Wacker Neuson DW60 DW90 DW100 Dumper Service Manual – PDF DOWNLOAD

Description

Wacker Neuson DW60 DW90 DW100 Dumper Service Manual – PDF DOWNLOAD

FILE DETAILS:

Wacker Neuson DW60 DW90 DW100 Dumper Service Manual – PDF DOWNLOAD

Language : English
Pages : 264
Downloadable : Yes
File Type : PDF
Size: 14.9 MB

Machine models D18-01/D18-02/D18-03
Edition 1.4
Document order number 1000333465
Language en

IMAGES PREVIEW OF THE MANUAL:

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DESCRIPTION:

Wacker Neuson DW60 DW90 DW100 Dumper Service Manual – PDF DOWNLOAD

Operation:
1.1 Information on this service manual:

This service 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. It helps to avoid hazardous situations
and reduce repair costs and downtimes.
Furthermore, the reliability and the service life of the machine will be increased by following
the instructions in the Operator’s Manual.
Careful and prudent working is the best way to avoid accidents!
Operational safety and readiness of the machine do not only depend on your skill, but also
on maintenance and servicing of the machine. This is why regular maintenance and servicing
is absolutely necessary.
Extensive maintenance and repair work must always be performed by a Wacker Neuson
service center. Use only original spare parts for repairs. This ensures operational safety
and readiness of your machine, and maintains its value.
• We reserve the right to improve the technical standard of our machines without
adapting the service manual.
• Modifying Wacker Neuson products and fitting them with additional equipment and
attachments 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.
• Subject to modifications and printing errors.
Your Wacker Neuson dealer will be pleased to answer any further questions regarding the
machine or the service manual.

TABLE OF CONTENTS:

Wacker Neuson DW60 DW90 DW100 Dumper Service Manual – PDF DOWNLOAD

Operation
Information on this service manual 1-2
Identification of warnings and dangers 1-3
Explanation of symbols and abbreviations 1-3
Abbreviations 1-4
Conversion table 1-5
Warranty and liability 1-6
Exemption from warranty and liability 1-6
Labels 1-7
Type labels 1-7
Machine overview 1-10
Vehicle repair after recovery 1-12
Enabling the Pressure relief valve 1-12
Enabling the hydraulic parking 1-12
Fire extinguisher 1-13
Technical data
Model designations and trade names 2-2
Engine 2-3
Traveling drive/axles 2-4
Brakes 2-4
Tires 2-5
Steering system 2-5
Work hydraulics 2-6
Maximum speed 2-7
Coolant 2-8
Compound table 2-8
Noise emissions 2-8
Vibration 2-8
Hose identification code 2-8
Weight 2-9
Machine weights 2-9
Ground clearance 2-9
Payload/stability 2-10
Electrical system 2-11
Fuse box 2-11
Bulbs 2-13
Tightening torques 2-13
Model-specific tightening torques 2-13
General tightening torques 2-13
Tightening torques for hydraulic threaded fittings (dry assembly) 2-14
Tightening torques for high-resistance threaded fittings 2-16
Dimensions 2-18
Front skip (overview) 2-18
Swivel skip with rollbar (overview) 2-20
Swivel skip with cabin (overview) 2-22
Maintenance
Fluids and lubricants 3-2
Engine oil types (temperature-dependent) 3-4
Hydraulic oil types (depending on temperature) 3-4
Important information regarding operation with biodegradable hydraulic oil 3-5
Maintenance overview 3-6
Maintenance label 3-6
Lubrication work 3-9
Table of contents
I-2 SHB D18 en – Edition 1 4 * * D18sIVZ fm
Table of contents
Preparing lubrication 3-9
Lubrication plan 3-10
Maintenance plan 3-11
Information on maintenance 3-16
Responsibilities and prerequisites 3-16
Important safety instructions on maintenance 3-16
Maintenance accesses 3-17
Service flaps 3-17
Fan grid 3-18
Underbody maintenance access 3-18
Control stand maintenance access 3-18
Fuse box 3-19
Battery case 3-19
Battery master switch 3-19
Fuel system 3-20
Important information regarding the fuel system 3-20
Diesel fuel specification 3-20
Refueling 3-20
Water separator 3-22
Emptying the water separator 3-22
Replacing the water-separator prefilter element 3-23
Replacing the fuel filter 3-24
Bleeding the fuel system 3-27
Replace the breather filter of the fuel tank 3-28
Emptying the fuel tank 3-28
Engine lubrication system 3-29
Important information regarding the engine lubrication system 3-29
Checking the engine oil level 3-30
Adding engine oil 3-30
Changing engine oil 3-31
Replacing the engine-oil filter cartridge 3-32
Cooling system 3-34
Important information regarding the cooling system 3-34
Checking the coolant level 3-35
Adding coolant 3-35
Leakage check 3-35
Checking the antifreeze 3-36
Draining coolant 3-36
Replace the radiator cap 3-37
Cleaning the radiator 3-38
Checking/cleaning the condenser 3-39
Air filter 3-40
Important information regarding the air filter 3-40
Air filter monitoring 3-40
Replacing the air filter 3-40
Clean the dust valve 3-41
Checking the air intake 3-42
Replacing/cleaning the cabin air filter 3-42
Washer system 3-43
Important information regarding the washer system 3-43
Checking the fluid level and adding fluid 3-43
V-belt 3-44
Checking V-belt tension Tier III 3-44
Replacing the V-belt 3-44
Replacing the V-belt of the air conditioning system (option) Tier IV 3-46
Replace the crankcase breather filter 3-47
Pressure check 3-48
SHB D18 en – Edition 1 4 * D18sIVZ fm I-3
Table of contents
General 3-48
Prerequisites for pressure check 3-48
Preparations 3-48
Measurement connections 3-49
Checking main pressure 3-51
Checking the boost pressure of the hydraulic pump 3-52
Checking the operating hydraulics pressure 3-52
Adjusting the operating hydraulics pressure 3-52
Test report 3-53
Hydraulic system 3-55
Important information on the hydraulic system 3-55
Checking the hydraulic oil level 3-56
Adding hydraulic oil 3-56
Changing hydraulic oil 3-57
Replacing the filter insert of the machine-travel hydraulics 3-58
Replacing the filter insert of the operating hydraulics 3-58
Draining condensation water from the hydraulic oil reservoir 3-59
Replace the breather filter of the hydraulic oil reservoir 3-60
Checking the hydraulic system for leaks 3-60
Checking the condition and age of hydraulic hoses 3-61
Tires 3-62
Tires 3-62
Inspection work 3-62
Wheel change 3-63
Axles/traveling drive/transfer gearbox 3-64
Checking the oil level of the traveling drive 3-64
Checking the oil level of an axle 3-64
Checking the oil level of the transfer gearbox 3-65
Oil change planetary drive 3-66
Oil change in axles 3-66
Oil change on transfer gearbox 3-67
Leakage check 3-67
Braking system 3-68
Checking the brake fluid 3-68
Leakage check 3-68
Replacing the brake fluid 3-69
Air conditioning 3-70
Checking the air-conditioning compressor 3-71
Checking the refrigerant level 3-71
Checking the dehumidifier 3-72
Replacing the dehumidifier 3-73
Replacing the refrigerant 3-74
Replace the air conditioning compressor oil 3-75
Electrical system 3-76
Important information regarding the electrical system 3-76
Fuses and relays 3-76
Battery state of charge 3-77
Charging the battery 3-77
Removing the battery 3-77
Installing the battery 3-78
Checking electric cables and connectors 3-78
Exhaust gas treatment 3-79
Automatic regeneration/manual regeneration 3-79
Service regeneration 3-79
Resetting the maintenance meter 3-81
I-4 SHB D18 en – Edition 1 4 * * D18sIVZ fm
Table of contents
Engine
Perkins engine 854F-E34TTF 4-2
Engine overview 4-2
Engine exhaust aftertreatment system 4-7
Representation with auxiliary-flow diesel particulate filter 4-8
Engine block overview 4-9
Representation with separate intake-manifold pressure sensor and temperature
sensor 4-10
Turbocharger 4-11
Replacing the oxygen sensor 4-11
Check the water pump (visual check) 4-12
Fuel system 4-13
Engine malfunctions 4-14
Perkins engine 854E-E34TAWF/854F-E34TWF 4-17
Perkins Engine overview 854E-E34TAWF/854F-E34TWF 4-17
Engine exhaust aftertreatment system 4-22
Engine block overview 4-23
Turbocharger 4-24
Clean the diesel particulate filter 4-24
Replacing the oxygen sensor 4-24
Check the water pump (visual check) 4-25
Fuel system 4-26
Engine malfunctions 4-27
Perkins engine 1104D-44T 4-30
Overview of Perkins engine 1104D-44T 4-30
Turbocharger 4-32
Check the water pump (visual check) 4-33
Check valve clearance, adjust if necessary 4-33
Check the injection nozzles and clean and test them if necessary 4-33
Fuel system 4-34
Hydraulic system
Hydraulic pump 5-2
Hydraulic pump 5-3
Diagram 5-5
Standard operating pump 5-6
Steering valve 5-7
Priority valve 5-8
Main control block 5-9
Pressure relief valve 5-10
Secondary pressure limiting valve swiveling cylinder (swivel skip option) 5-10
Primary pressure limiting valve 5-11
Brake valve 5-12
Gearbox changeover valve (DW90/DW100) 5-13
Master brake cylinder 5-14
Traveling drive 5-15
Function 5-15
Hydraulic motor 5-16
Malfunctions of the hydraulic system 5-17
Electrical system
Ohmic law (current, voltage, resistance); Power 6-2
Measuring equipment, measuring methods 6-2
Cable color coding 6-3
Relays 6-4
Use, mode of function 6-4
Electrical system 6-4
Alternator 6-4
SHB D18 en – Edition 1 4 * D18sIVZ fm I-5
Table of contents
Starter 6-4
Lights wiring harness 6-6
Main wiring harness Tier IV 6-7
(up to serial no WNCD1801LPAL00293 (DW60), WNCD1802LPAL00206 (DW90),
WNCD1803KPAL00160 (DW100)) 6-7
List of strands 6-7
Main wiring harness Tier IV 6-12
Main wiring harness connector assignment Tier IV 6-13
Main wiring harness Tier IV 6-14
(from serial no WNCD1801HPAL00294 (DW60), WNCD1802HPAL00207 (DW90),
WNCD1803JPAL00161 (DW100)) 6-14
List of strands 6-14
Main wiring harness Tier IV 6-18
Main wiring harness Tier III 6-19
(up to serial no WNCD1801LPAL00293 (DW60) WNCD1802LPAL00206 (DW90)
WNCD1803KPAL00160 (DW100)) 6-19
List of strands 6-19
Main wiring harness Tier III 6-22
Main wiring harness Tier III 6-24
(from serial no WNCD1801HPAL00294 (DW60), WNCD1802HPAL00207 (DW90),
WNCD1803JPAL00161 (DW100)) 6-24
List of strands 6-24
Main wiring harness Tier III 6-27
Rear wiring harness (up to serial numbers WNCD1801EPAL00717 (DW60),
WNCD1802APAL00463 (DW90), WNCD1803KPAL00191 (DW100)) 6-28
Rear wiring harness (from serial numbers WNCD1801EPAL00717 (DW60),
WNCD1802APAL00463 (DW90), WNCD1803KPAL00191 (DW100)) 6-29
Front lights wiring harness 6-30
Socket wiring harness 6-31
Seat console wiring harness 6-32
(up to serial no WNCD1801LPAL00293 (DW60), WNCD1802LPAL00206 (DW90),
WNCD1803KPAL00160 (DW100)) 6-32
List of strands 6-32
Seat console wiring harness 6-33
Seat console wiring harness 6-34
(from serial no WNCD1801HPAL00294 (DW60), WNCD1802HPAL00207 (DW90),
WNCD1803JPAL00161 (DW100)) 6-34
List of strands 6-34
Seat console wiring harness 6-35
Battery wiring harness 6-36
Clearance lights wiring harness 6-37
Numberplate light wiring harness
(up to serial numbers WNCD1801TPAL00574 (DW60), WNCD1802HPAL00367
(DW90), WNCD1803KPAL00188 (DW100)) 6-38
Numberplate light wiring harness
(from serial numbers WNCD1801TPAL00574 (DW60), WNCD1802HPAL00367
(DW90), WNCD1803KPAL00188 (DW100)) 6-39
Cabin wiring harness 6-40
List of strands 6-40
Cabin wiring harness 6-41
I-6 SHB D18 en – Edition 1 4 * * D18sIVZ fm
Table of contents
Diagrams
Hydraulics diagram (legend) 7-2
Hydraulics diagram DW60/DW60P/DW60 LRC 7-3
Hydraulics diagram DW90/DW100 7-4
Wiring diagram (legend) 7-5
Wiring diagram Tier III 7-6
Wiring diagram Tier IV (DW60 up to serial number WNCD1801LPAL00570) 7-8
7-9
Wiring diagram legend Tier IV (DW 60 from serial number WNCD1801HPAL00571
7-10
Wiring diagram Tier IV (DW 60 from serial number WNCD1801HPAL00571) 7-11
7-12
Options
Immobilizer (option) 8-2
Diagnosis code list (SPN)

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

S.V