Wacker Neuson DW100, DW60, DW90 Operator's Manual

5100015363

Operator's Manual

Dumpers

DW60 DW90

DW100

Machine type Edition 1.1 Order no 5100015363 Language us

D18-01/D18-02/D18-03

Documentation Language Order no. Documentation Language Order no.

Operator’s manual us 5100015363

DW 60 [de en fr] 1000333050

Spare parts list

Legend Original Operator’s Manual x Translation of original Operator’s Manual –

Edition 1.1 Date 02/2016 Document BA D18 us*

DW 60 [it es en] 1000333061 DW 100 [it es en] 1000333065

Spare parts list

DW 90 [de en fr] 1000333062 DW 90 [it es en] 1000333063

DW 100 [de en fr] 1000333064

worldwide. No part of this publication may be reproduced, translated or used in any form or by any means – graphic,

electronic or mechanical including photocopying, recording, taping or information storage or retrieval systems – without prior permission in writing from the manufacturer.

No reproduction or translation of this publication, in whole or part, without the written consent of Wacker Neuso n Linz GmbH.

Violations of legal regulations, in particular of the copyright protection, will be subject to civil and criminal prosecution.

Wacker Neuson Linz GmbH keep abreast of the latest technical developments and constantly improve their products. For this reason, we may from time to time need to make changes to figures and descriptions in this documentation which do not reflect products that have already been delivered and that will not be implemented on these machines.

Technical data, dimensions and weights are only given as a n indicatio n. Non-me tric weig hts and mea sure ments are approximate.Responsibility for errors or omissions not accepted.

The cover features the machine with possible optional equipment. Photographs and graphics are symbolic representations and may differ from the actual products. Wacker Neuson is authorized to reprint the copyright-protected material of Perkins Engines Company Ltd

contained in this document. Translation of original Operator´s Manual. The Operator’s Manual and any amendments to it must always be available at the place of use of the machine.

Possible amendments are included at the end of the Operator’s Manual.

Wacker Neuson Linz G mbH Flughafenstr. 7 A-4063 Hörsching Phone: +43 (0) 7221 63000 Fax: +43 (0) 7221 63000-2200 E-mail: office.linz@wackerneuson.com www.wackerneuson.com

Table of contents

1Foreword

1.1 Operator’s Manual................................................................................................................................ 1-1

1.2 Warranty and liability ............................................................................................................................ 1-7

2 Safety

2.1 Safety symbols and signal words ....................................................... ... ... ... .... ... ... ... .... ........................ 2-1

2.2 Qualification of operating personnel..................................................................................................... 2-2

2.3 Conduct ................................................................................................................................................ 2-3

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

2.5 Lifting gear applications............... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... .... ... .................................................. 2-8

2.6 Trailer operation ................................................................................................................................. 2-10

2.7 Attachment operation ......................................................................................................................... 2-10

2.8 Towing, loading and transporting ....................................................................................................... 2-11

2.9 Maintenance....................................................................................................................................... 2-13

2.10 Measures for avoiding risks................................................................................................................ 2-17

3 Introduction

3.1 Machine overview. ... ....................................... ... .... ... ... ... .... ... ... ............................................................ 3-1

3.2 Brief description of machine ................................................................................................................. 3-3

3.3 Information and regulations on use ...................................................................................................... 3-4

3.4 Labels................................................................................................................................................... 3-5

4 Putting into operation

4.1 Cabin/control stand...................................... ... ... .... ... ... ... .... ... ....................................... ........................ 4-1

4.2 Overview of control elements ............................................................................................................. 4-17

4.3 Indicator lights and warning lights (overview)..................................................................................... 4-24

4.4 Preparatory work ................................................................................................................................ 4-29

4.5 Starting and stopping the engine........................................................................................................ 4-34

5Operation

5.1 Steering system.... ... ....................................... ... .... ... ... ....................................... ... ... .... ........................ 5-2

5.2 Accelerator actuation...... ....................................... ... ... ... .... ... ... ... .... ..................................................... 5-3

5.3 Brakes .................................................................................................................................................. 5-4

5.4 Machine travel ... ... ... .... ... ... ... ....................................... ... .... ... ... ... .... ... .................................................. 5-9

5.5 Differential lock................................................................................................................................... 5-15

5.6 Lights/signaling system ...................................................................................................................... 5-16

5.7 Wiper/wash system (option) ............................................................................................................... 5-20

5.8 Heating, ventilation and air conditioning system................................................................................. 5-21

5.9 Operating hydraulics .... ....................................................................................................................... 5-22

5.10 Attachments........................................................................................................................................ 5-24

5.11 Work operation ................................................................................................................................... 5-24

5.12 Emergency lowering.................................... ... ... ....................................... ... .... ... ... ... .... ... ................... 5-29

5.13 Options ............................................................................................................................................... 5-29

5.14 Putting out of operation/back into operation....................................................................................... 5-32

5.15 Permanently putting out of operation........ .......................................................................................... 5-34

6Transportation

6.1 Towing the machine ............................................................................................................................. 6-1

6.2 Loading the machine ............................................................................................................................ 6-5

6.3 Transporting the machine..................................................................................................................... 6-9

BA D18 us* 1.1 * D18us1_1IVZ.fm I-1

Table of contents

7 Maintenance

7.1 Information on maintenance................................................................................................................. 7-1

7.2 Maintenance overview................................................ ... ... ....................................... ... ... .... ...... ... ... .... ... 7-2

7.3 Fluids and lubricants........................................................................................................................... 7-10

7.4 Maintenance accesses .................................................. ... ... .... ... ... ... .... .............................................. 7-13

7.5 Cleaning and maintenance................................................................................................................. 7-16

7.6 Lubrication work................... ... ... .... ... ....................................... ... ... ... .... ... ... ... ... .................................. 7-19

7.7 Fuel system ........................................................................................................................................ 7-19

7.8 Engine lubrication system................. ... ... .... ... ... ....................................... ... ... ... .... ... ... ... .... ................. 7-25

7.9 Cooling system............. .... ... ... ... .... ...................................... .... ... ... ... .................................................. 7-28

7.10 Air filter................. ... ... ....................................... ... ... .... ... ..................................................................... 7-32

7.11 V-belt .................................................................................................................................................. 7-33

7.12 Hydraulic system ................................................................................................................................ 7-33

7.13 Electrical system............................................ ....................................... .............................................. 7-37

7.14 Heating, ventilation and air conditioning system................................................................................. 7-39

7.15 Washer system................................................................................................................................... 7-39

7.16 Axles................................................................................................................................................... 7-39

7.17 Braking system............. .... ... ... ... .... ... ... ....................................... ... ... .... ... ........................................... 7-39

7.18 Tires.................................................................................................................................................... 7-40

7.19 Maintenance of attachments............................................................................................................... 7-41

7.20 Maintenance of options........... ... .... ... ... ... .... ... ... ... ... ....................................... ... .... ... ... ... ..................... 7-41

7.21 Exhaust gas treatment........................................................................................................................ 7-42

7.22 Machine preservation ......................................................................................................................... 7-48

8Malfunctions

8.1 Engine warning lights.............. ... .... ... ... ... .... ... ... ... ....................................... ... ... .... ... ... ... ....... ................ 8-1

8.2 Engine and engine oil indicator lights ................................................................................................... 8-2

8.3 Malfunctions (display element/multifunctional display)......................................................................... 8-2

8.4 General malfunctions................. .... ... ... ... ....................................... ... .... ... ... ... ... .... ................................ 8-4

9 Technical data

9.1 Model designations and trade names................................................................................................... 9-1

9.2 Engine................................................................................................................................................... 9-1

9.3 Traveling drive/axles............................................................................................................................. 9-2

9.4 Brakes............................................................................................................................................ .... ... 9-3

9.5 Tires...................................................................................................................................................... 9-4

9.6 Steering system............................................................................................................................. ... . ... 9-4

9.7 Operating hydraulics............................................................................................................................. 9-4

9.8 Electrical system..... ... ... .... ... ... ... .... ...................................... .... ... ................................................ ... ....... 9-5

9.9 Tightening torques.................................................. .... ... ... ... ....................................... ... .......... ... ... .... ... 9-9

9.10 Coolant ............................................................................................................................................... 9-10

9.11 Noise emissions.................................................................................................................................. 9-10

9.12 Vibration.............................................................................................................................................. 9-11

9.13 Weight................................................................................................................................................. 9-14

9.14 Payload............................................................................................................................................... 9-15

9.15 Dimensions......................................................................................................................................... 9-16

Index

Index ..............................................................................................................................................................S-1

I-2 BA D18 us* 1.1 * D18us1_1IVZ.fm

Manufacturer

Wacker Neuson Linz GmbH, Flughafenstr. 7, 4063 Hörsching, Austria

Product

Declaration of conformity

Notified body according to Directive 2006/42/EC, appendix XI: DGUV Test-, Prüf- und Zertifizierungsstelle Fachausschuss Bauwesen, Landsberger Str. 309, 80687 Munich, Germany Distinguishing EU number 0515

Notified body involved in procedure

TÜV SÜD Industrie Service GmbH Westendstr. 199 D-80686 Munich

Directives and standards

We hereby declare that this product corresponds to the relevant regulations of the following Directives and standards: 2006/42/EC, 2004/108/EC, 2005/88/EC, 2000/14/EC; DIN EN ISO 12100:2010, DIN EN 474-1:2006+A1:2009, DIN EN 474-6:2010, DIN EN ISO 3471:2010

Authorized representative for the compilation of technical documentation

Thomas Köck, team leader technical documentation Flughafenstr. 7 4063 Hörsching Austria

Machine designation Compact Dumper Model/version D18-01 Trade name DW60 Serial number -Output in kW 55 Measured sound power level dB(A) 101 Guaranteed sound power level dB(A) 101

Johannes Mahringer, Managing director

EC Declaration of Conformity

Declaration of conformity

The indications specified above correspond to the existing information at time of going to press. They have possibly changed in the meantime (refer to the original declaration o f conformity suppli ed with the ma chine ). Applies to EU countries, and countries with legislation similar to that of the EU. Applies to all machines with CE marks that have not been modified without authorization since the product was placed on the market.

BA D18 us* 1.1 * D18konf.fm EG-1

Declaration of conformity

Manufacturer

Wacker Neuson Linz GmbH, Flughafenstr. 7, 4063 Hörsching, Austria

Product

Declaration of conformity

Notified body involved in procedure

TÜV SÜD Industrie Service GmbH Westendstr. 199 D-80686 Munich

Directives and standards

Authorized representative for the compilation of technical documentation

Thomas Köck, team leader technical documentation Flughafenstr. 7 4063 Hörsching Austria

Machine designation Compact Dumper Model/version D18-01 Trade name DW60 Serial number -Output in kW 86 Measured sound power level dB(A) 101 Guaranteed sound power level dB(A) 103

Johannes Mahringer, Managing director

EC Declaration of Conformity

The indications specified above correspond to the existing information at time of going to press. They have possibly changed in the meantime (refer to the original declaration of conformity supplied with the machine). Applies to EU countries, and countries with legislation similar to that of the EU. Applies to all machines with CE marks that have not been modified without authorization since the product was placed on the market.

EG-2 BA D18 us* 1.1 * D18konf.fm

Manufacturer

Wacker Neuson Linz GmbH, Flughafenstr. 7, 4063 Hörsching, Austria

Product

Declaration of conformity

Notified body involved in procedure

TÜV SÜD Industrie Service GmbH Westendstr. 199 D-80686 Munich

Directives and standards

Authorized representative for the compilation of technical documentation

Thomas Köck, team leader technical documentation Flughafenstr. 7 4063 Hörsching Austria

Machine designation Compact Dumper Model/version D18-02 Trade name DW90 Serial number -Output in kW 55 Measured sound power level dB(A) 99 Guaranteed sound power level dB(A) 99

Johannes Mahringer, Managing director

EC Declaration of Conformity

Declaration of conformity

BA D18 us* 1.1 * D18konf.fm EG-3

Declaration of conformity

Manufacturer

Wacker Neuson Linz GmbH, Flughafenstr. 7, 4063 Hörsching, Austria

Product

Declaration of conformity

Notified body involved in procedure

TÜV SÜD Industrie Service GmbH Westendstr. 199 D-80686 Munich

Directives and standards

Authorized representative for the compilation of technical documentation

Thomas Köck, team leader technical documentation Flughafenstr. 7 4063 Hörsching Austria

Machine designation Compact Dumper Model/version D18-02 Trade name DW90 Serial number -Output in kW 86 Measured sound power level dB(A) 103 Guaranteed sound power level dB(A) 103

Johannes Mahringer, Managing director

EC Declaration of Conformity

The indications specified above correspond to the existing information at time of going to press. They have possibly changed in the meantime (refer to the original declaration of conformity supplied with the machine). Applies to EU countries, and countries with legislation similar to that of the EU. Applies to all machines with CE marks that have not been modified without authorization since the product was placed on the market.

EG-4 BA D18 us* 1.1 * D18konf.fm

Manufacturer

Wacker Neuson Linz GmbH, Flughafenstr. 7, 4063 Hörsching, Austria

Product

Declaration of conformity

Notified body involved in procedure

TÜV SÜD Industrie Service GmbH Westendstr. 199 D-80686 Munich

Directives and standards

Authorized representative for the compilation of technical documentation

Thomas Köck, team leader technical documentation Flughafenstr. 7 4063 Hörsching Austria

Machine designation Compact Dumper Model/version D18-03 Trade name DW100 Serial number -Output in kW 55 Measured sound power level dB(A) 99 Guaranteed sound power level dB(A) 99

Johannes Mahringer, Managing director

EC Declaration of Conformity

Declaration of conformity

BA D18 us* 1.1 * D18konf.fm EG-5

Declaration of conformity

Manufacturer

Wacker Neuson Linz GmbH, Flughafenstr. 7, 4063 Hörsching, Austria

Product

Declaration of conformity

Notified body involved in procedure

TÜV SÜD Industrie Service GmbH Westendstr. 199 D-80686 Munich

Directives and standards

Authorized representative for the compilation of technical documentation

Thomas Köck, team leader technical documentation Flughafenstr. 7 4063 Hörsching Austria

Machine designation Compact Dumper Model/version D18-03 Trade name DW100 Serial number -Output in kW 86 Measured sound power level dB(A) 103 Guaranteed sound power level dB(A) 103

Johannes Mahringer, Managing director

EC Declaration of Conformity

The indications specified above correspond to the existing information at time of going to press. They have possibly changed in the meantime (refer to the original declaration of conformity supplied with the machine). Applies to EU countries, and countries with legislation similar to that of the EU. Applies to all machines with CE marks that have not been modified without authorization since the product was placed on the market.

EG-6 BA D18 us* 1.1 * D18konf.fm

Table of contents Index

Foreword

1 Foreword

1.1 Operator’s Manual

Information on this Operator’s Manual

The Operator’s Manual is stored in the document box under the seat. This Operator’s Manual contains important information on how to work

safely, correctly and economically with the machine. Therefore, it aims not only at new personnel, but it also serves as a reference for experienced personnel.

This is why the Operator’s Manual must be kept at hand in the machine. The operator must carefully read and understand the Operator’s Manual

before starting up, servicing or repairing the machine. This Operator’s Manual will help to familiarize yourself more easily with

the machine, thereby enabling you to use it more safely and efficiently. This Operator’s Manual does not include special superstructures. Please contact your dealer if you require more information on the machine

or the Operator’s Manual.

Foreword 1

BA D18 us* 1.1 * D18v100.fm 1-1

1 Foreword

Information

Environment

Explanation of symbols and abbreviations

Explanation of symbols

• Identifies a list

- Identifies a subdivision of a list ➥ Description of a result

1. Identifies an activity Follow the order of the activity!

2. Continuation of an activity Follow the order of the activity!

A Identifies an alphabetical list B Continuation of an alphabetical list

Cross references: see page 1-1 (page) Cross references: 7 (pos. no. or table no.) Cross references: fig. 3 (fig. no. 1) Cross references: – see chapter “5 Operation” on page 5-1

(see chapter) Cross references: – see “Operation” on page 5-1 (– see text)

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

Failure to observe the instructions identified by this symbol can cause damage to the environment.

1-2 BA D18 us* 1.1 * D18v100.fm

Abbreviations (in alphabetic order)

Fig. Figure o/h Operating hours approx. approximately PCM particulate matter catalysts FGPS Front Guard Protective Structure FOPS Falling Objects Protective Structure if nec. if necessary max. maximum min. minimum Pos. Position ROPS Roll Over Protective Structure (without losing contact with the ground) TOPS Tip Over Protective Structure

Foreword 1

e.g. for example

BA D18 us* 1.1 * D18v100.fm 1-3

1 Foreword

Fig. 1

Definitions

Towing The dumper tows another vehicle on public roads, or is towed itself.

Towing

Operating company/person

The dumper is towed out of an immediate danger zone (for e xample a ra ilroad crossing or job site).

A company (or person) operating the machine. This can be a construction company, for example.

Operators Person performing machine travel or operation.

Machine

Unless otherwise specified, the term “machine” refers to the dumpers described in this Operator’s Manual.

All work (for example machine travel, moving material, daily maintenance) an

Machine operation

operator is allowed to or has to perform in connection with the machine. The term “machine operation” does not include maintenance only a Wacker Neuson service center is allowed to perform.

Visual aids

Tier III/Tier IV (exhaust-gas standards)

Visual aids are, for example, rearview mirrors, cameras, but also persons assisting the operator during machine operation.

The machine can be equipped with an Tier III or Tier IV engine, depending on the destination country. Both engine variants are described separately if there are engine-specific differences (for example regarding operation).

Right/left/front/rear

These terms are used as seen by the operator on the seat.

• 1: left

• 2: right

• 3: front

• 4: rear

1-4 BA D18 us* 1.1 * D18v100.fm

Target-group definition

This Operator’s Manual is intended both for professional personnel on construction sites accustomed to handling construction machin es, and also for private persons, for example, renting and operati ng a construction machine.

The Operator’s Manual has been written in a way that allows machine operation by trained private persons without any special knowledge. As far as possible, no technical terms specific to construction machines are used.

This Operator’s Manual must be fully read and understood both by private persons and the professional personnel on construction sites.

A dealer or person renting the machine must instruct the operator and have this confirmed in writing.

Operator qualification and requirements for safe operation

Among other things, safe machine operation depends on the following points:

• Machine model and equ ipment.

• Machine maintenance.

• Work and travel speed.

• Nature of ground and work environment. The most important points are the operator’s qualification and power of

judgement. A well-trained operator following the Operator’s Manual and maintenance plan ensures a long service life and durability of the machine.

Specific training enables the operator to acquire, among other things, the following skills:

• Correct assessment of work situations.

• Feeling for the machine.

• Recognition of possible risk situations.

• Safe working by making the correct decisions for man, machine and

the environment. The operator is at risk if the machine is not operated correctly. Follow the operating procedures and instructions described for the

machine. Access to the machine or machine operation is prohibite d for childr en and

persons under the influence of alcohol, drugs or medicine.

Foreword 1

BA D18 us* 1.1 * D18v100.fm 1-5

1 Foreword

Conversion table

The rounded imperial values are indicated in brackets, for example 1060 cm³ (64.7 in³).

Volume unit

1 cm³ (0.061 in³)

1 m³ (35.31 ft³) 1 ml (0.034 US fl.oz.)

1 l (0.26 gal)

1 l/min (0.26 gal/min)

Unit of length

1 mm (0.039 in)

1 m (3.28 ft)

Weight

1 kg (2.2 lbs)

1 g (0.035 oz)

Pressure

1 bar (14.5 psi)

1 kg/cm² (14.22 lbs/in²)

Force/output

1 kN (224.81 lbf) 1 kW (1.34 hp) 1 PS (0.986 hp)

Torque

1 Nm (0.74 ft.lbs.)

Speed

1 kph (0.62 mph)

Acceleration

1 m/s² (3.28 ft/s²)

1-6 BA D18 us* 1.1 * D18v100.fm

1.2 Warranty and liability

Exemption from warranty and liability

Warranty

Warranty claims can be made only if the conditions of warranty have been observed. They are included in the General Conditions of Sales and Delivery for new machines and spare parts sold by the dealers of Wacker Neuson Linz GmbH. Furthermore, all instructions in this Operator’s Manual must be observed.

Have the maintenance, delivery inspection and the entries in the service booklet performed by a Wacker Neuson service center, otherwise warranty claims will not be acknowledged.

Exemption from liability

• Modifying Wacker Neuson products and fitting them with additional equipment not included in our delivery program requires Wacker Neuson’s written authorization, otherwise warranty and product liability for possible damage caused by these modifications shall not be applicable.

• The safety of the machine can be negatively affe cted by performing machine modifications without proper authority and by using spare parts, equipment, attachments and option al eq uip m en t th at ha ve not been checked and released by Wacker Neuson GmbH. Warranty and product liability for possible damage caused by these modifications shall not be applicable.

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

- handling

- operating

- servicing and performing maintenance 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 as well as in the Operator’s an d maintenance manuals.

- Read and understand the Operator’s Manual before starting up,

servicing or repairing the machine. Observe all safety instructions.

Foreword 1

BA D18 us* 1.1 * D18v100.fm 1-7

1 Foreword

Notes:

1-8 BA D18 us* 1.1 * D18v100.fm

DANGER

WARNING

CAUTION

NOTICE

Safety

2 Safety

2.1 Safety symbols and signal words

Explanation

The following symbol identifies safety instructions. It is used for warning against potential personal risk or danger.

DANGER identifies a situation causing death or serious injury if it is not avoided.

Consequences in case of non-observance. ► Avoidance of injury or death.

Safety 2

WARNING identifies a situation that can cause death or serious injury if it is not avoided.

Consequences in case of non-observance. ► Avoidance of injury or death.

CAUTION identifies a situation that can cause injury if it is not avoided.

Consequences in case of non-observance. ► Avoidance of injury.

NOTICE identifies a situation that causes da mag e to the m achin e if it is not observed.

► Avoidance of damage to property.

OM D18 us* 1.1 * Sicherheit_25022014.fm 2-1

2 Safety

2.2 Qualification of operating personnel

Owner’s duties

• Only allow specifically authorized, trained and experienced persons to operate, drive and perform maintenance on the machine.

• Do not allow persons to be trained or instructed by anyone other than an authorized and experienced person.

• Have persons to be trained or instructed practice under supervision until they are familiar with the machine and its behavior (for example with the steering and braking behavior).

• Access to the machine or machine operation is prohibited for children and persons under the influence of alcohol, drugs or medicine.

• Clearly and unequivocally define the responsibilities of the operating and maintenance personnel.

• Clearly and unequivocally define the responsibilities on the job site, also in view of traffic regulations.

• Give the operator the authority to refuse instructions by other persons that are contrary to safety.

• Have the machine serviced and repaired only by a Wacker Neuson service center.

Required knowledge of operator

• The operator is responsible for other persons.

• Avoid any operational mode that might be preju dicial to safety.

• The specific national driving license is required.

• The machine may only be operated by authorized and safetyconscious persons who are fully aware of the risks involved in operating the machine.

• The operator an d owner are obligated to operate the machine on ly in a safe and working condition.

• All persons working on or with the machine must have read and understood the safety instructions in this Operator’s Manual before starting work.

• Follow, and instruct the operator in, legal and other mandatory regulations relevant to accident prevention.

• Observe and instruct the operator in regulations regarding road traffic and environmental protection.

• Use only the defined accesses for getting on and off the machine.

• Be familiar with the emergency exit of the machine.

Preparatory measures for the operator

• Before starting, check the machine whether it can be driven and operated safely.

• Tie back long hair and remove all jewelry.

• Wear close-fitting work clothes that do not hinder movement.

2-2 OM D18 us* 1.1 * Sicherheit_25022014.fm

2.3 Conduct

Prerequisites for operation

Safety 2

• The machine has been designed and built in accordance with state-of-

the-art standards and the recognized safety regulations. Nevertheless its use can cause danger to the operator or other persons, or damage to the machine.

• Store this Operator’s Manual in the place provided for this in or on the

machine. Immediately replace a damaged or illegible Operator’s Manual and any supplements to it.

• The machine m ust only be operated in accordance with its designated

use and the instructions set forth in this Operator’s Manual.

• The operator and owner are obligated not to put into operation or

operate a damaged or malfunctioning machine.

- If a damage or malfunction occurs during operation, put the machine out of operation immediately and secure it against restart.

- Have all malfunctions jeopardizing the safety of the operator or other persons immediately repaired by a Wacker Neuson service center.

• Do not put the machine into operation or operate it after an accident; have it inspected for damage by a Wacker Neuson service center.

- Have the seat belt replaced by a Wacker Neuson service center after

an accident, even if there is no visible damage.

- Cabin and protective structures

• Remove all dirt, snow an d ice from climbing aids (for example from the handholds, footholds, handrails).

• The owner is responsible for requiring the operating and maintenance personnel to wear protective clothing and equipmen t as required by the circumstances.

OM D18 us* 1.1 * Sicherheit_25022014.fm 2-3

2 Safety

2.4 Operation

Preparatory measures

• Operation is only allowed with correctly installed and intact protective structures.

• Keep the machine clean. This reduces injury, accident and fire hazards.

• Safely store objects you carry with you in the places provided for this (for example in the storage compartment, drinks holder).

• Do not carry objects with you that protrude into the operator’s work space. They can create another danger in case of an accident.

• Observe all safety, warning and information labels.

• Start and operate the machine only with the se at belt fastened and only from the place provided for this.

• Check the condition and the fastening of the seat belt. Have malfunctioning seat belts and mounting hardware r eplaced by a Wacker Neuson service center.

• Before starting work, adjust the seating position so that all control elements can be reached and fully operated.

• Perform the personal adjustment at machine standstill only (for example of the operator seat, steering column).

• Ensure that all safety devices are properly installed and functional before starting work.

• Before starting work or after interrupting work, ensure that the brake, steering, signaling and light systems are functional.

• Before putting the mach ine into operation , ensu re that nobody is i n the danger zone.

2-4 OM D18 us* 1.1 * Sicherheit_25022014.fm

Job site

Safety 2

• The operator is responsible for other persons.

• Before starting work, familiarize yourself with the job site. This applies

to, for example:

- Obstacles in the job site and machine travel area

- Any barriers separating the job site from public roads

- Soil weight-bearing capacity

- Existing overhead and underground lines

- Special operating conditions (for example dust, steam, smoke, asbestos)

• The operator must know the maximum di mensions of the m achine and the attachment – see “Technical data”.

• Maintain a safe distance (for example from buildings, edges of building pits).

• During work in buildings or in enclose d areas, look out for:

- Height of the ceiling/clearances

- Width of entries/passages

- Maximum load of ceilings and floors

- Sufficient room ventilation (for example risk of carbon monoxide

poisoning)

• Use existing visual aids to stay aware of the danger zone.

• In conditions of darkness and poor visibility, switch on existing work lights and ensure that motorists are not blinded by these lights.

• If the existing lights of the machine are not sufficient for performing work safely, ensure additional lighting of the job site.

• Due to hot machine parts, mainta in a safe distance from easily flammable material (for example from hay, dry leaves).

Danger zone

Carrying passengers

• The danger zone is the area in which person s are in d anger due to the movements of the machine, attachment and/or load.

• The danger zone also includes the area that can be affected by falling material, equipment or by debris that is thrown out.

• Extend the danger zo ne sufficiently in the immediate vicinity of buildings, scaffolds or other elements of constr uction.

• Seal off the danger zone should it not be possible to keep a sufficient safety distance.

• Stop machine operation immediately if perso ns do not stay clear o f the danger zone.

• Carrying passengers with the machine is PROHIBITED.

• Carrying passengers on/in attachments/tools is PROHIBITED.

• Carrying passengers on/in trailers is PROHIBITED.

OM D18 us* 1.1 * Sicherheit_25022014.fm 2-5

2 Safety

Mechanical integrity

• The operator an d owner are obligated to operate the machine on ly in a safe and working condition.

• Operate the machine only if all protective and safety-oriented equipment (for example protective structures such as a cabin or rollbar, removable safety devices) is installed and functional.

• Check the machine for visible damage and defects.

• In case of damage and/or unusual behavior, put the machine out of operation immediately and secure it against restart.

• Have all malfunctions jeopardizing the safety of the operator or other persons immediately repaired by a Wacker Neuson service center.

Starting the engine of the machine

• Start the engine only according to the Operator’s Manual.

• Observe all warning and indicator lights.

• Do not use any liquid or gaseous starting aids (for example ether or starting fuel).

Machine operation

• Start and operate the machine only with the se at belt fastened and only from the place provided for this.

• Put the machine into operation only if visibility is sufficient (have another person guide you if necessary).

• Operation on slopes:

- Travel/work only uphill or downhill.

- Avoid machine travel across a slope, observe the machine’s permis-

sible inclination (and of the trailer if necessary).

- Keep loads on the uphill side of the machine and as close as

possible to it.

- Keep attachments/work equipment close to the ground.

• Adapt the travel speed to the circumstances (for example the ground conditions, weather conditions).

• There is increased dange r during backward machine travel. Persons in the blind spot of the machine cannot be seen by the operator.

- Ensure that nobody is in the danger zone when you change the

travel direction.

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

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Machine travel on public roads/sites

• The specific national driving license is required.

• Observe the national regulations (for example the road traffic regula-

tions) during machine travel on public roads/sites.

• Ensure that the machine is in compliance with the national regulations.

• In order not to blind other motorists, using the existing work lights

during machine travel on public roads/site is prohibited.

• When crossing underpasses, bridges, tunnels, for example, ensure

that the clearance height and width is sufficient.

• The attachment fitted onto the machine must be certified for travel on

public roads/sites (see for example the registration documents).

• The attachment fitte d onto the machine must be em pty and in transport

position.

• The attachment fitted onto the ma chine must be equipped with the

mandatory lights and protective equipment.

• Take measures against unintentional op eration of the operating

hydraulics.

• If the machine ha s different steering mo des, ensure that the mandatory

steering mode is selected.

Safety 2

Stopping the engine of the machine

• Stop the engine only according to the Operator’s Manual.

• Before stopping the engine, lower the work equipment/attachment to

the ground.

Stopping and securing the machine

• Unbuckle the seat belt only after stopping the engine.

• Before leaving the machine, secure it to prevent it from rolling away

(for example with the parking brake, suitable wheel chocks).

• Remove the starting key an d secure the machine against unauthorized

operation.

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2 Safety

2.5 Lifting gear applications

Requirements

• Have loads fastened and the operator guided by a qualified person having specific knowledge of lifting gear applicat ion s an d th e us ua l hand signals.

• The person giving instructions to the operator must stay in visual contact with the operator when fastening, guiding or removing the load (maintain visual contact).

• If this not be possible, ask one more person with the same qualifications to guide.

• The operator may not leave his seat as long as the load is raised.

Fastening, guiding and removing loads

• Follow the applicable specific regulations for fastening, guiding and removing a load.

• Wear protective clothing and equipment when fastening, guiding and removing loads (for example a hard hat, safety glasses, protective gloves, safety boots).

• Do not place lifting and fastening gear over sharp edges or rotating parts. Loads must be fastened so as to prevent them from slipping or falling.

• Move loads only on horizontal, level and firm ground.

• Move loads close to the ground.

• In order to avoid oscillating movements of loads:

- Perform smooth, slow movements with the machine.

- Use cables to guide the load (do not use hands to guide).

- Bear in mind the weather conditions (for example the wind force).

- Keep a minimum safety distance from objects.

• The operator may allow the load to be fastened and removed only if the machine and its work equipment are not being moved.

• Danger zones must not over lap with the work zones of other machines.

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Lifting gear applications

Safety 2

• The machine must be certified for lifting gear applications.

• Observe the national regulations for lifting gear applications.

• Lifting gear applications are procedures involving raising, transporting

and lowering loads with the help of lifting and fastening gear.

• The help of an accompanying person is necessary for fastening,

guiding and removing the load.

• There must be nobody under the load.

• Stop the mach ine immediately and stop th e engine if persons enter the

danger zone.

• Use the machine for lifting gear applications ONLY if the mandatory

lifting gear (for example a joint rod and load hook) and safety equipment (for example optical and acoustic warning devices, hose burst valve, stability table) is installed and functional.

• Use only lifting and fastening gear certified by a test/certification body,

observe the inspection intervals (Use only chains and shackles. No belts, slings or cables).

• Do not use any lifting and fastening gear that is dirty, damaged or not

of sufficient size.

• Do not interrupt the work process with a load attached.

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2 Safety

2.6 Trailer operation

Trailer operation

• The machine must be certified for trailer operation.

• Observe the natio nal regulations for trailer operation.

• The specific national driving license is required.

• Carrying passengers on/in trailers is PROHIBITED.

• Observe the maximum permissible vertical and trailer load.

• Do not exceed the permissible trailer speed.

• Trailer operation with the towing gear of the machine is prohibited.

• Trailer operation changes the machine’s operating behavior, the operator must be familiar with this and act accordingly.

• Bear in mind the machine’s steering mode and the trailer’s turning circle.

• Before hitching/unhitching the tra iler, secure it to prevent it from rolling away (for example with the parking brake, suitable wheel chocks).

• There must be nobody between the machine and the trailer when hitching a trailer.

• Hitch the trailer onto the machine correctly.

• Ensure that all equipment works correctly (for example the brakes, lights).

• Before starting machine travel, ensure that nobody is between the machine and the trailer.

2.7 Attachment operation

Attachments

• Use only attachments that are certif ied for the machine or its protective equipment (for example a shatter protection).

• All other attachments require the machine manufacturer’s release.

• The danger zon e and the work zon e depend on the attachment used – see the Operator’s Manual of the attachment.

• Secure the load.

• Do not overload attachments.

• Check the correct position of the lock.

Operation

• Carrying persons on/in an attachment is prohibited.

• Installing a work platform is prohibited.

- Exception: The machine is certified and equipped with th e necessary

• Attachments and counterweights modify handling, as well as the steering and brake capability of the machine.

• The operator must be familiar with these modifications and act accordingly.

• Before starting work, operate the attachment to check that it works correctly.

• Before putting the attachment into operation, ensure that nobody is in danger.

• Lower the attachment to the ground before leaving the operator seat.

safety equipment.

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Removing and fitting attachments

• Before uncoupling or coupling hydraulic connections:

- Stop the engine

- Releasing the pressure in the operating hydraulics

• Picking up and lowering attachments to the ground require s special

care:

- Pick up and safely lock the attachment in accordance with the Operator’s Manual.

- Lower the attachment only to firm, level ground and secure it to prevent it from tipping over or rolling away.

• Put the machine and the attachment into operation only if:

- The protective equipment has been installed and is functional.

- The connections for the lights and the hy dr au lic syst em ha ve be e n established and are functional.

• Perform a visual check of the lock after locking the attachment.

• There must be n obody b etwe en th e m achine and the eq uipm ent whe n picking up or lowering an attachment to the ground.

2.8 Towing, loading and transporting

Towing

• Seal off the danger zone.

• Ensure that no one is near the towing bar or cable. The safety distance is equal to 1.5 times the length of the towing equipment. Use a towing cable for machines with a total weight of up to 4.0 tons. Use a towing bar for machines with a total weight of over 4.0 tons.

• Observe the mandatory transport position, permissible speed and itinerary.

• A tractor vehicle of the same weight category must be used as a minimum. Furthermore, the tractor vehicle must be equipped with a safe braking system and sufficient tractive power.

• Use only towing bars or cables certified by a test/certification body, observe the inspection intervals.

• Do not use any towin g bars or cables that are dirty, damaged or not of sufficient size.

• Fasten towing bars or cables only at the defined points.

• Tow away only in accordance with this Operator’s Manual to avoid damage to the machine.

• Observe the national regulations (for example the light regulations) when towing on public roads/sites.

Safety 2

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2 Safety

Crane-lifting

• Seal off the danger zone.

• The crane and the lifting gear must have suitable dimensions.

• Observe the machine’s overall weight – see “Technical data”.

• Wear protective clothing and equipment when fastening, guiding and removing the machine (for example a hard hat, safety glasses, safety boots).

• Use only lifting and fastening gear certified by a test/certification body (for example cables, belts, hooks, shackles), observe the inspection intervals.

• Do not use any lifting and fastening gear that is dirty, damaged or not of sufficient size.

• Perform a visual check to ensure that all slinging points are neither damaged nor worn (no widening, no sharp edges, no cracks).

• Have loads fastene d and crane operators only guided by experienced persons.

• The person guid ing the crane oper ator must be within sight or sound of him.

• Observe all movements of the machine and lifting gea r.

• Secure the machine against unintentional movement.

• Raise the machine only after it is safely attached and the person attaching the machine has given his approval.

• Use only the slinging points provided for fastening the lifting gear (for example cables, belts).

• Do not attach the machine by twining the lifting gear (for example cables, belts) around it.

• Ensure an even load distribution (center of gravity!) when fastening the lifting gear.

• Ensure that no one is in, on or under the machine when loading the machine.

• Observe the national regulations (for example “Merkheft Erdbaumaschinen”, leaflet on earth moving machines of the German employers’ liability insurance association for construction engineering).

• Load the machine only in accordance with this Operator’s Manual to avoid damage to the machine.

• Do not raise a machine that is stuck or frozen onto the ground, for example.

• Bear in mind the weather conditions (for example the wind force, visibility conditions).

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+ 198 hidden pages

Wacker Neuson DW100, DW60, DW90 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 Foreword

1.1 Operator’s Manual

1.2 Warranty and liability

2 Safety

2.1 Safety symbols and signal words

2.2 Qualification of operating personnel

2.3 Conduct

2.4 Operation

2.5 Lifting gear applications

2.6 Trailer operation

2.7 Attachment operation

2.8 Towing, loading and transporting