Wacker Neuson DT08-D, DT08-P, DT08 Series Operator's Manual

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Operator’s Manual

Track dumper

Machine model DT08-P/DT08-D

Edition 1.0

Language en

Article number 1000268368

Documentation

Description Language Order no.

Operator’s Manual en 1000268368

de/en/fr 1000271904

Spare parts list

de/it/es 1000271905

Edition Issued

1.0 03/2012

No part of this publication may be reproduced, translated or used in any form or by any means – graphic, electronic or mechanical including photocopying, recording, taping or information storage or retrieval systems – without prior permission in writing from the manufacturer.

The cover features the machine with possible optional equipment.

Wacker Neuson Linz GmbH Haidfeldstr. 37 A-4060 Linz-Leonding

Phone

+43 (0) 732 90 5 90-0

E-mail: office.linz@wackerneuson.com www.wackerneuson.com

Document: BA DT08 SL EN Order no.: 1000268368 Edition: 1.0

Table of contents

Introduction

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

Overall view of machine ........................................................................................... 1-2

Brief description ....................................................................................................... 1-3

Definition of operator’s control stand ................................................................. 1-3

Regulations .............................................................................................................. 1-3

EC declaration of conformity model DT08-P, for machines with CE mark on type label 1-4 Declaration of conformity model DT08-P, for machines without CE mark on type label 1-5 EC declaration of conformity model DT08-D, for machines with CE mark on type label 1-6 Declaration of conformity model DT08-D, for machines without CE mark on type label 1-7

Type labels and component numbers ...................................................................... 1-8

Signs and symbols ................................................................................................... 1-9

Safety instructions

Identification of warnings and dangers .................................................................... 2-1

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

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

Designated use and exemption from liability ........................................................... 2-2

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

Organisational measures ................................................................................... 2-2

Selection and qualification of staff, basic responsibilities .................................. 2-3

Safety instructions regarding operation ................................................................... 2-4

Normal operation ............................................................................................... 2-4

Applications with lifting gear .............................................................................. 2-6

Trailers ............................................................................................................... 2-6

Transport ........................................................................................................... 2-6

Temperature ranges .......................................................................................... 2-6

Safety instructions for maintenance ......................................................................... 2-7

Warning of special hazards ..................................................................................... 2-9

Electrical energy ................................................................................................ 2-9

Gas, dust, steam, smoke ................................................................................... 2-9

Hydraulics .......................................................................................................... 2-9

Noise ............................................................................................................... 2-10

Oil, grease and other chemical substances ..................................................... 2-10

Battery ............................................................................................................. 2-10

Tracks .............................................................................................................. 2-10

Operation

Control stand overview (model DT08-P skip and high-tip skip) .............................. 3-1

Control stand overview (model DT08-D skip and high-tip skip) ............................... 3-2

Putting into operation ............................................................................................... 3-4

Safety instructions ............................................................................................. 3-4

Putting the machine into operation for the first time .......................................... 3-4

Running-in period .............................................................................................. 3-4

Check lists ......................................................................................................... 3-5

Start-up checklist ............................................................................................... 3-5

Operation checklist ............................................................................................ 3-5

Parking checklist ................................................................................................ 3-5

Before starting the engine ................................................................................. 3-6

General information on starting the petrol engine ............................................. 3-6

Procedure .......................................................................................................... 3-6

BA DT08 SL EN - Edition 1.0 * BaDT08en1_0IVZ.fm 1-1

Table of contents

Manual starter .................................................................................................... 3-7

Electric starter .................................................................................................... 3-7

Starting at low temperatures .............................................................................. 3-7

When the engine has started ............................................................................. 3-7

Stopping the petrol engine ................................................................................. 3-8

General Informationen on starting the diesel engine ......................................... 3-9

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

Manual starter .................................................................................................. 3-10

Electric starter .................................................................................................. 3-10

Starting at low temperatures ............................................................................ 3-11

When the engine has started ........................................................................... 3-11

Stopping the diesel engine .............................................................................. 3-11

Jump-starting the engine (supply battery) ....................................................... 3-12

Special instructions for driving on public roads ................................................ 3-12

Moving off ........................................................................................................ 3-13

Drive levers ...................................................................................................... 3-13

Driving on slopes ............................................................................................. 3-14

Specific safety instructions .............................................................................. 3-14

Driving across slopes ....................................................................................... 3-15

Driving on slopes ............................................................................................. 3-15

Driving on slopes with a high-tip skip ............................................................... 3-16

Skip operation .................................................................................................. 3-17

High-tip skip (option) ........................................................................................ 3-17

Loader unit operation (option) .......................................................................... 3-18

Parking the machine ........................................................................................ 3-19

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

Crane handling the machine ............................................................................ 3-20

Loading and transporting the machine ............................................................ 3-21

Tying down the machine .................................................................................. 3-22

Towing the machine ......................................................................................... 3-22

Working with the machine ...................................................................................... 3-23

General safety instructions .............................................................................. 3-23

Working with the loader unit ............................................................................ 3-23

Transporting with a full bucket ......................................................................... 3-23

Loading loose material ..................................................................................... 3-24

Ending loading ................................................................................................. 3-24

Transporting with a full skip ............................................................................. 3-25

Dumping out the skip ....................................................................................... 3-26

Dumping out the skip upwards (option) ........................................................... 3-27

Emergency lowering of the skip ....................................................................... 3-27

Auxiliary hydraulics (option) ............................................................................. 3-28

Troubleshooting

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

Maintenance

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

Maintenance strut .............................................................................................. 5-1

Maintenance strut for high-tip skip ..................................................................... 5-2

Fuel system .............................................................................................................. 5-3

Specific safety instructions ................................................................................ 5-3

Checking the fuel level ....................................................................................... 5-3

Refuelling ........................................................................................................... 5-4

Stationary fuel pumps ........................................................................................ 5-4

Petrol specification ............................................................................................. 5-5

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

Cleaning the fuel filter (petrol engine) ................................................................ 5-5

Cleaning the fuel filter of the diesel engine ........................................................ 5-6

1-2 BA DT08 SL EN - Edition 1.0 * BaDT08en1_0IVZ.fm

Table of contents

Spark plug (petrol engine) ................................................................................. 5-7

Engine lubrication system ........................................................................................ 5-8

Checking the oil level ......................................................................................... 5-8

Filling up engine oil ............................................................................................ 5-9

Air filter ................................................................................................................... 5-10

Replacing the filter (petrol engine) ................................................................... 5-11

Replacing the filter (diesel engine) .................................................................. 5-12

Hydraulic system ................................................................................................... 5-13

Specific safety instructions .............................................................................. 5-13

Checking the hydraulic oil level ....................................................................... 5-14

Filling up hydraulic oil ...................................................................................... 5-14

Important information for the use of biodegradable oil .................................... 5-15

Checking hydraulic pressure lines ................................................................... 5-16

Tracks .................................................................................................................... 5-17

Checking track tension .................................................................................... 5-17

Increasing track tension ................................................................................... 5-17

Decreasing track tension ................................................................................. 5-18

Electrical system .................................................................................................... 5-19

Specific safety instructions .............................................................................. 5-19

Service and maintenance work at regular intervals ......................................... 5-19

Instructions concerning specific components .................................................. 5-20

Alternator ......................................................................................................... 5-20

Battery ............................................................................................................. 5-21

General maintenance work .................................................................................... 5-22

Cleaning .......................................................................................................... 5-22

General instructions for all areas of the machine ............................................ 5-22

Exterior of the machine .................................................................................... 5-23

Engine compartment ....................................................................................... 5-23

Screw connections and attachments ............................................................... 5-23

Pivots and hinges ............................................................................................ 5-23

Fluids and lubricants .............................................................................................. 5-24

Maintenance plan DT08-P (petrol engine) ............................................................. 5-25

Maintenance plan DT08-D (diesel engine) ............................................................ 5-27

Lubrication plan DT08 with skip ............................................................................. 5-29

Lubrication plan DT08 with high-tip skip (option) ................................................... 5-30

Maintenance opening ...................................................................................... 5-31

Specifications

Engine .................................................................................................................... 6-33

Hydraulic system ................................................................................................... 6-33

Undercarriage ........................................................................................................ 6-33

Work hydraulics ..................................................................................................... 6-34

Skip ........................................................................................................................ 6-34

High-tip skip (option) .............................................................................................. 6-34

Loader unit (option) ................................................................................................ 6-34

Noise levels ........................................................................................................... 6-35

Vibration ................................................................................................................. 6-35

Dimensions model DT08-D with skip ..................................................................... 6-36

Dimensions model DT08-D with high-tip skip (option) ........................................... 6-37

Dimensions model DT08-P with skip ..................................................................... 6-38

Dimensions model DT08-P with high-tip skip (option) ........................................... 6-39

Electrical system .................................................................................................... 6-40

Fuses ..................................................................................................................... 6-40

BA DT08 SL EN - Edition 1.0 * BaDT08en1_0IVZ.fm 1-3

Index

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

Acoustic warning system for control panel ............................................3-2

Air filter .................................................................................................5-10

Applications with lifting gear ..................................................................2-6

Biodegradable oil .................................................................................5-15

Charge function .....................................................................................3-3

Check lists .............................................................................................3-5

Clean the filter cup .................................................................................5-5

Clean the fuel filter .................................................................................5-6

Control stand overview ..........................................................................3-2

Crane-handling bracket .......................................................................3-20

Designated use and exemption from liability .........................................2-2

Driving on public roads ........................................................................3-12

Dumping out the skip ...........................................................................3-27

EC declaration of conformity for model DT08 ........................................1-8

Emergency lowering of the skip ...........................................................3-27

Engine number ......................................................................................1-8

Fluids and lubricants ............................................................................5-24

Important information

On this Operator’s Manual ..............................................................1-1

Instrument panel overview ............................................................. 3-1, 3-2

Legal regulations ...................................................................................1-3

Machine

Brief description .............................................................................. 1-3

Loading and transporting .............................................................. 3-21

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

Maintenance

Air filter ................................................................................5-11, 5-12

Biodegradable oil .......................................................................... 5-15

Check the engine oil level .............................................................. 5-8

Checking the hydraulic oil level .................................................... 5-14

Clean ............................................................................................ 5-22

Diesel engine maintenance plan .................................................. 5-27

Electrical system .......................................................................... 5-19

Engine lubrication system .............................................................. 5-8

Filling in engine oil .......................................................................... 5-9

Filling up hydraulic oil ................................................................... 5-14

Fluids and lubricants .................................................................... 5-24

Fuel filter ......................................................................................... 5-8

Fuel system .................................................................................... 5-3

General maintenance work .......................................................... 5-22

Hydraulic pressure lines ............................................................... 5-16

Hydraulic system .......................................................................... 5-13

Instructions concerning specific components ............................... 5-20

Lubricating the lift ram .................................................................. 5-31

Lubrication plan ............................................................................ 5-29

Maintenance opening ................................................................... 5-31

Petrol engine maintenance plan ................................................... 5-25

Pivots and hinges ......................................................................... 5-23

Screw connections ....................................................................... 5-23

Service and maintenance work at regular intervals ...................... 5-19

Track maintenance ....................................................................... 5-17

Water separator .............................................................................. 5-8

Maintenance strut .................................................................................. 5-1

Noise levels ......................................................................................... 1-10

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

Before starting the engine .............................................................. 3-6

Control stand overview ............................................................ 3-1, 3-2

Moving off ..................................................................................... 3-13

Parking the machine ..................................................................... 3-19

Starting the engine ......................................................................... 3-6

Putting into operation ............................................................................ 3-1

Check lists ...................................................................................... 3-5

Putting the machine into operation for the first time ....................... 3-4

Safety instructions .......................................................................... 3-4

Refuelling .............................................................................................. 5-4

Running-in period .................................................................................. 3-4

1-1 BA DT08 SL EN - Edition 1.0 * BaDT08en1_0SIX.fm

Safety instructions .................................................................................2-1

Applications with lifting gear ............................................................2-6

General conduct ..............................................................................2-2

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

Maintenance ...................................................................................2-7

Operation ........................................................................................2-4

Special hazards ..............................................................................2-9

Trailers and attachments ................................................................2-6

Transport .........................................................................................2-6

Signs and symbols .................................................................................1-9

Spark plug ..............................................................................................5-7

Specifications

Coolant compound table ...............................................................6-40

Electrical system ...........................................................................6-40

Engine ...........................................................................................6-40

Noise levels ...................................................................................6-40

Work hydraulics ............................................................................6-40

Starting aid ...........................................................................................3-12

Track maintenance ..............................................................................5-17

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

Index

BA DT08 SL EN - Edition 1.0 * BaDT08en1_0SIX.fm 1-2

Index

1-3 BA DT08 SL EN - Edition 1.0 * BaDT08en1_0SIX.fm

1 Introduction

1.1 Important information on this Operator’s Manual

Please store the Operator’s Manual in the storage tube under the engine cover. This Operator’s Manual contains important information on how to work safely, correctly

and economically with the machine. Therefore, it aims not only at new operators, but it also serves as a reference for experienced ones. It helps to avoid dangerous situations and reduce repair costs and downtimes. Furthermore, the reliability and the service life of the machine will be increased by following the instructions in the Operator’s Manual. This is why the Operator’s Manual must always be kept at hand in the machine.

The safety of the driver and other persons heavily depends on how safely the machine is used. Therefore, carefully read and understand this Operator’s Manual prior to the first drive. This Operator’s Manual will help to familiarise yourself more easily with the machine, thereby enabling you to use it more safely and efficiently.

Prior to the first drive, carefully read chapter “Safety Instructions” as well, in order to be prepared for possible dangerous situations, as it will be too late for it during operation. As a rule, keep the following in mind:

Careful and prudent working is the best way to avoid accidents!

Operational safety and readiness of the machine do not only depend on your skill, but also on maintenance and servicing of the machine. This is why regular maintenance and service work is absolutely necessary. Extensive maintenance and repair work must always be carried out by an expert with appropriate training. Insist on using original spare parts when carrying out maintenance and repair work. This ensures operational safety and readiness of your machine, and maintains its value.

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

Introduction

Abbreviations/symbols

• This symbol stands for a list

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

☞ This symbol requires you to carry out the activity described ➥ 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.

This symbol shows the driving direction – for better orientation in figures and

graphics.

BA DT08 SL EN – Edition 1.0 * dt08b110.fm 1-1

Introduction

Fig. 1: Machine outside views

1 Control stand/handle 2Skip 3 Loader unit (option) 4 Engine 5 Travelling drive

Eye hook for loading/tying down the

machine 7 Undercarriage 8Track 9 Foothold 10 Engine cover 11 Auxiliary hydraulics (option)

1.2 Overall view of machine

1-2 BA DT08 SL EN – Edition 1.0 * * dt08b110.fm

1.3 Brief description

Danger!

Fig. 2: Control stand

Definition of operator’s control stand

Introduction

The model DT08 dumper is a self-propelled work machine. Get informed on and follow the legal regulations of your country.

The main components of the machine are:

• Tracked travel gear

• Control stand with integrated oil and fuel tanks

• Internal combustion engine

• Model DT08-P: single-cylinder petrol engine

• Model DT08-D: single-cylinder diesel engine

•Skip

• High-tip skip (option)

• Loader unit (option)

The dumper’s control stand is the:

• Foothold

• Control stand Operate the machine only by means of the foothold and the control stand.

The driver must not lean or reach outside the dimensions of the machine. This applies in particular to his feet –

1.4 Regulations

Danger of accidents

☞ Stand on the foothold ensuring that neither your feet nor other limbs pro-

trude beyond the dimensions of the machine!

The driver must always firmly hold onto the handle of the control stand with both hands –

Danger of accidents

☞ The driver is subjected to high acceleration forces in particular when mov-

ing off with the machine!

Requirements to be met by the driver

Earth moving machines may be driven 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 carry out work reliably.

They have been appointed by the contractor for driving and servicing the earth moving machine.

Get informed on and follow the legal regulations of your country.

BA DT08 SL EN – Edition 1.0 * dt08b110.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 A-4060 Linz-Leonding

Product

Machine designation: Compact Dumper Machine model: DT08-P Serial no.: ______________ Output (kW): 6.6 kW Measured sound power level: 100 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 0515

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:

2004/108/EC, 2000/14/EC, 97/68/EC, EN ISO 12100; EN 474-1 (except 5.5.8.1, 5.9, 5.19.1), EN 474-6 (except 5.7.3.3)

Managing directorResponsible for documentation

Leonding, Place, date

1.5

EC declaration of conformity model DT08-P, for machines with CE mark on type label

1-4 BA DT08 SL EN – Edition 1.0 * * dt08b110.fm

1.6

Declaration of conformity

Manufacturer

Wacker Neuson Linz GmbH Haidfeldstr. 37 A-4060 Linz-Leonding

Product

Machine designation: Compact Dumper Machine model: DT08-P Serial no.: ______________ Output (kW): 6.6 kW Measured sound power level: 100 dB (A) Guaranteed sound power level: 101 dB (A)

Directives and standards

We hereby declare that this product corresponds to the relevant regulations and requirements of the following Directives and standards:

2004/108/EC, 2000/14/EC, 97/68/EC, EN ISO 12100; EN 474-1 (except 5.5.8.1, 5.9, 5.19.1), EN 474-6 (except 5.7.3.3)

Managing directorResponsible for documentation

Leonding, Place, date

Declaration of conformity model DT08-P, for machines without CE mark on type label

Introduction

BA DT08 SL EN – Edition 1.0 * dt08b110.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 A-4060 Linz-Leonding

Product

Machine designation: Compact Dumper Machine model: DT08-D Serial no.: ______________ Output (kW): 6.8 kW Measured sound power level: 100 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

We hereby declare that this product corresponds to the relevant regulations and requirements of the following Directives and standards:

2004/108/EC, 2000/14/EC, 97/68/EC, EN ISO 12100; EN 474-1 (except 5.5.8.1, 5.9, 5.19.1), EN 474-6 (except 5.7.3.3)

Managing directorResponsible for documentation

Leonding, Place, date

1.7

EC declaration of conformity model DT08-D, for machines with CE mark on type label

1-6 BA DT08 SL EN – Edition 1.0 * * dt08b110.fm

1.8

Declaration of conformity

Manufacturer

Wacker Neuson Linz GmbH Haidfeldstr. 37 A-4060 Linz-Leonding

Product

Machine designation: Compact Dumper Machine model: DT08-D Serial no.: ______________ Output (kW): 6.8 kW Measured sound power level: 100 dB (A) Guaranteed sound power level: 101 dB (A)

Directives and standards

We hereby declare that this product corresponds to the relevant regulations and requirements of the following Directives and standards:

2004/108/EC, 2000/14/EC, 97/68/EC, EN ISO 12100; EN 474-1 (except 5.5.8.1, 5.9, 5.19.1), EN 474-6 (except 5.7.3.3)

Managing directorResponsible for documentation

Leonding, Place, date

Declaration of conformity model DT08-D, for machines without CE mark on type label

Introduction

BA DT08 SL EN – Edition 1.0 * dt08b110.fm 1-7

Introduction

Fig. 3: Position of the type label

COMPACT DUMPER

Fig. 4: Engine number (petrol engine)

Fig. 5: Diesel engine number

1.9 Type labels and component numbers

Serial number

The serial number is located on the type label. The type label is located at the rear right of the control stand. Type label information Machine designation: COMPACT DUMPER Model: ---------------

Model year: --------------CEE no.: --------------Output: --------------Serial no.: --------------Max. payload: --------------GWR: --------------Operating weight: --------------Front GAWR: --------------Transport weight: --------------Rear GAWR: --------------Version: --------------Other information – see chapter 6 Specifications on page 6-33

Engine number

The type label (arrow) is located next to the oil check plug.

The type label (arrow) is located below the tank (engine).

1-8 BA DT08 SL EN – Edition 1.0 * * dt08b110.fm

1.10 Signs and symbols

Introduction

BA DT08 SL EN – Edition 1.0 * dt08b110.fm 1-9

Introduction

Fig. 6: Eye hook label

Fig. 7: Label for points used for tying down the machine

Fig. 8: Noise level label

Fig. 9: Label with indication of sound pressure

Fig. 10: Danger label

Fig. 11: CE mark

The following states signs and symbols which are not unequivocally comprehensible. They do not contain explanatory text and are not explained in the following chapters.

Meaning

Machine is raised by the eye hooks

– see chapter Crane handling the machine on page 3-20

Location

On the chassis near the front and rear eye hooks

Meaning

Points for tying down the machine. The eye hooks are used for tying down the machine during loading and transport.

– see chapter Tying down the machine on page 3-22

Location

On the chassis near the front and rear eye hooks.

Meaning

Noise levels produced by the machine. L

= sound power level

Other information – see chapter on page 6-35

Location

Protective plate on control stand

Meaning

Indication of driver-perceived sound pressure level. L

= sound pressure level

Other information – see chapter on page 6-35

Location

Protective plate on control stand

Meaning

General indication of danger

This symbol alerts persons standing or working near the machine of an existing danger.

Location

On left and right of skip

Meaning

The CE mark means that the machine meets the requirements of the Machine Directive and that the conformity procedure has been carried out. The machine meets all the health and safety requirements of the Machine Directive.

Location

On the type label

1-10 BA DT08 SL EN – Edition 1.0 * * dt08b110.fm

Meaning

Fig. 12: Petrol

Fig. 13: Diesel Fig. 14: Hydraulic oil

Fig. 15: Read the Operator’s Manual

Fig. 16: Safety strut

Fig. 17: Danger of shearing Fig. 18: Hot surfaces

Fig. 19: Track tension adjustment

Fill in petrol only! 91 octane regular

Location

On the control stand (model DT08-P)

Meaning

Fill in diesel fuel only!

Location

On the control stand (model DT08-D)

Meaning

The tank contains hydraulic oil.

– see chapter Filling up hydraulic oil on page 5-14

Location

Next to the filler inlet of the hydraulic oil tank

Introduction

Meaning

Read the Operator’s Manual before using the machine.

Location

On left and right of skip

Meaning

Use a safety strut before carrying out work under the skip.

Location

On left and right of skip

Meaning

General indication of danger

This symbol alerts persons standing or working near the machine of an existing danger of shearing around the machine.

Location

On left and right of skip

Meaning

Do not touch hot surfaces, wait for parts to cool down.

Location

Near the exhaust system

BA DT08 SL EN – Edition 1.0 * dt08b110.fm 1-11

Meaning

Danger due to spring-loaded components! Always read the Operator’s Manual before working on the tracks.

Location

Right and left-hand side of chassis

Introduction

Fig. 20: Main label

Fig. 21: Throttle

Fig. 22: Ear protection

Meaning

This label explains the machine’s control elements

– see chapter 3.1 Control stand overview (model DT08-P skip and high-tip skip) on

page 3-1 and

– see chapter 3.2 Control stand overview (model DT08-D skip and high-tip skip) on

page 3-2

Location

On the control stand

Meaning

Indication of throttle.

Location

On the control stand

Meaning

The machine’s control stand is not enclosed, therefore always carry an ear protection.

Location

On the control stand

1-12 BA DT08 SL EN – Edition 1.0 * * dt08b110.fm

2 Safety instructions

Danger!

Caution!

Notice!

Environment!

2.1 Identification of warnings and dangers

Important indications regarding the safety of the staff and the machine are identified in this Operator’s Manual with the following terms and symbols:

Failure to observe the instructions identified by this symbol can result in personal injury or death for the operator or other persons.

☞ Measures for avoiding danger

Failure to observe the instructions identified by this symbol can result in damage to the machine.

Safety instructions

2.2 Warranty

2.3 Disposal

☞ Measures for avoiding danger for the machine

This symbol identifies instructions 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 in danger if environmentally hazardous material (e.g. waste oil) is not subject to proper use or disposal.

Warranty claims can be brought forward to your Wacker Neuson dealer only. Furthermore, the instructions in this Operator’s Manual must be observed.

All fluids, lubricants, material, etc., used on the machine are subject to specific regulations regarding collection and disposal. Dispose of different materials and consumables separately and in an environmentally friendly manner!

Disposal may be carried out by a Wacker Neuson dealer only. Also observe the national regulations regarding disposal!

Avoid damage to the environment! Do not allow the oil and oily wastes to get into the ground or stretches of water!

BA DT08 SL EN – Edition 1.0 * dt08b210.fm 2-1

Safety instructions

2.4 Designated use and exemption from liability

• 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 shall not be liable for damage resulting from this and the risk shall be fully borne by the user. Designated use also includes observing the instructions set forth in the Operator’s Manual and observing the maintenance and service conditions.

• The safety of the machine can be negatively affected by carrying out machine modifications without proper authority and by using spare parts, equipment and options which have not been checked and released by Wacker Neuson. Wacker Neuson GmbH will not be liable for damage resulting from this

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

• handling

• operating

• servicing and carrying out maintenance work and

• repairing the machine. This is also applicable in those cases in which special

attention has not been drawn to the duty to exercise due care, in the safety instructions, the Operator’s Manuals and maintenance manuals (machine/engine).

• Read and understand the Operator’s Manual before starting up, servicing or repairing

the machine. Observe the safety instructions!

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

2.5 General conduct and safety instructions

Organisational measures

• The machine has been designed and built in accordance with state-of-the-art standards and the recognised safety regulations. Nevertheless, its use can constitute a risk to life and limb of the user or of third parties, or cause damage to the machine and to other material property

• The machine must only be used in technically perfect condition in accordance with its designated use and the instructions set forth in the Operator’s Manual, and only by safety-conscious persons who are fully aware of the risks involved in operating the machine! Any malfunctions, especially those affecting safety, must therefore be rectified immediately!

Basic rule:

Before putting the machine into operation, inspect the machine for safety in work and road operation!

• Careful and prudent working is the best way to avoid accidents!

• The Operator’s Manual must always be at hand at the place of use of the machine, and must therefore be kept in its storage bin. Immediately complete or 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 organisation, work sequences or the persons entrusted with the work, supplement the Operator’s Manual by corresponding instructions, including those relevant to supervising and reporting duties

2-2 BA DT08 SL EN – Edition 1.0 * * dt08b210.fm

Safety instructions

• Persons entrusted with work on the machine must have read and understood the Operator’s Manual and in particular, chapter “Safety Instructions” before beginning work. This applies especially to persons working only occasionally on the machine, e.g. set-up or maintenance

• The user/owner must check – at least from time to time – whether the persons entrusted with operation or maintenance are working in compliance with the Operator’s Manual and are aware of risks and safety factors.

• The user/owner commits himself to operate and keep the machine in perfect condition, and, if necessary or required by law, to require the operating or servicing persons to wear protective clothing (e. g. safety shoes, hard hat).

• In the event of safety-relevant modifications or changes on the machine or of its behaviour, 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 (e.g. control stand, skip etc.), as well as to the attachments, which might affect safety without the approval of Wacker Neuson! This also applies to the installation and the adjustment of safety devices and valves, as well as to welding work on load-bearing elements

• Spare parts must comply with the technical requirements specified by Wacker Neuson. Original spare parts can be relied to do so

• Replace hydraulic hoses within stipulated and appropriate intervals even if no safetyrelevant defects have been detected

• Before working on or with the machine, remove jewellery, such as rings, wristwatches, bracelets etc., and tie back long hair and do not wear loose-fitting garments, such as unbuttoned or unzipped jackets, ties or scarves. Injury can result from being caught up in the machinery or from rings catching on moving parts!

• Keep the machine clean. This reduces

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

• Danger of injury, e.g. due to dirt or debris on the foothold, and

• Danger of accidents e.g. due to dirt pile-up on the control elements

• 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 work!

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

Selection and qualification of staff, basic responsibilities

• Any work on or with the machine must be carried out by reliable staff only. Do not let unauthorised persons drive or work with the machine! Observe statutory minimum age limits!

• The machine may be used by correctly trained or competent staff only. The staff’s authorities for operating, equipping and carrying out maintenance and repair of the machine must be defined clearly and distinctly!

• 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!

BA DT08 SL EN – Edition 1.0 * dt08b210.fm 2-3

Safety instructions

• Work on the electrical system and equipment, on the undercarriage and the steering and brake systems may be carried out only by skilled staff which has been specially trained for such work. Work on the hydraulic system of the machine must be carried out only by staff with special knowledge and experience in hydraulic equipment!

• Seal off the danger zone should it not be possible to keep a safe distance. Stop work 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 in danger 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 parts 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

2.6 Safety instructions regarding operation

Normal operation

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

• Before beginning work, familiarise yourself with the surroundings and circumstances of the work site. These are e.g. obstacles in the working and travelling area, the soil bearing capacity and any necessary barriers separating the work site from public roads

• Take the necessary precautions to ensure that the machine is used only when in a safe and reliable state! Operate the machine only if all protective and safety-oriented devices, e.g. removable safety-devices, soundproofing elements and exhausters etc., are in place and fully functional!

• Check the machine at least once a day/per work shift for visible damage and defects! Report any changes (incl. changes in working behaviour) to the competent organisation/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 seat only!

• Carry out start-up and shut-down procedures in accordance with the Operator’s Manual, and observe the indicator lights!

• Before putting the machine/attachment into operation (start-up/moving), ensure that noone is at risk by putting the machine/attachment into operation!

• Before driving with the machine, and also after interrupting work, check whether all control levers are functional!

• Before moving the machine always check whether the supplementary equipment has safely stowed away or attached!

• When driving on public roads, ways and places for purposes of construction work, observe the traffic regulations in force and, if necessary, ensure beforehand that the machine is in a condition perfectly compatible with these regulations!

• Ensure good illumination of the machine’s work area in conditions of poor visibility or after dark!

• Stop work if this is not possible to a reasonable degree!

• Since the machine has no acoustic warning system, stop the machine or interrupt work immediately if a person is likely to approach the working range of the machine!

2-4 BA DT08 SL EN – Edition 1.0 * * dt08b210.fm

Safety instructions

• No lifting, lowering or carrying persons!

• Installing a man basket or a working platform is prohibited!

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

• Always keep 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 – danger of poisoning!

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

• During operation on slopes, drive or work uphill or downhill. If driving across a slope cannot be avoided, bear in mind the tilting limit of the machine! Always keep the work equipment close to the ground! This also applies to driving downhill! When driving or working across a slope, the load must be on the uphill side of the machine.

• If the skip is less than half full, drive backwards uphill or forwards downhill.

• If the skip is more than half full, drive forwards uphill or backwards downhill.

• On sloping terrain always adapt your drive speed to the prevailing ground conditions! Never change to lower gear on a slope but always before reaching it!

• Before leaving the seat always secure the machine against unintentional movement and unauthorised use! Lower the work equipment to the ground

• The machine has no FOPS protection. Therefore, do not use the machine in areas with danger of falling objects!

• Before starting work check whether

• all safety devices are properly installed and functional

• Before moving the machine or before taking up work:

• Ensure that visibility is sufficient

• Inspect the immediate area (children!)

• In the work area the operator is responsible for third parties!

• Caution when handling fuel – increased danger of fire!

• Ensure that fuel does not come into contact with hot parts!

Do not smoke during refuelling, and avoid fire and sparks. Stop the engine during refuelling and do not smoke!

• Operation in potentially explosive areas is forbidden.

• Never get on or off a moving machine! Never jump off the machine!

• The drive levers take time getting used to them. Drive speed must be adapted to your skills and to the prevailing conditions.

BA DT08 SL EN – Edition 1.0 * dt08b210.fm 2-5

Safety instructions

Applications with lifting gear

Trailers

Transport

Temperature ranges

Definition:

Applications with lifting gear are understood as procedures involving raising, transporting and lowering loads with the help of slings and load-securing devices (e.g. ropes, chains). In doing so, the help of persons is necessary for securing and detaching the load. This applies for example to lifting and lowering pipes, shaft rings or containers.

• No applications with lifting gear!

• Hitching and towing other vehicles is not allowed!

• The machine must be loaded and transported only in accordance with the Operator’s Manual!

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

• Use only suitable means of transport of adequate capacity/payload!

• Safely secure the machine on means of transport! Use suitable mounting points and load-securing devices

• The recommissioning procedure must be strictly in accordance with the Operator’s Manual!

The machine can be used at a maximum temperature of +45 °C and a minimum temperature of −15 °C. Get in touch with your Wacker Neuson dealer if you intend to use the machine in other temperature ranges (e. g. tropical temperatures, etc.).

Carry out all maintenance and inspection work before storing the machine for the winter. Then store the machine in a dry place at ambient temperature (about +15 °C). Observe these temperature ranges so as not to affect the machine’s service life.

2-6 BA DT08 SL EN – Edition 1.0 * * dt08b210.fm

2.7 Safety instructions for maintenance

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

• Observe the adjustment, maintenance and inspection activities and intervals set forth in the Operator’s Manual, including information on the replacement of parts/partial equipment! These activities must be carried out by technical staff only.

• The machine may not be serviced, repaired or test-driven by unauthorised staff

• Brief the staff/the driver before beginning special operations and maintenance work! Appoint a person to supervise the activities!

• In any work concerning the operation, conversion or adjustment of the machine and its safety-oriented devices, or any work related to maintenance, inspection and repair, observe the start-up and shut-down procedures set forth in the Operator’s Manual, and the information on maintenance work.

• If required, secure the maintenance area appropriately!

• Prior to carrying out service, maintenance and repair work, attach a warning label, such as “Repair work – do not start machine!”, to the ignition lock/steering wheel or to the control elements. Remove the ignition key!

• Carry out service, maintenance and repair work only if the

• machine is positioned on firm and level ground

• the forwards-reverse lever is in neutral

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

the ground

• engine is stopped

• ignition key is removed and

• machine has been secured against unintentional movement

• the maintenance strut is installed – see chapter Maintenance strut on page 5-1

• Should maintenance or repair be inevitable with the engine running:

• Only work in groups of two

• Both persons must be authorised for the operation of the machine

• Observe the specific safety instructions in the work manual

• Keep a safe distance from all rotating and moving parts, e.g. fan blades, V-belt

drives, fans etc.

• Prior to carrying out assembly work on the machine, ensure that no movable parts will roll away or start moving.

• To avoid the risk of accidents, parts and large assemblies being moved for replacement purposes must be carefully attached and secured to lifting gear. Use only suitable lifting gear and suspension systems in a technically perfect state with adequate load-bearing capacity! Stay clear of suspended loads!

Safety instructions

BA DT08 SL EN – Edition 1.0 * dt08b210.fm 2-7

Safety instructions

• Have loads fastened and crane operators guided by experienced persons only! The person guiding the operator must be within sight or sound of him

• Always use specially designed or otherwise safety-oriented ladders and working platforms to carry out overhead assembly work. Never use machine parts or attachments/superstructures as a climbing aid! Wear a safety harness when carrying out maintenance work at greater heights! Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow and ice!

• Clean the machine, especially connections and threaded unions, of any traces of oil, fuel or preservatives before carrying out maintenance/repair work! Do not use aggressive detergents! Use lint-free cleaning rags!

• Before cleaning the machine with water, steam jet (high-pressure cleaner) or detergents, cover or tape up all openings which – for safety and functional reasons – must be protected against water, steam or detergent penetration. Special care must be taken with the electrical system.

• After cleaning, remove all covers and tapes applied for that purpose!

• After cleaning, examine all fuel, lubricant and hydraulic oil lines for leaks, chafe marks and damage! Rectify all defects without delay!

• Always tighten any screw connections that have been loosened during maintenance and repair!

• Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immediately upon completion of the maintenance and repair work.

• Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental impact!

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

• Before taking up work on machine parts dangerous for life and limb (bruising, cutting), always ensure safe blocking/support of these areas

• Carry out maintenance and repair work beneath a raised machine, attachments or additional equipment only if a safe and secure support has been provided for (the sole use of hydraulic rams, jacks etc. does not sufficiently secure raised machines or equipment/attachments)

• Avoid contact with hot parts, such as the engine block or the exhaust system during the operation of the machine and for some time afterwards – danger of burns!

• Retainer pins can fly out or splinter when struck with force – danger of personal injury!

• Do not use starting fuel! This especially applies to those cases in which a heater plug (intake-air preheating) is used at the same time – danger of explosions!

• Apply special care when working on the fuel system – increased danger of fire!

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2.8 Warning of special hazards

Electrical energy

• Use only original fuses with the specified current rating! Switch off the machine immediately and rectify the malfunction if trouble occurs in the electrical system!

• When working with the machine, maintain a safe distance from overhead electric lines! If work must be carried out close to overhead lines, the equipment/attachments must be kept well away from them. Caution, danger! Get informed on the prescribed safety distances!

• If your machine comes into contact with a live wire

• Warn others against approaching and touching the machine

• Have the live wire de-energised

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

• Work on the electrical system may only be carried out by a technician with appropriate training, in accordance with the applicable electrical engineering rules

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

• Observe the machine’s operating voltage!

• Always remove the earthing strap from the battery when working on the electrical system or when carrying out welding work!

• Starting with a battery jumper cable can be dangerous if carried out improperly. Observe the safety instructions regarding the battery!

Safety instructions

safely de-energised!

Gas, dust, steam, smoke

Hydraulics

• Operate the machine only on adequately ventilated premises! Before starting the internal combustion engine on enclosed premises, ensure that there is sufficient ventilation! Observe the regulations in force at the respective site!

• Welding, burning and grinding work on the machine may only be carried out by a Wacker Neuson dealer. Risk of fire and explosion!

• Before carrying out welding, flame-cutting and grinding work, clean the machine and its surroundings from dust and other inflammable substances, and ensure that the premises are adequately ventilated – danger of explosions!

• In areas with special hazards (e.g. toxic gases, caustic vapours, toxic environments), wear appropriate protective equipment (breathing filters, protective clothing)!

• Work on the hydraulic equipment of the machine must be carried out only by persons having specific technical knowledge and experience in hydraulic systems!

• Check all lines, hoses and screw connections regularly for leaks and obvious damage! Repair any damage and leaks immediately! Splashed oil can cause injury and fire

• In accordance with the Operator’s Manual/instructions for the respective assembly, release the pressure in all system sections and pressure lines (hydraulic system) to be opened before carrying out any implementing/repair work!

• Hydraulic and compressed-air lines must be laid and fitted properly! Ensure that no connections are interchanged! The fittings, lengths and quality of the hoses must comply with the technical requirements

BA DT08 SL EN – Edition 1.0 * dt08b210.fm 2-9

Safety instructions

Noise

Oil, grease and other chemical substances

Battery

Tracks

• During operation all sound baffles must be closed.

• Wear ear protectors if necessary!

• When handling oil, grease and other chemical substances (e.g. battery electrolyte – sulphuric acid), observe the product-related safety regulations (safety data sheet)!

• Be careful when handling hot consumables – risk of being burned or scalded by fluids!

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

• When charging batteries in particular, as well as during normal operation of batteries, an oxyhydrogen mixture is formed in the battery cells. Danger of explosion!

• In case of a frozen battery or of an insufficient electrolyte level, do not try start-up with a battery jumper cable. The battery can burst or explode

☞ Dispose of the battery immediately

• Repair work on the tracks must be carried out by technical staff or by an authorised workshop only!

• Defective tracks reduce the machine’s operational safety. Therefore carry out regular checks of the tracks for

• Cracks, cuts or other damage

• Check track tension at regular intervals.

2-10 BA DT08 SL EN – Edition 1.0 * * dt08b210.fm

3Operation

This chapter describes the controls, and contains information on the function and handling of the indicator lights and controls.

The pages stated in the table refer to the description of the controls. Numeric or alphanumeric combinations (for example 40/18 or 40/A) used for identifying

control elements, mean: figure no. 40/control element no. 18, or position A in figure no. 40

Figures carry no numbers if they are placed to the left of the text.

3.1 Control stand overview (model DT08-P skip and high-tip skip)

Operation

Pos.

BA DT08 SL EN – Edition 1.0 * dt08b320.fm 3-1

Description For more information see page

1 Loader unit operation (option)/raise skip (option) ......................................................................................................................3-18

2 Skip operation ......................................................................................................................................................................3-17

3 Normal or high speed lever .................................................................................................................................................... 3-13

4 Drive lever (left)....................................................................................................................................................................3-13

5 Drive lever (right)..................................................................................................................................................................3-13

6 Throttle

7 Auxiliary hydraulics (option).................................................................................................................................................................... 3-28

8 Hour meter 9Lock

Operation

3.2 Control stand overview (model DT08-D skip and high-tip skip)

Pos.

Description For more information see page

1 Loader unit operation (option)/raise skip (option) ......................................................................................................................3-18

2 Skip operation ......................................................................................................................................................................3-17

3 Normal or high speed lever ....................................................................................................................................................3-13

4 Drive lever (left) ....................................................................................................................................................................3-13

5 Drive lever (right) ..................................................................................................................................................................3-13

6 Throttle

7 Auxiliary hydraulics (option)....................................................................................................................................................................

8 Hour meter

9 Ignition lock

10 Alternator charge function indicator light ....................................................................................................................................3-3

11 Engine oil pressure indicator light 3-3 12 Lock

13 Buzzer ...................................................................................................................................................................................................... 3-3

3-28

3-2 BA DT08 SL EN – Edition 1.0 * * dt08b320.fm

Operation

Caution!

10 Alternator charge function indicator light

If the indicator light comes on with the engine running:

☞ Stop the engine immediately and ☞ Have the cause repaired by an authorised workshop

The alternator or the charging circuit of the alternator is faulty if the indicator light comes on with the engine running. The battery is no longer charged.

11 Engine oil pressure indicator light

If the indicator light comes on with the engine running:

☞ Stop the engine immediately and ☞ Check the oil level. If it is too low, fill up the engine oil. If it is correct, contact

an authorised workshop.

The oil pressure is too low if this indicator light comes on with the engine running. Operating the machine with insufficient oil pressure can cause engine damage!

13 Buzzer

The buzzer sounds as soon as ignition is switched on. This avoids emptying the battery by leaving ignition switched on unintentionally.

☞ Turn the ignition key and switch off the control panel.

BA DT08 SL EN – Edition 1.0 * dt08b320.fm 3-3

Operation

3.3 Putting into operation

Safety instructions

• Always face the machine as you get on and off the machine

• Never use the controls or movable lines and cables as handles

• Never get on or off a moving machine! Never jump off the machine

Putting the machine into operation for the first time

Important information

• The machine may be put into operation by authorised staff only – see chapter

Selection and qualification of staff, basic responsibilities on page 2-3 and – see

chapter 2 Safety instructions on page 2-1 of this Operator’s Manual.

• The staff must have read and understood this Operator’s Manual before putting the machine into operation

• The machine may only be used in technically perfect condition in accordance with its designated use and the instructions set forth in the Operator’s Manual, and only by safety-conscious persons who are fully aware of the risks involved in operating the machine

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

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 drive too cautiously either, as the machine will never reach its proper operating temperature

• Do not run the engine at high speed for extended periods

• Increase the load gradually whilst varying the engine speed

• Strictly observe the maintenance schedules in the appendix

– see chapter 5.10 Maintenance plan DT08-P (petrol engine) on page 5-25 – see chapter 5.11 Maintenance plan DT08-D (diesel engine) on page 5-27

3-4 BA DT08 SL EN – Edition 1.0 * * dt08b320.fm

Check lists

Start-up checklist

Operation

The checklists below are intended to assist you in checking and monitoring the machine before, during and after operation.

These checklists cannot claim to be exhaustive; they are merely intended as an aid for you in fulfilling your duties as a conscientious operator.

The checking and monitoring jobs listed below are described in greater detail in the 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:

Operation checklist

Parking checklist

No.

Question

Enough fuel in the tank? (➠ 5-3)

Engine oil level OK? (➠ 5-8)

Oil level in hydraulic tank OK? (➠ 5-14)

Starter cable pull OK?

Lubrication points greased? (➠ 5-29)

Tracks checked for cracks, cuts etc.? (➠ 5-17) Especially after cleaning, maintenance or repair work:

➥ Rags, tools and other loose objects removed?

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

No. Question

Anyone dangerously close to the machine?

Drive levers working correctly? (➠ 3-13)

Check and observe the following points when parking the machine:

No. Question

Loader unit (option) lowered to the ground? (➠ 3-18)

When parking on public roads:

Machine adequately secured?

When parking on slopes:

Machine also secured with chocks under the tracks to prevent it from rolling

away?

✔

BA DT08 SL EN – Edition 1.0 * dt08b320.fm 3-5

Caution!

Notice!

Fig. 23: Fuel cock

Fig. 24: Throttle

Fig. 25: Engine switch

Operation

Before starting the engine

☞ Run through the “Start-up” checklist

General information on starting the petrol engine

Never start the petrol engine without petrol!

☞ Always check the fuel tank contents before!

• The engine will not start unless the fuel cock is open

• Do not run the starter for more than 5 seconds if the engine does not start

• Wait about 10 seconds before trying again

Procedure

After you have completed the starting preparations:

☞ Open the engine cover ☞ Turn fuel cock A to the right ☞ Turn choke lever B to the left

Do not use choke lever B if the engine is warm or at high air temperatures.

☞ Slightly move throttle 6 forwards

☞ Turn the engine switch to position E

3-6 BA DT08 SL EN – Edition 1.0 * * dt08b330.fm

Manual starter

Caution!

Notice!

Fig. 26: Starter handle

Fig. 27: Electric starter

Fig. 28: Choke lever

Electric starter

Operation

Do not allow starter handle F to whiplash against the engine.

☞ Carefully move back handle F to avoid damage to the starter.

☞ Slightly pull starter handle F until you can feel a resistance, then firmly pull the handle.

☞ Turn starter G to position H and keep it in this position until the engine starts.

➥ Move the switch back to position I after the engine has started.

Do not actuate the electric starter for more than 5 seconds. If the engine does not start, release the ignition switch and wait 10 seconds before actuating the starter again.

Starting at low temperatures

When the engine has started

Circuit-breaker (for electric starter):

The circuit-breaker protects the battery’s load circuit. The circuit-breaker is triggered in case of a short circuit or if the battery’s terminals are inverted.

The green indicator in the circuit-breaker is ejected to indicate that the circuit-breaker has been triggered. In this case find out the cause for the error or contact your Wacker Neuson workshop before resetting the circuit-breaker.

☞ Press circuit-breaker button J back in to reset.

When the engine runs smoothly (increased engine speed):

In general, a battery delivers less energy in cold conditions. Therefore ensure that the battery is always well charged.

☞ Gradually push choke lever A to position B ☞ Let the engine warm up

➥ After the engine has reached its operating temperature, move choke lever A fully to

the right

At cold temperatures:

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

BA DT08 SL EN – Edition 1.0 * dt08b330.fm 3-7

Operation

Fig. 29: Auxiliary hydraulics (option)

Fig. 30: Throttle

Fig. 31: Engine switch

Fig. 32: Fuel cock

Stopping the petrol engine

☞ Check whether the switch for auxiliary hydraulics 7 is in the centre position

➥ The auxiliary hydraulics is switched off

☞ Push throttle 6 fully backwards ☞ Push lever 2 fully backwards

➥ The engine stops

☞ Turn the engine switch to position B

Machine equipped with electric starter

☞ Turn the engine switch to position K – See Electric starter on page 3-7.

☞ Turn fuel cock D to the right

3-8 BA DT08 SL EN – Edition 1.0 * * dt08b330.fm

General Informationen on starting the diesel engine

Caution!

Fig. 33: Fuel cock

Fig. 34: Throttle

Never start the diesel engine without diesel fuel – the injection pump is fuellubricated! Otherwise you run the

☞ Always check the fuel level before starting!

• The engine will not start unless the fuel cock is open

• Do not run the starter for more than 5 seconds if the engine does not start

• Wait about 1 minute before trying again

Procedure

After you have completed the starting preparations:

☞ Turn fuel cock A clockwise to position O

➥ The fuel cock is open

Operation

Risk of engine damage!

☞ Push throttle 6 fully forwards

BA DT08 SL EN – Edition 1.0 * dt08b330.fm 3-9

Operation

Caution!

Notice!

Fig. 35: Starter handle

Fig. 36: Decompression lever

Fig. 37: Starting

Manual starter

Do not allow starter handle C to whiplash against the engine.

☞ Carefully move back handle C to avoid damage to the starter.

☞ Slightly pull starter handle C until you can feel a resistance, then slowly release starter

handle C.

☞ Press decompression lever D all the way down. ☞ Firmly and quickly pull starter handle C with both hands

➥ If the engine does not start:

☞ Repeat the procedure.

Electric starter

The engine will not start unless the cable is pull fully and firmly!

☞ Turn the ignition key to position 1

Turn and hold the ignition key in position 3 until the engine starts

➥ If the engine does not start after 5 seconds

☞ Stop starting the engine and try again after 10 seconds

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

☞ Contact a Wacker Neuson workshop for troubleshooting

➥ As soon as the engine runs:

☞ Release the ignition key

Do not actuate the electric starter for more than 5 seconds.

3-10 BA DT08 SL EN – Edition 1.0 * * dt08b330.fm

Starting at low temperatures

Notice!

Fig. 38: Auxiliary hydraulics (option)

Fig. 39: Throttle

Fig. 40: Electric starter

Fig. 41: Fuel cock

When the engine has started

Stopping the diesel engine

Operation

When the engine runs smoothly (increased engine speed):

In general, a battery delivers less energy in cold conditions. Therefore ensure that the battery is always well charged.

☞ 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

☞ Check whether the switch for auxiliary hydraulics 7 is in the centre position

➥ The auxiliary hydraulics is switched off

☞ Push throttle 6 fully backwards until the engine stops

➥ The acoustic warning system 13 sounds to indicate that the control panel is still

switched on.

☞ Turn ignition key B to position E

☞ Turn fuel cock F counterclockwise to position S

BA DT08 SL EN – Edition 1.0 * dt08b330.fm 3-11

Operation

Notice!

12 V

34001b710_05.eps

Fig. 42: Starting aid with jump leads

Flat battery

Starting battery

Jump-starting the engine (supply battery)

Safety instructions

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

☞ Dispose of a frozen battery!

• The dumper must not touch the jump-starting vehicle when connected with jump leads – risk of sparking!

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

• Use only authorised jump leads 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 – danger of short

circuit!

• Route the jump leads so they cannot catch on rotating components in the engine compartment!

Procedure

☞ Drive 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 flat 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 jump lead (–) onto a solid metal component fimly

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

☞ Start the engine of the machine with the flat battery

Once the engine has started:

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

remove the the battery!

– terminal, then the + terminal) – this prevents sparking in the vicinity of

Special instructions for driving on public roads

3-12 BA DT08 SL EN – Edition 1.0 * * dt08b330.fm

The machine is subject to the:

• Applicable legal regulations of your country (e.g. road traffic regulations)

Operation of electric consumers (e.g. lighting equipment) is not allowed. This is why the machine has no socket.

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

Moving off

Danger!

Caution!

Notice!

Fig. 43: Drive lever

Drive levers

Operation

After starting the engine:

☞ Slowly actuate the drive lever

➥ Machine moves off

The machine has no rearview mirrors –

Danger of accidents when reversing!

☞ The driver must be guided by another person if he does not have sufficient

visibility to the rear.

Never drive the machine with the skip dumped out and with the loader unit lowered.

☞ Dump in the skip. ☞ Raise the loader unit.

The drive movements of the machine are controlled with drive levers 4 and 5.

Position Function

•A

•B

•C

•D

•C

•B

•A

•D

The machine has two drive speeds which can be selected as follows:

4Push forwards 5 Push forwards

4 Pull backwards 5 Pull backwards

4Pull backwards 5 Push forwards

4Push forwards 5 Pull backwards

Track dumper moves forwards

Track dumper moves backwards

Track dumper turns to the left

Track dumper turns to the right

☞ Push lever 3 forwards – see Control stand overview (model DT08-P skip and high-

tip skip) on page 3-1 or – see Control stand overview (model DT08-D skip and high-tip skip) on page 3-2

➥ The machine moves at high speed

☞ Pull lever 3 backwards

➥ The machine moves at slow speed.

Ensure that both tracks move as you change direction, otherwise the rubber tracks are subject to increased abrasion.

BA DT08 SL EN – Edition 1.0 * dt08b330.fm 3-13

Operation

Driving on slopes

Specific safety instructions

In order to avoid accidents, observe these safety instructions in particular when driving on slopes.

☞ Dump in the skip when driving the machine. ☞ Always drive in low speed on slopes!

➥ This also ensures more precise and smooth movements of the steering system.

• When driving on slopes or across obstacles,

• do not steer or drive across slopes.

☞ If possible, avoid changing direction when driving on slopes

☞ When steering the machine, ensure that you can stop safely at all times if the machine

starts to skid or if it becomes unstable.

• Dumping, swivelling or using the skip on slopes can cause the machine to lose its balance and to tip over.

☞ Avoid this under all circumstances.

☞ Do not drive on slopes steeper than 15°, otherwise the machine can tip over. ☞ Do not drive across slopes steeper than 10° otherwise the machine can tip over laterally.

• If the tracks slip when driving uphill and it is no longer possible to move on with the force of the tracks alone

☞ Do not use any auxiliary means to move the machine otherwise it can tip over.

☞ Always drive straight ahead when driving uphill or downhill. Driving diagonally or at an

angle to the slope is very dangerous.

☞ Avoid changing direction on slopes or driving across a slope. ☞ Drive slowly in meadows, on leaves or wet steel plates. The machine risks slipping

even if the slope is not steep. If the engine stops as you drive across a slope, immediately put the control levers to neutral position and start the engine again.

3-14 BA DT08 SL EN – Edition 1.0 * * dt08b330.fm

Driving across slopes

Danger!

Fig. 44: Driving across slopes

max. 10°

Fig. 45: Driving with a load on slopes

Fig. 45: Driving an empty machine on slopes

max. 15°

Operation

The dumper may be driven on firm ground across a slope of up to 10°.

Do not exceed the maximum slope.

Danger of accidents!

☞ The angle must be smaller in the case of soft and uneven ground! ☞ Do not actuate the skip as you drive on slopes ☞ Always dump in the skip before driving on slopes ☞ Always keep the loader unit 30 – 40 cm above the ground when driving the

machine.

☞ Always reduce your speed as you drive on slopes – see Drive levers on

page 3-13

☞ Always drive straight ahead when driving uphill or downhill. Avoid driving

diagonally or at an angle.

☞ The machine is very narrow. Therefore, drive very carefully on slopes or on

soft or uneven ground.

☞ Drive with extreme care on slopes in rain or if the ground is wet or slippery.

Driving on slopes

The dumper may be driven on firm ground on a slope of up to 15°.

Do not exceed the maximum slope.

Danger of accidents!

☞ The driver is not allowed to stand on the foothold when driving on slopes

with a loaded machine!

☞ If the skip is less than half full, drive backwards uphill or forwards downhill. ☞ If the skip is more than half full, drive forwards uphill or backwards downhill. ☞ The angle must be smaller in the case of soft and uneven ground! ☞ Before driving on a slope, lower the skip and do not operate it on the slope! ☞ Always keep the loader unit 30 – 40 cm above the ground. ☞ Always reduce your speed as you drive on slopes

– see Drive levers on page 3-13

☞ Always drive straight ahead when driving uphill or downhill. Avoid driving

diagonally or at an angle.

☞ The machine is very narrow. Therefore, drive very carefully on slopes or on

soft or uneven ground.

☞ Drive with extreme care on slopes in rain or if the ground is wet or slippery.

BA DT08 SL EN – Edition 1.0 * dt08b330.fm 3-15

Operation

Fig. 46: Do not raise or dump out the skip on slopes, other-

wise the machine can tip forwards.

< 15°

< 10°

Fig. 47: Driving with a high-tip skip

Driving on slopes with a high-tip skip

☞ Do not raise or dump out the skip on slopes, otherwise the machine can tip forwards. ☞ Unloading on slopes is not allowed.

☞ Driving with a raised and tilted skip is forbidden regardless of the ground the machine is

driving on.

☞ Raise and dump out the skip only if the machine is at a standstill.

3-16 BA DT08 SL EN – Edition 1.0 * * dt08b330.fm

Skip operation

Danger!

Notice!

Danger!

Notice!

Fig. 48: Skip operation

Fig. 49: Operating the high-tip skip

Operation

Do not operate the skip when driving on slopes, otherwise –

Danger of accidents!

☞ Do not actuate the skip when driving across slopes ☞ Do not actuate the skip when driving up or down slopes

Position Function

•A 2 Push forwards Skip is dumped out

•B 2 Pull backwards Skip is dumped in

The loader unit also moves as the skip is dumped in and out.

High-tip skip (option)

Do not operate the skip when driving on slopes, otherwise –

Danger of accidents!

☞ Do not actuate the skip when driving across slopes ☞ Do not actuate the skip when driving up or down slopes

Position Function

•A 1 Push forwards Skip is lowered

•B 1 Pull backwards Skip is raised

•E 2 Push forwards Skip is dumped out

•F 2 Pull backwards Skip is dumped in

The loader unit also moves as the skip is dumped in and out.

BA DT08 SL EN – Edition 1.0 * dt08b330.fm 3-17

Operation

Notice!

Fig. 50: Loader unit

Loader unit operation (option)

Position Function

•A 1 Push forwards Loader unit is lowered

•B 1 Pull backwards Loader unit is raised

Always keep the loader unit 30 – 40 cm above the ground when driving the machine.

3-18 BA DT08 SL EN – Edition 1.0 * * dt08b330.fm

Parking the machine

Danger!

Caution!

Fig. 51: Folding up the foothold

Fig. 52: Folding down the foothold

Operation

Always park the machine on firm ground –

Danger of accidents

☞ Park the machine on level ground ☞ Fasten the tracks with fastening elements (e. g. chocks)

☞ Stop the machine ☞ Dump in the skip ☞ Lower the loader unit to the ground ☞ Reduce engine speed completely ☞ Switch off ignition ☞ Remove the ignition key

Foothold

Never stop the engine under full load.

☞ Let the engine run at idling speed for at least 1 minute before switching it

off.

Folding up the foothold:

☞ Fold up foothold A with both hands to the upright position.

Folding down the foothold:

☞ Hold foothold A with both hands. ☞ Fold it down to the horizontal position.

BA DT08 SL EN – Edition 1.0 * dt08b330.fm 3-19

Operation

Danger!

Fig. 53: Craning operation

Crane handling 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!

Incorrect crane handling of the machine –

Danger of accidents!

☞ 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

load-bearing capacity!

☞ Only raise the machine with an empty loader unit and skip ☞ 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!

☞ Load the machine as follows:

• Empty the skip and the loader unit

• Lower the skip

• Stop the engine

• Remove the ignition key.

• Use suitable lifting gear, chains etc.

☞ Length L1 of the lifting gear on the skip must be at least 2.0 m long ☞ Length L2 of the lifting gear (two cables or chains) on the control stand must be at

least 2.0 m long

• Slowly raise the machine

3-20 BA DT08 SL EN – Edition 1.0 * * dt08b330.fm

Loading and transporting the machine

Danger!

Notice!

<17°

Fig. 54: Access ramps

< 17°

Safety instructions

• The transport vehicle must be of sufficient size. See Chapter 6 “Specifications” for the dimensions and the weight of the machine!

• Remove any mud, snow or ice from the tracks so that the machine can be safely driven onto the ramps

• Secure the machine against unintentional movement – see Parking the machine on page 3-19!

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 15° (27 %). Use access ramps with an antiskid surface only.

☞ Ensure that the loading area is clear and access to it is not obstructed – e.g. by super-

structures

☞ Ensure that the ramps and the tracks of the dumper are free of oil, grease and ice ☞ Start the engine of the dumper ☞ Lower the skip ☞ Raise the loader unit enough so that it will not touch the access ramps ☞ Carefully drive the dumper onto the middle of the transport vehicle ☞ Lower the loader unit to the loading area ☞ Stop the engine ☞ Remove the ignition key (option)

Operation

The machine must be loaded and transported properly –

Danger of accidents!

☞ 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!

The manufacturer’s warranty shall not apply to accidents or damage caused by loading or transporting the machine.

BA DT08 SL EN – Edition 1.0 * dt08b330.fm 3-21

Operation

Danger!

Notice!

Fig. 55: Tying down the dumper

Fig. 56: Tying down the dumper

Tying down the machine

The machine must be loaded and transported properly –

Danger of accidents!

☞ 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!

☞ Ensure that the authorised maximum height is not exceeded ☞ Secure the tracks of the dumper on the sides. ☞ Lower the skip and the loader unit ☞ Firmly fasten the dumper onto the platform. To this end, use chains or straps to pass

the cables between the tracks and the skip

☞ Before transporting the machine through heavy rain:

Cover the exhaust pipe with a suitable cover

☞ Before transporting, ensure that the driver of the transport vehicle knows the overall

height, width and weight of the machine (incl. the dumper) and the applicable legal regulations in the country where this type of transport is to take place!

Towing the machine

Keep out of the danger zone of the machine –

Danger of accidents!

☞ Ensure that no-one is dangerously close to the dumper.

The manufacturer’s warranty shall not apply to accidents or damage caused by towing the machine. No towing away other machines with the eye hook. The machine can also be salvaged with a crane.

3-22 BA DT08 SL EN – Edition 1.0 * * dt08b330.fm

Caution!

Operation

3.4 Working with the machine

1.01.03

General safety instructions

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

• Do not drive under projecting earth. Stones or earth can fall onto the machine.

• When working on roofs or similar structures, check the resistance and the structure

• Do not place the machine directly under the workplace during demolition, otherwise

• Operation of the machine by unauthorised staff is prohibited!

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

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

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

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

• No transporting of persons, animals etc. in the skip.

• When transporting material, actuating the skip and/or the loader unit (option) is not

• Always carry out precise and smooth control movements, do not carry out abrupt

• Do not get off the machine when it is moving.

• Avoid dangerous work conditions on the work site, do not work in severe weather and

• Transporting persons is prohibited.

Working with the loader unit

The following section describes work operations with the machine equipped with the loader unit. The loader unit is mainly used for earth-moving applications, and for loosening, picking up and loading loose material.

Transporting with a full bucket

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

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 which are to be opened before starting setup or repair work, e.g. fitting/removing an attachment with hydraulic functions.

wheel chocks or other auxiliary means.

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

allowed!

movements.

ensure that no-one is at risk.

No transport of material: the loader unit is designed for loading loose material only.

☞ Loading loose material is described below ☞ Only load material with the skip dumped in

BA DT08 SL EN – Edition 1.0 * dt08b340.fm 3-23

Operation

Caution!

Notice!

Fig. 57: Horizontal lowering of the loader unit

Fig. 58: Driving into the material

Fig. 59: Tilt in the loader unit

Loading loose material

Do not carry out any steering movements once the bucket has penetrated the material. Lower the loader unit only when the machine is at a standstill and if there is enough room to the front. The loader unit is not designed for loading compacted material (hard to penetrate), severe loader unit damage can occur.

☞ Only load loose material

☞ Lower the loader unit to the ground A

☞ Push control lever 1 forwards B

Do not carry out any steering movements once the bucket has penetrated the material.

Ending loading

Load the machine only on firm and level ground!

☞ Drive forwards into the material A

If the engine speed decreases due to too much material:

☞ Raise the loader unit a little

☞ Pull control lever 1 backwards D

If the loader unit cannot be raised in the material

• Reduce the load on the loader unit by reversing

☞ Set the loader unit to position C

☞ Pull control lever 1 backwards D

3-24 BA DT08 SL EN – Edition 1.0 * * dt08b340.fm

Notice!

Transporting with a full skip

Danger!

Fig. 60: Fully tilt in the loader unit

Fig. 61: Transporting with a full skip

Operation

☞ Tilt in the loader unit fully E

☞ Pull control lever 1 backwards D

Carry out slow movements of the loader unit. This distributes the material evenly in the skip.

Careful when driving in rough terrain with a full skip –

Danger of accidents!

Pay particular attention to this when cornering or driving on slopes. In order to avoid accidents:

☞ Fully dump in the skip ☞ Observe the maximum angle when driving on slopes

☞ Fully dump in the skip A ☞ Lower the loader unit (option) to transport position B ☞ Always reverse up a slope at low speed with a full skip

BA DT08 SL EN – Edition 1.0 * dt08b340.fm 3-25

Operation

Danger!

Caution!

Fig. 62: Dumping out the skip

Dumping out the skip

Dumping out the skip alongside a pit is dangerous –

Danger of accidents!

☞ Ensure sufficient stability ☞ Do not drive too closely to the pit

• Secure the machine with chocks if necessary

☞ Slowly dump out the skip ☞ Always watch the material as you dump out the skip: ensure that the mate-

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

☞ Dump out the skip A

☞ Push control lever 2 forwards C

➥ The loader unit is raised

As you dump out the skip, ensure that the loader unit does not touch the ground or the material transported in the skip, otherwise the loader unit can be damaged.

☞ Always select the optimal position for the loader unit

3-26 BA DT08 SL EN – Edition 1.0 * * dt08b340.fm

Dumping out the skip upwards (option)

Danger!

Fig. 63: Dumping out the skip upwards (option)

Fig. 64: Emergency lowering of the skip

Operation

Careful when handling the high-tip skip –

Danger of accidents!

☞ Do not raise or dump out the skip when driving ☞ Do not raise or dump out the skip on slopes or in an inclined position

☞ Place the machine on level and horizontal ground ☞ Dump out skipA upwards

☞ Pull control lever 1 backwards C

➥ Skip is raised

☞ Dump out skip D

☞ Push control lever 2 forwards F

➥ Skip dumps out

Emergency lowering of the skip

Emergency lowering of the skip –

Danger of crushing and injury!

☞ Stay clear of the skip

Emergency lowering of the skip is only possible with the help of two persons.

☞ Pull lever 2 backwards A during emergency lowering and keep it in this position

• Once the skip is fully dumped out

☞ Push the skip downwards by hand beyond pivot point B and at the same time, pull

lever 2 backwards A

☞ The skip is lowered by its own weight once it is beyond the pivot point.

BA DT08 SL EN – Edition 1.0 * dt08b340.fm 3-27

Operation

Caution!

Fig. 65: Auxiliary hydraulics (option)

Auxiliary hydraulics (option)

The auxiliary hydraulics has a throughput of 20 l/min at 150 bar.

☞ Stop the engine ☞ Check whether the switch for auxiliary hydraulics 7 is in the centre position

➥ The auxiliary hydraulics is switched off

☞ Connect the quick couplers of the equipment to the corresponding ports P and P1 of

the auxiliary hydraulics of the machine.

☞ Switch on the auxiliary hydraulics and move lever 7 to position A or B depending on the

line used as pressure line.

☞ Regulate the dumper’s throttle so as to adapt the output to the equipment connected

Position Function

•A 7 Push to the right Uppoer auxiliary hydraulics port P

•B 7 Push to the left Lower auxiliary hydraulics port P1

Switch on the auxiliary hydraulics only if an equipment is connected by means of the quickcouplers. Switching on the auxiliary hydraulics with no work equipment connected can be the cause of starting failure (no start) or output

loss of the dumper, or of oil overheating in the hydraulic system

3-28 BA DT08 SL EN – Edition 1.0 * * dt08b340.fm

4 Troubleshooting

4.1 Engine trouble

Problem Possible causes See

Engine does not start or is not easy to start

Troubleshooting

The information given in this chapter is provided for maintenance staff, for fast and reliable detection of malfunctions and their appropriate repair.

Repairs must be carried out by authorised staff.

Wrong SAE grade of engine lubrication oil 5-24

Fuel grade does not comply with specifications 5-24

Defective or flat battery 5-21

Loose or oxidised cable connections in starter circuit

Defective starter, or pinion does not engage

Wrong valve clearance

Defective fuel injector

Engine starts, but does not run smoothly or faultless

Engine overheats

Insufficient engine output

Defective fuse

Check the spark plug 5-7

Fuel grade does not comply with specifications 5-24

Wrong valve clearance

Injection line leaks

Defective fuel injector

Oil level too low 5-8

Oil level too high 5-8

Dirty air filter 5-10

Defective fuel injector

Oil level too high 5-8

Fuel grade does not comply with specifications 5-24

Dirty air filter 5-10

Wrong valve clearance

Injection line leaks

Defective fuel injector

Dirty carburettor (DT08-P only)

Defective ignition (DT08-P only)

Defective spark plugs (DT08-P only)

Oil level too low 5-8

Insufficient or no engine oil pressure

Engine oil consumption too high

BA DT08 SL EN – Edition 1.0 * dt08b410.fm 4-1

Too much machine inclination (max. 15°)

Wrong SAE grade of engine lubrication oil 5-24

Oil level too high 5-8

Too much machine inclination (max. 15°)

Troubleshooting

Problem Possible causes See

Engine smoke

Blue

White

Black

Oil level too high 5-8

Too much machine inclination (max. 15°)

Engine starting temperature too low

Fuel grade does not comply with specifications 5-24

Wrong valve clearance

Defective fuel injector

Dirty air filter 5-10

Wrong valve clearance

Defective fuel injector

4-2 BA DT08 SL EN – Edition 1.0 * * dt08b410.fm

5 Maintenance

Danger!

Fig. 66: Maintenance strut

Fig. 66: Transport bracket

5.1 Introduction

Maintenance strut

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 carry out the prescribed maintenance work.

Before carrying out service and maintenance work, always read, understand and follow the instructions given in:

• Chapter 2 “Safety instructions” of this Operator’s Manual and

• The Operator’s Manuals of the attachments.

Daily service and maintenance work, and maintenance according to maintenance plan “A” must be carried out by a specifically trained driver. All other maintenance work must be carried out by trained and qualified staff only.

The maintenance plans indicate when the maintenance work mentioned below must be carried out.

Careful when carrying out maintenance work on or under the skip, and in general when carrying out maintenance work with the dumper body dumped out –

Danger of accidents!

☞ Use the maintenance strut

Mount the maintenance strut as follows:

☞ Take maintenance strut A out of its bracket

☞ The maintenance strut is fastened with lock pin C and pin D

☞ Fit maintenance strut A onto tilt ram B ☞ Secure maintenance strut A with lock pin C and pin D

During transport fit maintenance strut A as shown in Fig. 66 – transport bracket.

BA DT08 SL EN – Edition 1.0 * dt08b510.fm 5-1

Maintenance

Danger!

Fig. 67: Maintenance strut

Maintenance strut for high-tip skip

Careful when carrying out maintenance work on or under the skip, and in general when carrying out maintenance work with the dumper body dumped out –

Danger of accidents!

☞ Use the maintenance strut

Mount the maintenance strut as follows:

☞ Raise the skip ☞ Dump out the skip ☞ Raise safety rod A

➥ The skip is blocked in the raised position

☞ Remove the safety pin and the stud from opening B and insert them in opening C

➥ The skip is blocked in the raised position

5-2 BA DT08 SL EN – Edition 1.0 * * dt08b510.fm

5.2 Fuel system

Notice!

Fig. 68: Model DT08-P (petrol engine)

Min.

Max.

Fig. 69: Model DT08-D (diesel engine)

Min.

Max.

Specific safety instructions

Checking the fuel level

Maintenance

• Caution when handling fuel – increased danger of fire!

• Never carry out work on the fuel system in the vicinity of naked flames or sparks!

• Do not smoke when working on the fuel system or when refuelling!

• Before refuelling, stop the engine and remove the ignition key!

• Do not refuel in closed rooms!

• Wipe away fuel spills immediately!

• Keep the machine clean to reduce the risk of fire!

Model DT08-P (petrol engine)

Check the fuel level as follows:

☞ The fuel level must be between the min. und max. levels ☞ If the fuel level is below min.

☞ Refuel

The machine has no filling level indicator, therefore always check the fuel level before putting the machine into operation.

Model DT08-D (diesel engine):

Check the fuel level as follows:

☞ Check the fuel level on sight glass A ☞ The fuel level must be between the min. und max. levels ☞ If the fuel level is below min.

☞ Refuel

The machine has no filling level indicator, therefore always check the fuel level before putting the machine into operation.

BA DT08 SL EN – Edition 1.0 * dt08b510.fm 5-3

Maintenance

Danger!

Notice!

Environment!

Fig. 70: Model DT08-D (diesel engine)

Fig. 70: Model DT08-P (petrol engine)

Wrong

Right

Fig. 71: Refuelling from a barrel

Refuelling

Filler inlet B of the fuel tank is located on the top side of the engine.

All work involving fuel carries an increased

Danger of fire and poisoning!

☞ Do not refuel in closed rooms ☞ Never carry out work on the fuel system in the vicinity of naked flames or

sparks

Ensure that you refuel with the correct fuel. It is indicated on the label beside the filler inlet.

Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner!

Stationary fuel pumps

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

Refuelling from barrels

If refuelling from barrels cannot be avoided, note the following points (see fig. 71):

• Barrels must neither be rolled nor tilted before refuelling

• Protect the suction pipe opening of the barrel pump with a fine-mesh screen

• Immerse it down to a max. 15 cm above the floor of the barrel

• Only fill the tank using refuelling aids (funnels or filler pipes) with integral microfilter

• Keep all refuelling containers clean at all times

5-4 BA DT08 SL EN – Edition 1.0 * * dt08b510.fm

Petrol specification

Danger!

Fig. 72: Filter cup DT08-P (petrol engine)

Maintenance

Use only high-grade fuels

Grade

• Regular DIN 51607 91 −15 °C to 45 °C

For model DT08-P (petrol engine)

Diesel fuel specification

Use only high-grade fuels

Grade

• No. 2-D according to DIN

• No. 1-D according to DIN

For model DT08-D (diesel engine)

Cleaning the fuel filter (petrol engine)

Octane number

Cetane number

51 601

Min. 45

51601

Petrol is extremely flammable, and explosive under certain circumstances.

Use

4 °C to 45 °C

For outside temperatures below 4 °C or for operation above 1500 m altitude

Danger of accidents!

☞ No smoking in the work area, no naked flames or sparks. ☞ Once the filter cup is back in position, check for leaks and ensure that all

petrol spills have been wiped away before starting the engine.

☞ Set the fuel cock to OFF ☞ Unscrew filter cup A with a suitable tool ☞ Remove filter cup A and O-ring B, and wash with a nonflammable solvent. ☞ Allow filter cup A to dry thoroughly ☞ Screw filter cup A back on again with a suitable tool ☞ Set the fuel cock to ON and check for leaks

BA DT08 SL EN – Edition 1.0 * dt08b510.fm 5-5

Maintenance

Environment!

Fig. 73: Clean the fuel filter

Cleaning the fuel filter of the diesel engine

☞ Open drain plug A with a suitable tool

➥ The fuel drains

☞ Close drain plug A again after the fuel has drained completely ☞ Open screw B on the fuel cock ☞ Pull filter C out of the filler inlet of the fuel tank ☞ Wash filter C with a nonflammable solvent. ☞ Allow filter C to dry thoroughly ☞ Insert filter C back into the filler inlet of the fuel tank ☞ Close screw B on the fuel cock

Dispose of the drained fuel in an environmentally friendly manner.

5-6 BA DT08 SL EN – Edition 1.0 * * dt08b510.fm

Spark plug (petrol engine)

Danger!

Caution!

Fig. 74: Spark plug

0.70 mm –

0.80 mm

Maintenance

The engine is very hot after it has been in service.

Danger of burns!

☞ Allow the engine to cool down

If the spark plug is not tightened correctly, it can become very hot and cause engine damage.

☞ Always tighten the spark plug firmly ☞ Never use a spark plug with the wrong heat range

The spark plug must be set correctly and be free of deposits to ensure that the engine runs correctly.

Remove spark plug B as follows:

☞ Stop the engine ☞ Remove spark plug connector A ☞ Remove spark plug B with a suitable spark plug key ☞ Check spark plug B as follows:

☞ Check the outside of spark plug B

➥ Dispose of spark plug B if it is worn, or if the insulator is torn or cracked.

☞ Measure the electrode gap with a suitable tool

➥ The gap must be between 0.70 and 0.80 mm

☞ Check the sealing ring for wear

☞ Clean spark plug B with a suitable tool (e.g. wire brush etc.) if it can be used again

Mount spark plug B as follows:

☞ Screw in spark plug B by hand to avoid damage to the thread ☞ Tighten spark plug B with a suitable spark plug key.

☞ Tighten a new spark plug B by ½ a revolution after it makes contact, in order to com-

press the sealing ring

☞ Tighten a spark plug B that is already used by 1/8 – 1/4 of a revolution after it makes

contact, in order to compress the sealing ring

☞ Fit spark plug connector A back on again

The following spark plugs have been released:

Manufacturer’s description Manufacturer

• BPR6ES NGK

• W20EPR-U DENSO

BA DT08 SL EN – Edition 1.0 * dt08b510.fm 5-7

Maintenance

Caution!

Notice!

Fig. 75: Oil level check (petrol engine)

max min

Fig. 75: Oil level check (diesel engine)

max min

5.3 Engine lubrication system

Checking the oil level

The oil level can be checked from either side.

If the engine oil level is too low or if an oil change is overdue, this can cause

Loss of output and engine damage!

☞ Have the oil changed by an authorised workshop

– see chapter 5.11 Maintenance plan DT08-D (diesel engine) on

page 5-27

– see chapter 5.10 Maintenance plan DT08-P (petrol engine) on

page 5-25

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

➥ Max. inclination about 5°

• Stop the engine!

• 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, fill up oil at the latest when the oil reaches the MIN mark on the

oil dipstick A

5-8 BA DT08 SL EN – Edition 1.0 * * dt08b510.fm

Filling up engine oil

Caution!

Environment!

OIL

Fig. 76: Filling up engine oil (petrol engine)

Fig. 76: Filling up engine oil (diesel engine)

OIL

Maintenance

Too much or incorrect engine oil can result in engine damage! Therefore:

☞ Do not add engine oil above the MAX mark of the oil dipstick 76/A ☞ Use only the specified engine oil

Use a suitable container to collect the engine oil as it drains and dispose of it in an environmentally friendly manner!

Proceed as follows:

☞ Clean the area around filler cap A with a clean lint-free cloth ☞ Open filler cap A ☞ Fill in engine oil ☞ Wait a moment until all the oil has run into the oil sump ☞ Check the oil level ☞ Fill up if necessary and check the oil level again ☞ Close filler cap A ☞ Completely remove all oil spills

BA DT08 SL EN – Edition 1.0 * dt08b510.fm 5-9

Caution!

Fig. 77: Air filter (petrol engine)

Fig. 77: Air filter (diesel engine)

Maintenance

5.4 Air filter

The filter element will be damaged if it is washed or brushed out! Bear in mind the following to avoid premature engine wear!

☞ Never let the engine run without the air filter installed ☞ Replace the filter cartridge according to the maintenance plan ☞ Never reuse a damaged filter cartridge ☞ Ensure cleanliness when replacing the filter cartridge!

☞ Replace filter cartridge A according to the maintenance plan.

Filter cartridges degrade prematurely when in service in acidic air for longer periods of time. This risk is present for example in acid production facilities, steel and aluminium mills, chemical plants and other nonferrous-metal plants

☞ Replace filter cartridge A after 50 service hours at the latest!

5-10 BA DT08 SL EN – Edition 1.0 * * dt08b520.fm

Replacing the filter (petrol engine)

Environment!

Fig. 79: Cleaning/replacing the DT08-P filter (petrol

engine)

Maintenance

Replace filter cartridge A as follows:

☞ Stop the engine ☞ Unscrew wing nut B off cover C ☞ Remove cover C ☞ Unscrew wing nut D off filter cartridge A ☞ Insert the new filter cartridge A ☞ Tighten wing nut D on filter cartridge A ☞ Ensure that all dirt (dust) inside the cover C has been removed ☞ Position cover C (ensure that it is properly seated) ☞ Tighten wing nut B again on cover C

Dispose of filter cartridge A in an environmentally friendly manner.

BA DT08 SL EN – Edition 1.0 * dt08b520.fm 5-11

Maintenance

Environment!

Notice!

Fig. 80: Replacing the air filter (diesel engine)

Replacing the filter (diesel engine)

Replace filter cartridge A as follows:

☞ Stop the engine ☞ Unscrew wing nut B off cover C ☞ Remove cover C ☞ Remove filter cartridge A ☞ Insert the new filter cartridge A ☞ Ensure that all dirt (dust) inside the cover C has been removed ☞ Position cover C (ensure that it is properly seated) ☞ Tighten wing nut B again on cover C

Dispose of filter cartridge A in an environmentally friendly manner.

The filter cartridge of the diesel engine cannot be cleaned. Replace it if it is defective or according to the maintenance interval.

5-12 BA DT08 SL EN – Edition 1.0 * * dt08b520.fm

5.5 Hydraulic system

Caution!

Environment!

Specific safety instructions

Maintenance

• Release the pressure in all lines carrying hydraulic oil prior to any maintenance and repair work. To do this:

• Lower all hydraulically controlled attachments to the ground

• Move all control levers of the hydraulic control valves several times

• Hydraulic oil escaping under high pressure can penetrate the skin and cause serious injuries. Always consult a doctor immediately even if the wound seems insignificant – otherwise serious infections could set in!

• If the hydraulic oil in the sight glass is cloudy, this indicates that water or air has penetrated the hydraulic system. This can cause damage to the hydraulic system!

☞ Contact your Wacker Neuson dealer immediately

• Oil or fuel flowing out of high pressure lines can cause fire or malfunctions, and severe injuries or damage to property. Interrupt work immediately if slack nuts or damaged hoses and lines are detected.

☞ Contact your Wacker Neuson dealer immediately

• Replace a line if one of the following problems is detected:

☞ Damaged or leaky hydraulic seals. ☞ Worn or torn shell, or bare reinforcement ☞ Expanded shells in several positions. ☞ Entangled or crushed movable parts. ☞ Foreign bodies jammed or stuck in protective layers.

Dirty hydraulic oil, lack of oil or wrong hydraulic oil –

Danger of severe damage to the hydraulic system!

☞ Take care to avoid dirt when working! ☞ Always fill in hydraulic oil using the filling screen! ☞ Only use authorised oils of the same type

– see chapter 5.9 Fluids and lubricants on page 5-24

☞ Always fill up hydraulic oil before the level gets too low – see Filling up

hydraulic oil on page 5-14

☞ If the hydraulic system is filled with biodegradable oil, then use only biode-

gradable oil of the same type for filling up – observe the sticker on the hydraulic oil tank!

☞ Contact customer service if the hydraulic system filter is contaminated with

metal chippings. Otherwise, follow-on damage can result!

Collect drained hydraulic oil and biodegradable oil in a suitable container! Dispose of drained oil and used filters by an ecologically safe method. Always contact the relevant authorities or commercial establishments in charge of oil disposal before disposing of biodegradable oil.

BA DT08 SL EN – Edition 1.0 * dt08b520.fm 5-13

Maintenance

Fig. 81: Hydraulic oil level

Fig. 82: Hydraulic oil level

FULL

LOW

Checking the hydraulic oil level

Filling up hydraulic oil

Proceed as follows:

☞ Park the machine on level ground ☞ Raise the skip and lock it in the safety position See Maintenance strut on page 5-1. ☞ Stop the engine ☞ The dipstick is integrated in filler cap B of hydraulic oil tank A ☞ Check whether the oil level is between MIN and MAX

☞ Fill up hydraulic oil if the oil level is too low

Refill hydraulic oil only with the engine stopped otherwise hydraulic oil will overflow at the filler opening on the hydraulic oil tank.

Fill up as follows:

☞ Park the machine on level ground ☞ Raise the skip and lock it in the safety position See Maintenance strut on page 5-1. ☞ Stop the engine ☞ Unscrew filler cap B ☞ Use an oil funnel with microfilter to fill in oil

With the filter insert in place:

☞ Fill up hydraulic oil ☞ Check the hydraulic oil level with the dipstick integrated in filler cap B ☞ Fill up if necessary and check again ☞ Firmly tighten filler cap B by hand.

5-14 BA DT08 SL EN – Edition 1.0 * * dt08b520.fm

Important information for the use of biodegradable oil

• Use only the biodegradable hydraulic fluids which have been tested and approved by Wacker Neuson GmbH. Always contact Wacker Neuson GmbH for the use of other products which have not been recommended. In addition, ask the oil supplier for a written declaration of guarantee. This guarantee is applicable to damage occurring on the hydraulic components, which can be proved to be due to the hydraulic fluid

• Use only biodegradable oil of the same type for filling up. In order to avoid misunderstandings, a label providing clear information is located on the hydraulic oil tank (next to the filler inlet) regarding the type of oil currently used! The joint use of two different biodegradable oils can affect the quality of one of the oil types. Therefore, ensure that the remaining amount of initial hydraulic fluid in the hydraulic system does not exceed 8 % when changing biodegradable oil (manufacturer indications)

• Do not fill up with mineral oil – the content of mineral oil should not exceed 2 % in order to avoid foaming problems and to ensure biological degradability

• When running the machine with biodegradable oil, the same oil and filter replacement intervals are valid as for mineral oil

– see Maintenance plan DT08-P (petrol engine) on page 5-25 – see Maintenance plan DT08-D (diesel engine) on page 5-27

• Always have the condensation water in the hydraulic oil tank drained by an authorised workshop before the cold season. The water content may not exceed 0.1 % by weight

• The instructions in this Operator’s Manual concerning environmental protection are also valid for the use of biodegradable oil

• If additional hydraulic attachments are mounted or operated, use the same type of biodegradable oil for these attachments to avoid mixtures in the hydraulic system

Subsequent change from mineral oil to biodegradable oil must be carried out by an authorised workshop or by your Wacker Neuson partner

Maintenance

BA DT08 SL EN – Edition 1.0 * dt08b520.fm 5-15

Maintenance

Danger!

1 Q/07

Checking hydraulic pressure lines

Specific safety instructions

Caution when checking hydraulic lines, especially when searching for leaks. Hydraulic oil escaping under high pressure can penetrate the skin and cause serious injuries.

Danger of personal injury!

☞ Always consult a doctor immediately, even if the wound seems insignificant

– otherwise serious infections could set in!

☞ Always observe the following instructions:

• Retighten leaking screwed fittings and hose connections only when the system is not under pressure; i.e. release the pressure before working on pressurised lines!

• Never weld or solder damaged or leaking pressure lines and screw connections. Replace damaged parts with new ones!

• Never search for leaks with your bare hands, but wear protective gloves!

• Use paper or wood to check for minor leaks. Never use an unprotected light or naked flame!

• Have damaged flexible lines replaced by workshops only!

• Leaks and damaged pressure lines must be immediately repaired or replaced by an authorised workshop or after-sales staff. This not only increases the operating safety of your machine but also helps to protect the environment

• Replace hydraulic hoses every 6 years from the date of manufacture, even if they do not seem to be damaged

In this respect, we recommend that you observe all the relevant safety regulations for hydraulic lines, as well as the safety regulations regarding accident prevention and occupational health and safety in your country. Also observe DIN 20 066, part 5.

The date of manufacture (month or quarter and year) is indicated on the flexible line. Example: The indication “1 Q/07” means manufactured in the 1st quarter of 2007.

5-16 BA DT08 SL EN – Edition 1.0 * * dt08b520.fm

Danger!

Notice!

Fig. 83: Checking track tension

15 mm

Fig. 84: Increasing track tension

Maintenance

5.6 Tracks

Checking track tension

Maintenance

Careful when working with tracks –

Danger of accidents!

☞ Use suitable means to support and secure the machine ☞ In addition, ensure that the machine cannot overturn

Check track tension as follows:

☞ Park the dumper on firm and level ground ☞ Raise the dumper with suitable means ☞ Tracks must be raised off the ground ☞ Stop the engine ☞ Use additional supports for the dumper and ensure that it cannot overturn ☞ Measure the clearance at the middle track roller A

➥ The rubber track should not sag more than 15 mm when tight

Increasing track tension

If possible, the distance from the rollers should be the same for both tracks.

Proceed as follows:

☞ Park the dumper on firm and level ground ☞ Raise the dumper with suitable means ☞ Tracks should be raised off the ground ☞ Stop the engine ☞ Use additional supports for the dumper and ensure that it cannot overturn ☞ Screw in set screw B with a suitable tool

➥ Ram C is extended ➥ The track is tightened

☞ Check track tension

➥ Repeat the procedure if the tracks are not tight enough

BA DT08 SL EN – Edition 1.0 * dt08b530.fm 5-17

Check track tension once a day since excessive or insufficient track tension can damage the tracks and the components of the undercarriage.

Maintenance

Fig. 85: Decreasing track tension

Decreasing track tension

➥ The fork E is retracted ➥ The track is slackened

☞ Check track tension

➥ Repeat the procedure if track tension is too low or too high

5-18 BA DT08 SL EN – Edition 1.0 * * dt08b530.fm

5.7 Electrical system

Specific safety instructions

Maintenance

• The battery contains sulphuric acid! This acid must not be allowed to come into contact with the skin, the eyes, clothing or the machine

Therefore when recharging or working near the battery:

☞ Always wear goggles and protective clothing with long sleeves

If acid is spilt:

☞ Thoroughly rinse all affected surfaces immediately with plenty of water ☞ Thoroughly wash any part of the body touched by the acid immediately with plenty of

water and seek medical attention at once!

• Especially when charging batteries, as well as during normal operation of batteries, an oxyhydrogen mixture is formed in the battery cells – danger of explosion!

• In case of a frozen battery or of an insufficient electrolyte level, do not try start-up with a starting aid. The battery can burst or explode!

☞ Replace the battery immediately

• There must be no naked flame near open battery cells. Avoid sparks. No smoking. The gas that forms during normal battery operation can ignite!

• Use only 12 V power sources. Higher voltages will damage the electric components

• When connecting the battery leads, ensure that the poles +/– are not inverted, otherwise sensitive electric components will be damaged

• Do not interrupt voltage-carrying circuits at the battery terminals because of the danger of sparking!

• Never place tools or other conductive articles on the battery – danger of short circuit!

• Disconnect the negative (-) battery terminal from the battery before starting repair work on the electrical system

• First remove the (–) terminal and then the (+) terminal as you disconnect the electrical system

• Dispose of used batteries properly

Service and maintenance work at regular intervals

Every week

☞ Check once a week:

• Electric fuses

• Cable and earth connections

• Battery charge condition – see Battery on page 5-21

• Condition of battery terminals

BA DT08 SL EN – Edition 1.0 * dt08b530.fm 5-19

Maintenance

Notice!

Instructions concerning specific components

Electric lines and fuses Always observe the following instructions:

• Defective components of the electrical system must always be replaced by an authorised expert. Fuses may be changed by unqualified persons

• When carrying out maintenance work on the electrical system, pay particular attention to ensuring good contact in leads

Alternator

Always observe the following instructions:

• Only test run the engine with the battery connected

• When connecting the battery, ensure that the poles (+/–) are not inverted

• Always disconnect the battery before carrying out welding work or connecting a quick battery charger

Operation of electric consumers (e.g. lighting equipment) is not allowed. This is why the machine has no socket.

5-20 BA DT08 SL EN – Edition 1.0 * * dt08b530.fm

Battery

Danger!

Notice!

Fig. 86: Battery

Fig. 87: Battery

Maintenance

Battery acid is highly caustic!

Danger of burns!

Therefore when recharging and/or working near the battery:

☞ Always wear goggles and protective clothing with long sleeves

If acid is spilt:

☞ Thoroughly rinse all affected surfaces immediately with plenty of water ☞ Thoroughly wash any part of the body touched by the acid immediately with

plenty of water and seek medical attention at once!

Especially when charging batteries, as well as during normal operation of batteries, an oxyhydrogen mixture is formed in the battery cells –

Danger of explosion!

☞ Avoid naked lights and sparks in the vicinity of the battery and do not

smoke!

☞ Do not attempt to jump-start the machine if the battery is frozen or if the

acid level is low. The battery can rupture or explode!

• Replace the battery immediately

☞ Always disconnect the negative terminal (–) from the battery before starting

repair work on the electrical system!

Battery A is located under the cover. The battery is “maintenance-free”. However have the battery checked at regular intervals to ensure that the electrolyte level is between the MIN and MAX marks.

Checking the battery requires it to be removed and must be carried out by an authorised workshop.

Always follow the specific battery safety instructions!

Do not disconnect the battery while the engine is running!

Disconnecting the battery in an emergency

• Firmly pull cable C to disconnect the battery in an emergency.

Firmly pull cable C in an emergency only since this damages the electric line and possibly the starter.

BA DT08 SL EN – Edition 1.0 * dt08b530.fm 5-21

Maintenance

5.8 General maintenance work

Cleaning

Cleaning the machine is divided into 3 separate areas:

• Exterior of the machine

• Engine compartment

The wrong choice of cleaning equipment and agents can impair the operating safety of the machine on the one hand, and on the other undermine the health of the persons in charge of cleaning the machine. It is therefore essential to observe the following instructions.

General instructions for all areas of the machine

Cleaning with washing solvents

• Ensure adequate room ventilation

• Wear suitable protective clothing

• Do not use flammable liquids, such as petrol or diesel

Cleaning with compressed air

• Work carefully

• Wear goggles and protective clothing

• Do not aim the compressed air at the skin or at other people

• Do not use compressed air for cleaning your clothing

Cleaning with a high-pressure cleaner or steam jet

• Electric components and damping material must be covered and not directly exposed to the jet

• Cover the vent filter on the hydraulic oil tank and the filler caps for fuel, hydraulic oil etc.

• Protect the following components from moisture:

• Engine

• Electrical components such as the alternator etc.

• Control devices and seals

• Air intake filters etc.

Cleaning with volatile and easily flammable anticorrosion agents and sprays:

• Ensure adequate room ventilation

• Do not use unprotected lights or naked flames

• Do not smoke!

5-22 BA DT08 SL EN – Edition 1.0 * * dt08b530.fm

Exterior of the machine

Caution!

Danger!

Caution!

Engine compartment

Maintenance

Cleaning the machine can cause engine damage.

☞ Protect the engine against humidity

The following articles are generally suitable:

• High-pressure cleaner

• Steam jet

Clean the engine at engine standstill only –

Danger of personal injury!

☞ Stop the engine before cleaning

Screw connections and attachments

All screw connections must be checked regularly for tightness, even if they are not listed in the maintenance schedules.

☞ Engine fastening screws ☞ Fastening screws on the hydraulic system ☞ Line and pin fastenings on the attachment

Tighten loose connections immediately. Contact an authorised workshop if necessary.

Pivots and hinges

Lubricate all mechanical pivots on the machine (such as joints) and fittings at regular intervals even if they are not listed in the lubrication plan.

When cleaning the engine with a water or steam jet

☞ The engine must be cold ☞ and do not point the jet directly at electric sensors such as the oil pressure

switch.

The humidity penetrating any such sensors causes them to fail and leads to engine damage!

BA DT08 SL EN – Edition 1.0 * dt08b530.fm 5-23

Maintenance

5.9 Fluids and lubricants

Component/application

Engine/machine

fluid

Specification

Season/tempera-

ture

Capacities

Petrol engine (model DT08-P) Honda petrol

Engine oil AGIP MOTOROIL HD SAE 15W-40 Year-round 1.1 l

engine

Diesel engine (model DT08-D) Yanmar diesel engine

Hydraulic oil tank (model DT08-P)

Engine oil

Hydraulic oil AGIP ARNICA 46

Biodegradable oil

AGIP DIESEL SIGMA S 30

SAE

15W-40

PANOLIN HLP Synth 46

Year-round 0.6 l

Year-round 22.3 l

FINA BIOHYDRAN SE 46

Year-round 30.1 l

Hydraulic oil tank (model DT08-D)

Hydraulic oil AGIP ARNICA 46

PANOLIN HLP Synth 46

Biodegradable oil

FINA BIOHYDRAN SE 46

Grease

Roller and friction bearings

AGIP GR SM Year-round As required

Lubrication point Multipurpose grease AGIP GR SM Year-round As required

Fuel tank (model DT08-P) Honda petrol engine

Petrol Regular

91 octane, DIN 51 607

Year-round 6.0 l

Fuel tank (model DT08-D) Yanmar diesel

Diesel fuel

engine

1. The capacities indicated are approximate values; the oil level check alone is relevant for the correct oil level

1. Capacities indicated are no system fills

2. According to DIN 51511

3. According to DIN 51524 section 3

4. Biodegradable hydraulic oil based on saturated synthetic esters with an iodine value of < 10, according to DIN 51524, section 3, HVLP, HEES

5. According to DIN 51524 section 3

6. Biodegradable hydraulic oil based on saturated synthetic esters with an iodine value of < 10, according to DIN 51524, section 3, HVLP, HEES

7. KF2K-25 according to DIN 51502 multipurpose lithium grease with MoS² additive

8. Unleaded regular

No. 2-D, DIN 51601 grade Over 4 °C

No. 1-D, DIN 51601 grade Below 4 °C

5.4 l

5-24 BA DT08 SL EN – Edition 1.0 * * dt08b530.fm

Authorised

workshop

Customer

Every 1000 s/h

once a year

Maintenance

300 s/h

Every 100 s/h

Every 50 s/h

Every 20 s/h

Service work

(daily)

Maintenance plan/service hours (s/h)

●● ●

●●

●● ●

• Engine oil

• Fuel filter

• Hydraulic oil filter insert ●●●

• Hydraulic oil ●●

• Replace the air filter element ●●

• Hydraulic oil tank breather ●●

Maintenance

5.10 Maintenance plan DT08-P (petrol engine)

Work description

For service and maintenance work on the attachment, please refer to the operation and maintenance manual

of the attachment manufacturer as well.

Fluid and filter changes ( ):

Carry out the following oil and filter changes (check oil levels after test run):

BA DT08 SL EN – Edition 1.0 * * dt08b540.fm 5-25

• Replace the spark plug ●●

Inspection work ( ):

• Engine oil ●●

• Hydraulic oil ●●

Check the following material. Refill if necessary:

Check the fuel level, fill up fuel

Clean the filter cup

Check hydraulic oil radiator for dirt, clean if necessary

Check oil cooling systems and hoses for leaks and pressure (visual check)

Air filter (damage)

Check exhaust system for damage and condition

Check valve clearance, adjust if necessary

Check and clean the spark plug

Check/set idling speed

Empty the petrol tank

Check battery electrolyte. Fill up with distilled water if necessary

Check alternator, starter and electric connections, bearing play and function

Pressure check of primary pressure limiting valves

Maintenance

Authorised

workshop

Customer

Every 1000 s/h

once a year

300 s/h

Every 100 s/h

Every 50 s/h

Every 20 s/h

Service work

(daily)

Maintenance plan/service hours (s/h)

●●

●● ●

●●

●● ●

●●

•Skip ●●

• Tilt ram ●●

• Loader unit (option) ●●

• Loader unit rams (option) ●●

• Track tension ●●

Check tracks for cracks and cuts

Check track tension. Retighten if necessary

Bearing play of tread rollers, track carrier rollers, front idlers

Check piston rods for damage

Check screws for tightness

Pin lock

Line fixtures

Adhesive labels and Operator’s Manual

Lubrication service ( ):

5.10 Maintenance plan DT08-P (petrol engine)

Work description

For service and maintenance work on the attachment, please refer to the operation and maintenance manual

of the attachment manufacturer as well.

Lubricate the following assemblies/components – see Lubrication plan DT08 with skip on page 5-29:

• Track roller bearings ●●

Leakage check ( ):

• Visual check

☞ Engine and hydraulic system ●●

☞ Oil cooling circuit ●●

Check for tightness, leaks and chafing: pipes, flexible lines and screw connections of the following assemblies and components. Rectify if necessary:

☞ Travelling drive ●●

1. Replace the engine oil the first time after 20 s/h or the first month, then every 100 s/h or after 6 months at the latest

2. Replace the fuel filter the first time after 50 s/h, then every 400 s/h

5-26 BA DT08 SL EN – Edition 1.0 * * dt08b540.fm

Maintenance

Authorised

●

workshop

●

Customer

Every 1000 s/h

once a year

Every 6 months

or after 400 s/h

●

Every 3 months or

after 200 s/h

Once a month or

after 50 s/h

●●

●

Service work

(daily)

Maintenance plan/service hours (s/h)

●

●●

●

●●

●● ●

●●

• Engine oil filter

• Replace the fuel filter element

• Replace the air filter element ●●

• Hydraulic oil filter insert ●●●

• Hydraulic oil ●●

Maintenance

5.11 Maintenance plan DT08-D (diesel engine)

Work description

For service and maintenance work on the attachment, please refer to the operation and maintenance manual of the

attachment manufacturer as well.

BA DT08 SL EN – Edition 1.0 * * dt08b550.fm 5-27

• Engine oil

Fluid and filter changes ( ):

Carry out the following oil and filter changes (check oil levels after test run):

• Hydraulic oil tank breather ●●

Inspection work ( ):

Check the following material. Refill if necessary:

Check injection setting

Check and adjust injection time

Clean and adjust the fuel injection pump

Check and adjust the injection pressure of the injection nozzles, clean the injection needles/nozzles

Clean the fuel filter ●●

• Engine oil ●●

• Hydraulic oil ●●

Check condition and injection of fuel injection nozzle ●●

Check the fuel level, fill up fuel ●●

Check hydraulic oil radiator for dirt, clean if necessary

Check oil cooling systems and hoses for leaks and pressure (visual check)

Air filter (damage)

Check exhaust system for damage and condition

Intake and exhaust valve clearance

Empty diesel fuel tank

Check battery electrolyte. Fill up with distilled water if necessary

Check alternator, starter and electric connections, bearing play and function

Pressure check of primary pressure limiting valves

Check tracks for cracks and cuts

Maintenance

Authorised

workshop

●

Customer

Every 1000 s/h

once a year

Every 6 months

or after 400 s/h

●

●●

Every 3 months or

after 200 s/h

Once a month or

after 50 s/h

Service work

(daily)

●●

Maintenance plan/service hours (s/h)

●● ●

●●

•Skip ●●

• Tilt ram ●●

• Loader unit (option) ●●

• Loader unit rams (option) ●●

• Track tension ●●

5.11 Maintenance plan DT08-D (diesel engine)

Work description

For service and maintenance work on the attachment, please refer to the operation and maintenance manual of the

Check valve clearance. Adjust if necessary

Check track tension. Retighten if necessary

Bearing play of tread rollers, track carrier rollers, front idlers

Check piston rods for damage

Check screws for tightness

Pin lock

attachment manufacturer as well.

Line fixtures

• Track roller bearings ●●

Adhesive labels and Operator’s Manual

Lubrication service ( ):

Lubricate the following assemblies/components – see Lubrication plan DT08 with skip on page 5-29:

Leakage check ( ):

• Visual check

☞ Engine and hydraulic system ●●

☞ Oil cooling circuit ●●

Check for tightness, leaks and chafing: pipes, flexible lines and screw connections of the following assemblies and components. Rectify if necessary:

☞ Travelling drive ●●

1. Drain engine oil the first time after 50 s/h, then every 200 s/h

2. Replace the engine oil filter the first time after 50 s/h, then every 400 s/h

3. Replace the fuel filter the first time after 50 s/h, then every 400 s/h

4. Check and adjust injection time every other 1000 s/h servicing

5. Clean and adjust the fuel injection pump every other 1000 s/h servicing

5-28 BA DT08 SL EN – Edition 1.0 * * dt08b550.fm

5.12 Lubrication plan DT08 with skip

Explanation Symbol

Lubrication point

BA DT08 SL EN – Edition 1.0 * dt08b560.fm 5-29

5.13 Lubrication plan DT08 with high-tip skip (option)

Explanation Symbol

Lubrication point

5-30 BA DT08 SL EN – Edition 1.0 * * dt08b560.fm

Maintenance opening

Fig. 88: Maintenance opening

Maintenance opening for cleaning the chassis.

☞ Unscrew 4 screws to remove housing A.

BA DT08 SL EN – Edition 1.0 * dt08b560.fm 5-31

5-32 BA DT08 SL EN – Edition 1.0 * * dt08b560.fm

6 Specifications

6.1 Engine

Specifications

Sturdy steel sheet chassis, rubber-mounted engine

6.2 Hydraulic system

Engine

Product Type Design No. of cylinders Displacement Nominal bore and stroke Output Max. torque Max. engine speed without load Idling speed Fuel injection system Starting aid Battery Max. inclined position (engine no

longer supplied with oil): Exhaust values according to

Hydraulics

Pump

Flow rate Operating pressure for work

hydraulics Operating pressure for drive

hydraulics Hydraulic tank capacity

Model DT08-D Model DT08-P

Yanmar diesel engine Honda petrol engine

L100N6 CA1T1AAS1 GX 270 U QE OH

Air-cooled 4-stroke engine

435 cm³ 270 cm³

86 x 75 mm 77 x 58

6.8 kW at 3100 rpm 6.6 kW at 3600 rpm

22.5 Nm at 2000 rpm 17.7 Nm at 2500 rpm 3100 +/− 30 rpm 3850 +/− 100 rpm 1200 +/− 30 rpm 1400 +/− 150 rpm

Mechanical governor Electronic ignition

Reverse starter

12 V/44 Ah 12 V/30 Ah

20° continuously 20° continuously

97/68 EC, EPA 97/68 EC, EPA

Model DT08-D Model DT08-P

3 gear pumps

6 + 3.2 + 3.2 cm³/rev 41 l/min at 3600 rpm

150 bar

175 bar

22.3 l 22.3 l

6.3 Undercarriage

Undercarriage

2 drive speeds Theoretical climbing ability Track width No. of track rollers on either side Ground clearance Ground pressure

BA DT08 SL EN – Edition 1.0 * dt08b610.fm 6-33

Model DT08-D Model DT08-P

2.1 and 4.0 kph 20°

180 mm

110 mm

0.19 – 0.36 kg/cm² 0.16 – 0.34 kg/cm²

Specifications

6.4 Work hydraulics

6.5 Skip

6.6 High-tip skip (option)

Work hydraulics

Hydraulic pump displacement: Control valve Max. operating pressure Filter Hydraulic oil tank

Skip

Struck Heaped Liquid capacity Skip length Skip width Skip height

Skip (option)

Struck Heaped Liquid capacity Skip length Skip width Skip height

Model DT08-D Model DT08-P

20 l/min at 3600 rpm

1 section/2 sections

±5

150

bar

Return filter

22.3 l 22.3 l

Model DT08-D Model DT08-P

334 l 387 l 166 l

1135 mm

700 mm 374 mm

Model DT08

240 l 280 l 195 l

1134 mm

764 mm 442 mm

6.7 Loader unit (option)

Loader unit (option)

Width Scraping depth

Model DT08-D Model DT08-P

830 mm 130 mm

6-34 BA DT08 SL EN – Edition 1.0 * * dt08b610.fm

6.8 Noise levels

Notice!

------

Specifications

6.9 Vibration

Sound power level

Sound power level (L Driver-perceived sound pressure level

)

Uncertainty (K

1. According to ISO 6395

2. According to ISO 6396

3. According to EN ISO 4871

)

Model DT08-D

Model DT08-P

100 dB (A) 100 dB (A)

93 dB (A) 87 dB (A)

1.3 dB (A) 1.4 dB (A)

Sound power level measurement based on Directive 2000/14/EC. Driver-perceived noise level measured in compliance with EU Directives 84/532/EEC, 89/ 514/EEC and 95/27/EEC. Measurements carried out on asphalted surface.

Vibration

Effective acceleration value for the upper extremities of the body

Effective acceleration value for the body

DT08

< 2.5 < 0.5

1. Measurements as per 2002/44/EC, ISO EN 20643 and ISO/TR 25398 (measurement under the following conditions: excavating, driving). Machine and attachment operation and maintenance as per Operator’s Manual. Uncertainty of measurement: measurements as per EN 12096:1997 Value of vibrations transmitted to human body specified under special operational and ground conditions. Therefore it does not apply to a large number of applications. Therefore, the value of the vibrations transmitted to the human body (indicated by the machine manufacturer in accordance with European standards) must not be used as a reference for specifying machine operator exposure to vibrations.

BA DT08 SL EN – Edition 1.0 * dt08b610.fm 6-35

Specifications

830

700

180

790

174

234

1 3 °

3871660

2520

518753392

1320

45 750

386

1845

420

1240

1313

Fig. 89: Machine dimensions (model DT08-D with skip)

6.10 Dimensions model DT08-D with skip

Main data

Payload Dead weight incl. skip and loader unit Length Width Height Foothold projection Track width Ground contact length of tracks Front skip projection Skip load height (front edge) Skip length Skip width Skip depth Scraping depth

Model DT08-D

500 kg 560 kg

1660 mm

790 mm

1313 mm

387 mm 180 mm 753 mm 392 mm 750 mm

1320 mm

700 mm 386 mm

45 mm

6-36 BA DT08 SL EN – Edition 1.0 * * dt08b610.fm

6.11 Dimensions model DT08-D with high-tip skip (option)

2570

1426

757

964

1134

274 753 518

3871545

1 3 °

234

180

790

764

1646

1240

1898

112

442

Fig. 90: Machine dimensions (model DT08-D with high-tip skip)

Specifications

Main data

Model DT08-D

500 kg 625 kg

1545 mm

790 mm

1240 mm

387 mm 180 mm 753 mm 274 mm 964 mm

1134 mm

764 mm 442 mm

BA DT08 SL EN – Edition 1.0 * dt08b610.fm 6-37

Specifications

700

830

180

790

750

1845

386

1320

1 4

180

257

388

2520

515753

392

1660

420

1180

1313

Fig. 91: Machine dimensions (model DT08-P with skip)

6.12 Dimensions model DT08-P with skip

Main data

Model DT08-P

500 kg 515 kg

1660 mm

790 mm

1313 mm

388 mm 180 mm 753 mm 392 mm 750 mm

1320 mm

700 mm 386 mm

45 mm

6-38 BA DT08 SL EN – Edition 1.0 * * dt08b610.fm

6.13 Dimensions model DT08-P with high-tip skip (option)

1426

2570

757

965

1134

274 753 515

3881540

764

180

790

257

1 4

1646

1180

1898

112

442

Fig. 92: Machine dimensions (model DT08-P with high-tip skip)

Specifications

Main data

Model DT08-P

500 kg 580 kg

1540 mm

790 mm

1180 mm

388 mm 180 mm 753 mm 274 mm 965 mm

1134 mm

764 mm 442 mm

500 kg

BA DT08 SL EN – Edition 1.0 * dt08b610.fm 6-39

Specifications

Fig. 93: Diesel engine fuse

Fig. 93: Petrol engine fuse

6.14 Electrical system

6.15 Fuses

Electrical system

Model DT08-D Model DT08-P

Dynamo 12 V 15 A 12 V 1 A Starter 12 V 12 V Battery 12 V 44 Ah 12 V 30 Ah

Fuse Rated current (A)

Model DT08-D – diesel engine 20 A

Model DT08-P – petrol engine 5 A

Loader unit (option)

6-40 BA DT08 SL EN – Edition 1.0 * * dt08b610.fm

Wacker Neuson DT08-D, DT08-P, DT08 Series 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 Overall view of machine

1.3 Brief description

Definition of operator’s control stand

1.4 Regulations

EC declaration of conformity model DT08-P, for machines with CE mark on type label

Declaration of conformity model DT08-P, for machines without CE mark on type label

EC declaration of conformity model DT08-D, for machines with CE mark on type label

Declaration of conformity model DT08-D, for machines without CE mark on type label

1.9 Type labels and component numbers

1.10 Signs and symbols

2 Safety instructions

2.1 Identification of warnings and dangers

2.2 Warranty

2.3 Disposal

2.4 Designated use and exemption from liability

2.5 General conduct and safety instructions

Organisational measures

Selection and qualification of staff, basic responsibilities

2.6 Safety instructions regarding operation

Normal operation

Applications with lifting gear

Trailers

Transport

Temperature ranges

2.7 Safety instructions for maintenance

2.8 Warning of special hazards

Electrical energy

Gas, dust, steam, smoke

Hydraulics

Noise

Oil, grease and other chemical substances

Battery

Tracks

3Operation

3.1 Control stand overview (model DT08-P skip and high-tip skip)

3.2 Control stand overview (model DT08-D skip and high-tip skip)

3.3 Putting into operation

Safety instructions

Putting the machine into operation for the first time

Running-in period

Check lists

Start-up checklist

Operation checklist

Parking checklist

Before starting the engine

General information on starting the petrol engine

Procedure

Manual starter

Electric starter

Starting at low temperatures

When the engine has started

Stopping the petrol engine

General Informationen on starting the diesel engine

Procedure

Manual starter

Electric starter

Starting at low temperatures

When the engine has started

Stopping the diesel engine

Jump-starting the engine (supply battery)

Special instructions for driving on public roads

Moving off

Drive levers

Driving on slopes

Specific safety instructions

Driving across slopes

Driving on slopes

Driving on slopes with a high-tip skip

Skip operation

High-tip skip (option)

Loader unit operation (option)

Parking the machine

Foothold

Crane handling the machine