to

☞Avoid swiveling the skip downhill on slopes, otherwise the machine can lose its balance

☞Do not travel across slopes steeper than 20 % otherwise the machine can tip over laterally. ☞Always travel straight ahead when driving uphill or downhill. Driving diagonally or at an

☞Travel slowly in meadows, on leaves or wet steel plates. The machine can slip even if

skid or if it becomes unstable.

and tip over.

➥Always tilt out the skip uphill.

angle to the slope is very dangerous.

the ground is level.

BA 1001/1501/2001 us – Edition 3.3 * 12001b330.fm 3-23

Operation

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Fig. 40: Driving on slopes with a loaded skip

> 20 %

Fig. 41: Driving on slopes with an empty skip

> 20 %

Driving on slopes with a loaded skip

Proceed as follows to prevent the machine from tipping over or slipping sideways:

☞When driving on slopes (> 20 %) with a loaded skip, the skip must always face uphill

Machine travel on slopes with an empty skip

☞When traveling on slopes (> 20 %) with an empty skip, the skip must always face down-

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.

Accident hazard due to tipping over or slipping of the machine on slopes!

Can cause severe injury or death.

• Travel on slopes only on firm and level ground.

• Do not reverse down slopes.

• Traveling diagonally is prohibited.

hill since the heavier part of the machine – in this case the engine – must face uphill to prevent the machine from tipping over.

Machine travel across slopes

☞Do not travel across slopes with lateral inclinations steeper than 20 %! ☞When traveling across slopes with lateral inclinations up to 20 %, tilt out the skip only

uphill for stability reasons.

Accident hazard due to tipping over or slipping of the machine on slopes!

Can cause severe injury or death.

• Machine travel across slopes (max. inclination up to 20 %) is allowed only on firm ground.

3-24 BA 1001/1501/2001 us – Edition 3.3 * * 12001b330.fm

Parking the machine

Important

NOTICE

Important

Fig. 42: Neutral

Operation

Always park the machine on firm ground!

☞Select a level surface ☞Stop the machine ☞Move travel lever A to neutral position ☞Lower the skip ☞Apply the parking brake ☞Switch off the starter ☞If parking the machine on a slope cannot be avoided, place wheel chocks under the

wheels to ensure that the machine will not roll away under its own weight.

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.

Secure the machine against unauthorized operation.

• Remove the key.

BA 1001/1501/2001 us – Edition 3.3 * 12001b330.fm 3-25

Operation

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NOTICE

Loading the machine

Injury hazard when loading the machine!

Can cause severe injury or death.

• Leave the machine before the loading operation and only get onto it again after finishing the loading operation.

Incorrect loading causes damage on the machine.

☞Ensure that the payload is not exceeded!

• Ensure that the operator’s visibility is not impaired.

• Before loading:

☞Select the neutral position with the travel lever ☞Lower the skip ☞Apply the parking brake ☞Stay clear of the control stand and the danger zone

• Once loading is over:

☞Remove dirt, debris, dust, etc. from the control elements ☞Remove loose material

3-26 BA 1001/1501/2001 us – Edition 3.3 * * 12001b330.fm

3.17 Seat adjustment

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Important

Fig. 43: Weight adjustment

Fig. 44: Horizontal seat adjustment

Fig. 45: Backrest adjustment

Weight adjustment

Operation

Accident hazard! Do not change the seat position when traveling or operating.

Can cause severe injury or death.

• Adjust the operator seat only at machine standstill and with the brake applied.

Adjust the seat suspension correctly to ensure an optimal level of ride comfort.

To adjust to a higher weight:

☞Turn the adjusting wheel to the right.

To adjust to a lower weight:

☞Turn the adjusting wheel to the left.

Horizontal adjustment

Backrest adjustment

The specified weight is indicated by the yellow pointer next to the adjusting wheel.

☞Sit down on the seat ☞Pull lever 33 upward and at the same time. ☞Move the operator seat forward or backward.

☞Pull lever 29 up and at the same time press against the backrest to move it to the

required position.

☞Let lever 29 lock into place.

BA 1001/1501/2001 us – Edition 3.3 * 12001b330.fm 3-27

Operation

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Fig. 46: Fastening the seat belt

3.18 Seat belt

Personal injury hazard! Do not travel or operate with the seat belt unbuckled.

Can cause severe injury or death.

• Operating the machine without fastening the seat belt is prohibited under all circumstances.

• Seat belt must not be twisted.

• 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, rulers, glasses, pen) carried inside your clothes.

• Never buckle up 2 persons with one seat belt.

• Check seat belts regularly. Have damaged parts immediately replaced by a Wacker Neuson service center.

• Always keep the seat belt clean, as coarse dirt can impair proper functioning.

• Seat belt buckle must not be obstructed by foreign bodies, otherwise the buckle latch cannot lock into place.

• Depending on the situation, traveling over very short distances with a lowered rollbar is allowed (in case of low clearance heights, for example) – see

chapter Operation with lowered rollbar on page 2-7

After an accident the belt strap is stretched and no longer serviceable. In an accident, the seat belt does not provide enough safety.

• Replace the seat belt after an accident.

• Have fastening points and seat fixture checked for bearing capacity.

Seat belt C is for the operator’s safety during work on construction sites and during road travel.

Fastening the seat belt:

☞Fasten seat belt C as follows before moving the machine:

• Hold belt on buckle latch A and run it slowly and steadily over the hips to buckle B

• Insert buckle latch A into buckle B with an audible click (pull test)

3-28 BA 1001/1501/2001 us – Edition 3.3 * * 12001b330.fm

Engine cover

Important

Fig. 47: Unfastening the seat belt

Fig. 48: Engine cover lock

Operation

Unfastening the seat belt:

☞Unfasten seat belt A as follows:

• Hold the seat belt

• Press red button D on buckle C

➥Latch B is released from buckle C by spring pressure

• Slowly return the seat belt to the retractor

Opening:

☞Stop the machine. Stop the engine. ☞Let the engine cool down ☞Press buckle A of the engine cover downward and pull shackle C to the front ☞Pull the engine cover up with handle B

Closing:

☞Press down the engine cover ☞Press buckle A forward and hitch shackle C into the hook at the same time ☞Press lock A to the rear

Locking and unlocking:

The engine cover can be locked in eyelet D with an external lock

Do not lock the engine cover during machine operation since the emergency switch is located under the engine cover.

BA 1001/1501/2001 us – Edition 3.3 * 12001b330.fm 3-29

Operation

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NOTICE

3.19 Working with the machine

General safety instructions

• Never travel up to the edge of a pit from outside – danger of cave-in!

• Do not travel under 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

• Do not place the machine directly underneath the workplace during demolition,

• The hydraulic system of the machine is still pressurized even when the engine is not

• Before tilting out the skip next to an excavation, secure the machine with suitable wheel

• Always watch the material as you tilt out the skip: ensure that the material is dumped

• Do not dump the load when working on sloping ground.

• Always perform precise and smooth control movements, do not perform 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

• Machine operation is only allowed if the rollbar is raised and locked, and if the seat belt

• Use an external light source in case of poor illumination of the job site. If this is not

before starting work. The building can collapse, causing severe injury and damage.

otherwise demolished parts can fall onto the machine or the building can collapse, causing severe injury or damage.

running! Release the pressure in the sections of the system and hydraulic lines that are to be opened before starting setup or repair work.

chocks or other auxiliary means.

out evenly and does not remain stuck in the skip, otherwise the machine could tip over.

ensure that no one is at risk.

is fastened.

enough to illuminate the job site sufficiently, stop machine operation and start it again if sufficient illumination can be ensured.

Accident hazard when traveling with a tilted-out skip!

Can cause severe injury or death.

☞Machine travel with a tilted-out skip is prohibited. ☞Material that sticks in the skip may be tilted out only to the front in the

straight position of the machine.

☞Before tilting out the skip, keep a safe distance from buildings or the edges

of building pits, for example.

☞Secure the edge of the pit with a wooden beam anchored in the ground.

Lowering the skip too rapidly and knocking it against the chassis can cause damage.

3-30 BA 1001/1501/2001 us – Edition 3.3 * * 12001b330.fm

3.20 Skip operation

Important

Fig. 49: Operation of high-tip skip (1001/1501H)

Fig. 50: Swivel skip operation (1501S)

Fig. 51: Swivel skip operation (2001)

Operation of high-tip skip (1001/1501H)

Operation

The working speed of the skip is set with the travel of the control lever and with the accelerator pedal.

Swivel skip operation (1501S/option)

Position

Lever Function

Lever forward Raises the lift frame Lever to the rear Lowers the lift frame Lever forward Tilts out the skip Lever to the rear Lowers the skip

Lever Function

Lever forward Tilts out the skip Lever to the rear Lowers the skip Lever forward Skip is rotated to the right Lever to the rear Skip is rotated to the left

Swivel skip operation (2001S)

BA 1001/1501/2001 us – Edition 3.3 * 12001b330.fm 3-31

Position

Lever Function

Lever forward Tilts out the skip Lever to the rear Lowers the skip Lever to the left Skip is rotated to the left Lever to the right Skip is rotated to the right

Operation

Fig. 52: Switch position SLE (2001)

Fig. 53: Swivel skip operation (2001)

Fig. 54: Loader unit operation (2001)

Fig. 55: Loader unit operation (2001)

Swivel skip and loader unit operation (2001SLE)

Switch position 1: loader unit operation Switch position 2: skip operation

Switch position 2:

Position

Switch position 1:

Position

Lever Function

Lever forward Tilts out the skip Lever to the rear Lowers the skip Lever to the left Skip is rotated to the left Lever to the right Skip is rotated to the right

Lever Function

Lever forward Lowers the lift frame Lever to the rear Raises the lift frame Lever to the left Tilts in the bucket Lever to the right Tilts out the bucket

3-32 BA 1001/1501/2001 us – Edition 3.3 * * 12001b330.fm

Switch position 1:

Position

Lever Function

Lever to the left and forward Lowers the lift frame and tilts in the bucket

Lever to the right and rear Raises the lift frame and tilts out the bucket

Lever to the left and rear Raises the lift frame and tilts in the bucket

Lever to the right and front Lowers the lift frame and tilts out the bucket

3.21 Loader unit (option 2001)

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Important

Fig. 56: Loader unit (option 2001)

The loader unit has been designed for lifting up to 300 kg of loose material. Observe the following when working with the loader unit:

Operation

Crushing hazard! Falling objects.

Can cause severe injury or death.

• Do not perform jerky movements with the lift frame and bucket to avoid throw-

ing material over the skip.

In order to avoid damage to the machine, observe the following:

• Do not perform any excavating, grading, lifting or other movements with the loader unit.

• Avoid wheel spin when picking up material.

• Lower the loader unit before turning or tilting out the skip.

• Do not allow anyone to stay in the danger zone of the machine.

• Only tilt out the bucket if the skip is lowered.

• Do not work on slopes with the loader unit.

• Do not perform any steering movements when picking up material.

• Position the loader unit in the rear end position on the skip before traveling.

Grease all lubrication points of the loader unit daily.

BA 1001/1501/2001 us – Edition 3.3 * 12001b330.fm 3-33

Operation

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Fig. 57: Rollbar

3.22 Rollbar

Personal injury hazard when operating the machine with a lowered rollbar.

Can cause severe injury or death.

• Machine operation is only allowed if the rollbar is raised and locked, and if the seat belt is fastened.

• Wear protective equipment (protective clothing, safety glasses, for example).

• Depending on the situation, traveling over very short distances with a lowered rollbar is allowed (in case of low clearance heights, for example) – see

chapter Operation with lowered rollbar on page 2-7.

Injury hazard when lowering or raising the rollbar!

Can cause severe injury or death.

• Lowering or raising the rollbar must be performed by two persons.

Lowering the rollbar:

☞Park the machine on horizontal ground. ☞Remove the split pins from lock pins A. ☞Remove lock pins A. ☞Slowly and carefully lower the rollbar with the help of a second person.

Raising the rollbar:

☞Park the machine on horizontal ground. ☞Raise the rollbar. ☞Fasten the rollbar with lock pins A and secure these pins with split pins.

3-34 BA 1001/1501/2001 us – Edition 3.3 * * 12001b330.fm

3.23 Towing 1001/1501/2001

NOTICE

Important

Fig. 58: Opening the high-pressure circuit

In order to tow away the dumper, the high-pressure circuit on the hydrostatic pump must be opened and the hydraulic parking brake on both rear wheel motors must be released.

Opening the high-pressure circuit 1001/1501

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:

☞Stop the engine. ☞Open the floor panel. ☞Loosen locknuts 2 with half a revolution to the left. ☞Turn screws 1 to the right with an allen key until you can feel a firmer resistance. ☞Then screw in a further half revolution.

Operation

Screwing in any further damages the valve.

☞Retighten the locknuts ☞You can now slowly tow the machine (max. 2 kph/1.2 mph) over a short distance (max.

1 km/0.6 miles).

After towing the machine, the pressure must be set and the machine put back into operation by a Wacker Neuson service center.

BA 1001/1501/2001 us – Edition 3.3 * 12001b330.fm 3-35

Operation

Important

Fig. 59: Opening the high-pressure circuit

Fig. 60: Opening the high-pressure circuit

3.24 Releasing the hydraulic parking brake 1001/1501

☞Remove both extraction units (2) installed on the rear axle body to release the hydraulic

parking brake (1). Remove hexagon head screw (3) M12x35 (ws 19) to this effect.

☞Remove the plastic plugs (4) in the middle on the face of the wheel motors. ☞Place the extraction unit on the face of the wheel motor and fasten it with screw M12x35. ☞Tighten the screw to 42 Nm (31 ft.lbs) until the wheel turns freely.

3.25 Opening the high-pressure circuit 2001

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:

☞Loosen locknut ws 14 (part 2) and unscrew it to the end of the screw. ☞Screw in the screw with an allen key ws 4 part 1 until it is flush with the nut. ☞Retighten the locknut. ☞You can now slowly tow the machine (max. 2 kph/1.2 mph) over a short distance (max.

1 km/0.6 miles).

After towing the machine, the pressure must be set and the machine put back into operation by a Wacker Neuson service center.

3-36 BA 1001/1501/2001 us – Edition 3.3 * * 12001b330.fm

3.26 Releasing the hydraulic parking brake 2001

☞Remove both extraction units (2) installed at the front on the mudguard to release the

hydraulic parking brake (1). Remove hexagon head screw (3) M12x35 (ws 19) to this effect.

Operation

BA 1001/1501/2001 us – Edition 3.3 * 12001b330.fm 3-37

Operation

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Important

Fig. 61: Center-pivot prop

Fig. 62: Locking the control levers (1001/1501)

3.27 Center-pivot prop

Crushing hazard if the skip is not supported correctly!

Can cause severe injury or death.

• Support the skip before performing maintenance.

The center-pivot prop connects the front and rear chassis to prevent steering movements (via the articulated joint) when crane handling the dumper.

Proceed as follows:

☞Remove the spring plug from pin B ☞Turn center-pivot prop A toward the rear chassis ☞Secure center-pivot prop A with the spring plug and pin B

3.28 Locking the control levers

Locking the control levers (1001/1501)

Fold back control lever lock A.

Before putting the machine into operation again, install the center-pivot prop back onto the front chassis again by means of pin B.

Lock the control levers for the skip during road travel.

☞This avoids unintentional actuation of the skip.

3-38 BA 1001/1501/2001 us – Edition 3.3 * * 12001b330.fm

Locking the control levers (2001)

Fig. 63: Locking the control levers (1001/1501)

Fig. 64: Locking the control levers (2001)

Fig. 65: Locking the control levers (2001)

Operation

Fasten control lever lock A with split pin B.

Fold back control lever lock A.

Fasten control lever lock A with split pin B.

BA 1001/1501/2001 us – Edition 3.3 * 12001b330.fm 3-39

Operation

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Important

3.29 Lifting the machine

Safety instructions

• The crane and the lifting gear must have suitable dimensions.

• Crane handling the machine requires suitable lifting gear.

• Secure the machine against unintentional movement!

Accident hazard due to incorrect loading!

Can cause severe injury or death.

• Ensure that no one is near the machine!

• Have loads fastened and crane operators guided by experienced persons only! The person guiding the crane operator must be within sight or sound of him!

• Ensure that the crane and the lifting gear (cables, chains) have sufficient loadbearing capacity!

• Raise the machine only if the skip is empty!

• Stay clear of suspended loads!

• It is essential that you read the safety instructions at the beginning of this chapter and follow any other safety instructions relevant in your country!

Use OSHA-rated and approved lifting devices capable lifting the machine, attachments, options and accumulated debris. Refer to the general weight guidelines in the specification section of this manual. Do not attempt to lift the machine with any type of crane including wheel loaders unless the crane operator is qualified to lift loads in craning operations. The crane operator shall be knowledgable of OSHA 1910 craning regulations

☞Load the machine as follows:

• Empty the skip

• Lower the skip

• Stop and park the machine

• Lock the control levers

– see chapter 3.28 Locking the control levers on page 3-38

• The rollbar can be lowered to reduce the transport height.

• Put the cente-pivot prop in place

• Use suitable lifting gear, chains, etc.

3-40 BA 1001/1501/2001 us – Edition 3.3 * * 12001b330.fm

Operation

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Fig. 66: Crane-lifting

Fig. 67: Crane-lifting

Fig. 68: Access ramps

1001/1501/1501 S

Raise the dumper by hitching the lifting gear onto the eyelet. Do not hitch the lifting gear onto the handle.

• Fold in the center-pivot prop when raising the machine.

2001/2001 SLE

Raise the dumper by hitching the lifting gear onto the eyelet on the rear chassis and make it go through the handle at the edge of the skip. Fold in the center-pivot prop when raising the machine.

Loading and transporting the machine

Safety instructions

• The transport vehicle must be of adequate size. Dimensions and weights of machine: see

• Chapter 6 “Technical data (1001 – 1501)”

• and Chapter 6 “Technical data (2001)”.

• Remove any mud, snow or ice from the tires so that the machine can be safely traveled onto the ramps

• Secure the machine against unintentional movement

– see Parking the machine on page 3-25!

Accident hazard due to incorrect loading!

Can cause severe injury or death.

• Follow the safety instructions at the beginning of this chapter and any other safety instructions relevant in your country.

☞Load as follows:

• Secure the transport vehicle with chocks to prevent it from rolling

• Place the access ramps at the smallest possible angle. Ensure that the grade does not exceed 17° (30 %). Use access ramps with an antiskid surface only.

• Ensure that the loading area is clear and access to it is not obstructed – by superstructures, for example

• Ensure that the ramps and the tires of the dumper are free of oil, grease and ice

• Start the engine of the dumper

• Lower the skip of the dumper

• Carefully reverse the dumper onto the middle of the transport vehicle

BA 1001/1501/2001 us – Edition 3.3 * 12001b330.fm 3-41

Operation

Important

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Important

Fig. 69: Tying down the machine

Fig. 70: Battery master switch

Tying down the machine

• Stop and park the machine

The manufacturer’s warranty shall not apply to accidents or damage caused by loading or transporting.

Accident hazard due to incorrect loading!

Can cause severe injury or death.

• Follow the safety instructions at the beginning of this chapter and any other safety instructions relevant in your country.

Only use OSHA-approved lifting devices. Use edge protectors to avoid damage both to the machine and the OSHAapproved lifting devices.

• Secure the wheels of the dumper at the front, rear and at the sides.

• Two eyelets on the front chassis of the dumper and a pin on the rear chassis are used for this

• Ensure that the operator of the transport vehicle knows the overall height, width and weight of his vehicle (including the dumper) before starting machine travel, and the legal transport regulations of the country or countries in which transport will take place!

3.30 Battery master switch 1001 – 1501

Do not disconnect the battery while the engine is running!

Power supply is interrupted directly after the battery, by means of a key

• Before working on the electrical system.

Interrupting power supply:

☞Turn key A of the battery master switch to position B and remove it

Switching on power supply:

☞Insert key A in the battery master switch ☞Turn the key down to the notched position C

The 2001 dumper has a Quickpower Plus terminal instead of a main switch

3-42 BA 1001/1501/2001 us – Edition 3.3 * * 12001b330.fm

4 Malfunctions

4.1 Engine trouble

Problem Possible causes See

Engine does not start or is not easy to start

Malfunctions

The information given in this chapter is provided for maintenance personnel, for fast and reliable detection of malfunctions and their appropriate repair.

Repairs must only be performed by authorized personnel.

Wrong SAE grade of engine lubrication oil 5-32

Fuel grade does not comply with specifications 5-32

Malfunctioning or empty battery 5-29

Loose or oxidized cable connections in starter circuit

Malfunctioning starter, or pinion does not engage

Wrong valve clearance

Malfunctioning fuel injector

Engine starts, but does not run smoothly or faultless

Engine overheats. Temperature warning system responds

Insufficient engine output

Engine does not run on all cylinders

Fuel grade does not comply with specifications 5-32

Wrong valve clearance

Injection line leaks

Malfunctioning fuel injector

Oil level too low 5-10

Oil level too high 5-10

Dirty air filter 5-15

Dirty oil radiator fins

Malfunctioning fuel injector

Oil level too high 5-10

Fuel grade does not comply with specifications 5-32

Dirty air filter 5-15

Wrong valve clearance

Injection line leaks

Malfunctioning fuel injector

Injection line leaks

Malfunctioning fuel injector

Oil level too low 5-10

Insufficient or no engine oil pressure

Engine oil consumption too high

BA 1001/1501/2001 us – Edition 3.3 * 12001b410.fm 4-1

Machine inclination too high (max. 25°)

Wrong SAE grade of engine lubrication oil 5-32

Oil level too high 5-10

Machine inclination too high (max. 25°)

Malfunctions

Problem Possible causes See

Engine smoke

Blue

White

Black

Oil level too high 5-10

Machine inclination too high (max. 25°)

Engine starting temperature too low

Fuel grade does not comply with specifications 5-32

Wrong valve clearance

Malfunctioning fuel injector

Dirty air filter 5-15

Wrong valve clearance

Malfunctioning fuel injector

4-2 BA 1001/1501/2001 us – Edition 3.3 * * 12001b410.fm

5 Maintenance

5.1 Introduction

Maintenance

Operational readiness and the service life of machines are heavily dependent on maintenance. It is therefore in the interest of the machine owner to perform the mandatory maintenance. Before performing servicing and maintenance, always read, understand and follow the

instructions given in:

• Chapter 2 “SAFETY INSTRUCTIONS” of this Operator’s Manual Perform 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 injury when using compressed air. Always wear

safety glasses, protective masks and clothing. Daily servicing and maintenance, and maintenance according to maintenance plan “A”

must be performed by a specifically trained operator. All other maintenance must be performed by trained and qualified personnel only.

The maintenance plans indicate when the maintenance mentioned below must be performed – see Maintenance plan 2001 (overview) on page 5-39.

BA 1001/1501/2001 us – Edition 3.3 * 12001b510.fm 5-1

Maintenance

Important

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5.2 Brake test

Do not put the machine into operation if a brake test gives a negative result or if there are doubts as to the correct brake function. Contact a Wacker Neuson service center and have the malfunction rectified.

The following tests are performed to check the brake function on firm, level and horizontal ground. On slopes or in the case of machines with loads, for example, the braking effect of the parking brake may still be insufficient to safely brake the machine. If possible, always park the machine without any load and on level ground, and secure it with suitable means (chocks, for example).

Test the brakes once a day.

Parking brake test

Park the machine on firm, level and horizontal ground. With the parking brake applied, turn the steering wheel several times to the left and right limits.

➥The rear axle wheels must block when turning the steering wheel.

Service brake test

Models with brake pedal: Start machine travel in the slow speed range and press the brake pedal. Models without brake pedal: Start machine travel in low gear and move the travel direction lever to neutral.

➥Deceleration must be stronger than when only releasing the accelerator pedal.

Crushing hazard if the skip is not supported correctly!

Can cause severe injury or death.

• Support the skip before performing maintenance.

Crushing hazard when lowering the skip!

Can cause severe injury or death.

• Slowly and carefully lower the skip.

5-2 BA 1001/1501/2001 us – Edition 3.3 * * 12001b510.fm

High-tip skip maintenance prop (1001/1501H)

Fig. 71: High-tip skip maintenance prop 1001/1501H

Fig. 72: High-tip skip maintenance prop 1001/1501H

Fig. 73: Swivel skip maintenance prop 1501S

Fig. 74: Swivel skip maintenance prop 1501S

Remove split pin B and pin C.

Slowly lower the lift frame until maintenance prop A is firmly in its position.

Maintenance

Swivel skip maintenance prop (1501S/option)

Remove split pin B and pin C.

Slowly lower the skip until maintenance prop A is firmly in its position.

BA 1001/1501/2001 us – Edition 3.3 * 12001b510.fm 5-3

Maintenance

Fig. 75: Swivel skip maintenance prop 2001S

Fig. 76: Swivel skip maintenance prop 2001S

Swivel skip maintenance prop 2001S

Remove split pin B and pin C.

Slowly lower the skip until maintenance prop A is firmly in its position.

5-4 BA 1001/1501/2001 us – Edition 3.3 * * 12001b510.fm

5.3 Fuel system

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Fig. 77: Fuel filler inlet 1001/1501

Fig. 77: Fuel filler inlet 2001

Specific safety instructions

Maintenance

Explosion hazard when handling fuel!

Can cause severe burns or death.

• Before refueling, stop the engine and remove the starting key.

• Never perform work on the fuel system near open flames or sparks.

• Do not smoke.

• Keep the machine and the surroundings clean.

• Do not refuel in closed rooms.

• Wear protective clothes.

Fire hazard when handling fuel!

Can cause severe burns or death.

• Before refueling, stop the engine and remove the starting key.

• Never perform work on the fuel system near open flames or sparks.

• Do not smoke.

• Keep the machine and the surroundings clean.

• Do not refuel in closed rooms.

• Wear protective clothes.

Refueling

Filler inlet A for the fuel tank is located under the engine cover, on the right in driving direction.

BA 1001/1501/2001 us – Edition 3.3 * 12001b510.fm 5-5

Maintenance

Environment

Important

Use a suitable container to collect fluids and lubricants as they flow out and dispose of them in an environmentally friendly manner.

Do not run the fuel tank completely dry. Otherwise, air is drawn into the fuel system. This requires bleeding the fuel system

– see Bleeding the fuel system on page 5-7.

Fill up the tank with the correct fuel type at the end of each working day. This prevents 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.

5-6 BA 1001/1501/2001 us – Edition 3.3 * * 12001b510.fm

Stationary fuel pumps

Wrong

Right

Fig. 78: Refueling from a barrel

Maintenance

General

Only refuel from stationary fuel pumps. Fuel from barrels or cans is usually dirty. Even the smallest particles of dirt can cause

• Increased engine wear

• Malfunctions in the fuel system and

• Reduced effectiveness of the fuel filters

Refueling from barrels

If refueling from barrels cannot be avoided, note the following points (see fig. 78):

• Barrels must neither be rolled nor tilted before refueling

• Protect the suction pipe opening of the barrel pump with a fine-mesh screen

• Immerse it down to a max. 15 cm above the bottom of the barrel

• Only fill the tank using refueling aids (funnels or filler pipes) with integral microfilter

• Keep all refueling containers clean at all times

Diesel fuel specification

Bleeding the fuel system

Use only high-grade fuels

Grade

• No. 2-D according to DIN 51601

• No. 1-D according to DIN 51601

Bleed the fuel system in the following cases:

• After removing and fitting the fuel filter, prefilter or the fuel lines back on again

• After running the fuel tank empty

• After running the engine again, after it has been out of service for a longer period of time

Cetane number

Min. 45

Use

For normal outside temperatures For outside temperatures below 4 °C

(39.2 °F) or for operation above 1500 m (4,921 ft) altitude

BA 1001/1501/2001 us – Edition 3.3 * 12001b510.fm 5-7

Maintenance

Environment

Fig. 79: Fuel prefilter

Off

Fuel prefilter with water separator

Bleed the fuel system as follows:

☞Fill the fuel tank ☞Turn the starting key to the first position ☞Wait about 5 minutes while the fuel system bleeds itself automatically ☞Start the engine

If the engine runs smoothly for a while and then stops, or if it does not run smoothly:

☞Stop the engine ☞Bleed the fuel system again as described above ☞Have this checked by authorized personnel if necessary

Check the fuel prefilter as follows:

• If the red indicator ring D in sight glass E rises

☞Remove and clean the housing (sight glass) ☞Remove and clean filter insert B ☞Install the filter insert ☞Install the housing (sight glass) with the maintenance indicator (red ring) and spring D ☞Open stop cock A

Interrupt fuel supply as follows:

☞Turn ball-type cock A to the OFF mark

➥Fuel supply is interrupted

☞Turn ball-type cock A to the ON mark

➥Fuel supply is open again

Use a suitable container to collect fluids and lubricants as they flow out and dispose of them in an environmentally friendly manner.

5-8 BA 1001/1501/2001 us – Edition 3.3 * * 12001b510.fm

Replacing the fuel filter

Environment

Fig. 80: Fuel filter 1001/1501

Off

Fig. 80: Fuel filter 2001

Maintenance

Use a suitable container to collect fluids and lubricants as they flow out and dispose of them in an environmentally friendly manner.

Removing the fuel filter (D)

☞Close fuel cock B ☞Loosen union nut A

Caution: the filter housing contains fuel.

☞Remove filter housing C

Installing the fuel filter (D)

☞Install all elements in the reverse order with a new filter element ☞Open the stop cock on the water separator again ☞Bleed the fuel system – see Bleeding the fuel system on page 5-7 ☞Make a test run – and check for tightness! ☞Dispose of the old fuel filter cartridge by an ecologically safe method

BA 1001/1501/2001 us – Edition 3.3 * 12001b510.fm 5-9

Maintenance

NOTICE

Important

Fig. 81: Checking the oil level

5.4 Engine lubrication system

Checking the oil level

Engine damage and loss of output in case of insufficient engine oil level, or wrong engine oil!

☞Have the oil changed by a Wacker Neuson service center

– see chapter 5.16 Maintenance plan 2001 (overview) on page 5-39

In order to avoid engine damage, add the engine oil slowly so it can go down without entering the intake system.

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

☞Proceed as follows:

• Park the machine on level ground

• Stop the engine!

• Let the engine cool down

• Open the engine cover

• Clean the area around the oil dipstick with a lint-free cloth

• Oil dipstick A:

☞Pull it out ☞Wipe it with a lint-free cloth ☞Push it back in as far as possible ☞Withdraw it and read off the oil level

☞However if necessary, add oil at the latest when the oil reaches the MIN mark on the oil

dipstick A

5-10 BA 1001/1501/2001 us – Edition 3.3 * * 12001b510.fm

Adding engine oil

NOTICE

Important

Environment

Fig. 82: Adding engine oil

OIL

Maintenance

Too much or incorrect engine oil can cause engine damage! For this reason:

☞Do not add engine oil above the MAX mark of oil dipstick 81/A ☞Use only the specified engine oil

In order to avoid engine damage, add the engine oil slowly so it can go down without entering the intake system.

Use a suitable container to collect fluids and lubricants as they flow out and dispose of them in an environmentally friendly manner.

Adding engine oil

☞Proceed as follows:

• Clean the area around oil filler cap B with a lint-free cloth

• Open filler cap B

• Raise oil dipstick A slightly to allow any trapped air to escape

• Add engine oil

• Wait about 3 minutes until all the oil has run into the oil sump

• Check the oil level – see Checking the oil level on page 5-10

• Add oil if necessary and check the oil level again

• Close filler cap B

• Push oil dipstick A back in as far as possible

• Completely remove all oil spills from the engine

BA 1001/1501/2001 us – Edition 3.3 * 12001b510.fm 5-11

Maintenance

Environment

5.5 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 operating hydraulics.

The coolant reservoir is located in the engine compartment next to the toolbox.

Specific safety instructions

• Dirt on the radiator fins reduces the radiator’s heat dissipation capacity! To avoid this:

☞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

☞In 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 cause engine damage! Therefore:

☞Check the coolant level at regular intervals. Refer to the maintenance plans in the

appendix for the intervals

☞If coolant must be added frequently, check the cooling system for leaks and/or con-

tact your dealer!

☞Never add cold water/coolant if the engine is warm! ☞After filling the coolant reservoir, make a test run with the engine and check the cool-

ant level again after stopping the engine

• The use of the wrong coolant can destroy the engine and the radiator. Therefore:

☞Add enough antifreeze compound to the coolant – but never more than 50 %. If pos-

sible use brand-name antifreeze compounds with anticorrosion additives

☞Observe the coolant compound table ☞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 coolant reservoir:

☞Test run the engine ☞Stop the engine ☞Let the engine cool down ☞Check the coolant level again

Use a suitable container to collect fluids and lubricants as they flow out and dispose of them in an environmentally friendly manner.

5-12 BA 1001/1501/2001 us – Edition 3.3 * * 12001b510.fm

Checking the coolant level/adding coolant

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Maintenance

Burn hazard! The engine coolant is under pressure at high temperature.

Can cause severe injury or death.

• Wait at least 15 minutes after stopping the engine.

• Wear protective gloves and clothing.

• Open filler cap B

• Ensure that the coolant temperature is sufficiently low so you can touch the radiator plug with your hands.

Hazardous material! Antifreeze is poisonous.

Can cause severe injury or death.

• Keep away from flames.

• Avoid eye contact with antifreeze.

• If antifreeze comes into contact with the eyes:

• immediately rinse with clean water and seek medical assistance.

to the first notch and release the pressure.

BA 1001/1501/2001 us – Edition 3.3 * 12001b510.fm 5-13

Maintenance

Important

NOTICE

Important

Fig. 83: Radiator

Fig. 83: Coolant reservoir

LOW

FULL

Checking the coolant level

☞Proceed as follows:

• Park the machine on level ground

• Stop the engine!

• Remove the key and carry it with you

• Let the engine and the coolant cool down

• Open the engine cover

• Check the coolant level on the transparent coolant reservoir A and on the radiator B

☞If the coolant level is below the LOW seam or if there is no coolant at the radiator’s

filler inlet:

• Add coolant

Check the coolant level once a day. We recommend checking it before starting the engine.

Adding coolant

After the engine has cooled down:

☞Release overpressure in the radiator ☞Carefully open the cap to the first notch and fully release the pressure ☞Open filler cap B ☞Add coolant up to the lower edge of the filler inlet (radiator) ☞Close filler cap B ☞Start the engine and let it warm up for about 5 – 10 minutes. ☞Stop the engine ☞Remove the key and carry it with you ☞Let the engine cool down ☞Check the coolant level again

➥The coolant level must be between the LOW and FULL reservoir seams

☞If necessary, add coolant and repeat the procedure until the coolant level remains constant

5-14 BA 1001/1501/2001 us – Edition 3.3 * * 12001b510.fm

Do not add a different coolant to the one in the reservoir.

☞Use only the coolant prescribed by Wacker Neuson

– see chapter 5.13 Engine/machine fluids and lubricants (1001 and

1501) on page 5-32

– see chapter 5.14 Engine/machine fluids and lubricants (2001) on

page 5-34.

Check the antifreeze every year before the cold season sets in!

NOTICE

Important

NOTICE

Fig. 84: Indicator for air filter contamination

Fig. 84: Air filter maintenance

Maintenance

5.6 Air filter (1001/1501: up to serial no. EA01742)

The filter cartridge will be damaged if it is washed or brushed out! Bear in mind the following to avoid premature engine wear!

☞Do not clean the filter cartridge ☞Replace the filter cartridge when the indicator light illuminates ☞Never reuse a damaged filter cartridge ☞Ensure cleanliness when replacing the filter cartridge!

Control element A on the air filter monitors the filter cartridge.

☞Replace filter B if:

• Control element A indicates air filter contamination

• According to the maintenance plan

For applications in especially dusty environment, replace or clean the air filter more frequently.

Maintenance

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 aluminum mills, chemical plants and other nonferrous-metal plants

☞Replace filter B after no more than 50 operating hours.

General instructions for air filter maintenance:

• Store filters in their original packaging and in a dry place

• Do not knock the filter against other objects as you install it

• Check air filter attachments, air intake hoses and air filters for damage, and immediately repair or replace if necessary

• Check the screws at the induction manifold and the clamps for tightness

BA 1001/1501/2001 us – Edition 3.3 * 12001b520.fm 5-15

Maintenance

Fig. 85: Removing the lower housing section

Fig. 86: Removing the filter element

Replacing the filter

• Replace filter A as follows:

☞Stop the engine ☞Remove the key and carry it with you ☞Let the engine cool down ☞Open the engine cover ☞Remove dirt and dust from the air filter and the area around the air filter ☞Fold both bow clips D on lower housing section E to the outside ☞Remove lower housing section E ☞Unscrew wing nut F ☞Carefully remove filter B with slightly turning movements ☞Ensure that all dirt (dust) inside the air filter housing has been removed

☞Clean the parts with a clean lint-free cloth, do not use compressed air ☞Check the air filter cartridges for damage. Use only intact and clean filters ☞Carefully insert the new filter B in the air filter housing ☞Position lower housing section E (ensure that it is properly seated) ☞Close both bow clips D

5-16 BA 1001/1501/2001 us – Edition 3.3 * * 12001b520.fm

Wacker Neuson 1001, 1501, 2001 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 Introduction

1.1 Important information on this Operator’s Manual

1.2 Brief description

1.3 Regulations

1.4 EC declaration of conformity 1001 for all machines delivered before 29 December 2009

1.5 EC declaration of conformity 1001 for all machines delivered after 29 December 2009

1.6 EC declaration of conformity 1501 for all machines delivered before 29 December 2009

1.7 EC declaration of conformity 1501 for all machines delivered after 29 December 2009

1.8 EC declaration of conformity 2001 for all machines delivered before 29 December 2009

1.9 EC declaration of conformity 2001 for all machines delivered after 29 December 2009

1.10 Type labels and component numbers

1.11 Other signs and symbols

2 Safety Information

2.1 Safety Symbols Found in this Manual

2.2 Warranty

2.3 Designated use

2.4 General Conduct and Safety Instructions

User training and knowledge

Preparing for use

Modifications and spare parts

2.5 General conduct and safety instructions

Organizational measures

Selection and qualification of staff, basic responsibilities

2.6 Safety instructions regarding operation

Normal operation

Operation with lowered rollbar

Trailer operation

2.7 Staff Qualifications and Basic Responsibilities

User/owner responsibility

Repair person qualifications

2.8 Safety instructions regarding operation

Preparing for use

Startup and shutdown

Job Site awareness

Danger zone awareness

Operating the machine

Special operating notes

Carrying passengers

Mechanical integrity

Traveling on public roads

2.9 Trailering and Transport

Trailers

Transport

2.10 Temperature Range

2.11 Safety Guidelines for Maintenance

General maintenance notes

Personal safety measures

Preparing for maintenance and repair work

Performing maintenance and repairs

2.12 Special hazards

Battery

Tracks (track dumpers)

Electric energy

Gas, dust, steam, smoke

Hydraulics

Noise

Oil, grease and other chemical substances

MSDS

Tires (wheel dumpers)

2.13 Safety Guidelines while using Internal Combustion Engines

Guidelines for running the engine

Guidelines for fueling the engine

3Operation

3.1 Description of 2001S components (overview)

3.2 Description of 2001 SLE components

3.3 1001/1501/1501S operating equipment up to serial no. AB ...

3.4 1001/1501/1501S operating equipment from serial no. AB ...

3.5 2001/2001SLE operating equipment

3.6 Putting into operation

Safety instructions

Putting into operation for the first time

Running-in period

Check lists

Start-up checklist

Operation checklist

“Parking” checklist