Neuson Dumper 1001 Bedienungsanleitung

Dumper

1001, 1501, 2001

OPERATOR’S MANUAL

1000184998 2.3

0608

1000184998

Documentation

Description Order no.

Operator's Manual 1000184998

Service manual 1001

1501

2001

1000144662

1000144667

1000154504

Spare parts catalogue 1001

1501

2001

1000135891/1000164057

1000165936/1000135893

1000110328

Legend

Edition Issued

2.3 06/2008

Printed in Michigan U.S.A

Nopartofthispublicationmay be reproduced, translated or used in any form orbyanymeans–graphic, electronic

or mechanical including photocopying, recording, taping or information storage orretrieval systems – without prior

permission in writing from the manufacturer.

The cover features the machine with possible optional equipment.

Neuson Baumaschinen GmbH

Haidfeldstr. 37

A-4060 Linz-Leonding

Document: BA 1001/1501/2001 US

Order no.: 1000184998

Edition: 2.3

BA 1001/1501/2001 US - Edition 2.3 * Ba12001us2_3IVZ.fm T-1

Table of contents

Introduction....................................................................................................................... 1

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

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

Operator Qualifications ............................................................................................ 1-2

EC declaration of conformity dumper 1001AB (serial number: AB ...) ..................... 1-3

EC declaration of conformity dumper 1501AB from serial number: AB ... ............... 1-4

EC declaration of conformity dumper 2001 CB (serial number: CB ...) ................... 1-5

Type labels and component numbers ...................................................................... 1-6

Label Overview 1001 ............................................................................................... 1-7

Symbol descriptions ................................................................................................. 1-8

Safety Information ............................................................................................................ 2

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

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

Designated Use ....................................................................................................... 2-2

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

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

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

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

Staff Qualifications and Basic Responsibilities ........................................................ 2-4

User/owner responsibility .................................................................................. 2-4

Repair person qualifications .............................................................................. 2-4

Safety instructions Regarding Operation ................................................................. 2-4

Preparing for use ............................................................................................... 2-4

Startup and shutdown ........................................................................................ 2-4

........................................................................................................................... 2-5

Work area awareness ........................................................................................ 2-5

Danger area awareness .................................................................................... 2-5

Operating the machine ...................................................................................... 2-5

Carrying passengers ......................................................................................... 2-6

Mechanical integrity ........................................................................................... 2-6

Driving on public roads ...................................................................................... 2-6

Trailering and Transport .......................................................................................... 2-7

Trailers ............................................................................................................... 2-7

Transport ........................................................................................................... 2-7

Temperature Range ................................................................................................. 2-7

Safety Guidelines for Maintenance .......................................................................... 2-7

General maintenance notes .............................................................................. 2-7

Personal safety measures ................................................................................. 2-8

Preparing for maintenance and repair work ...................................................... 2-8

Performing maintenance and repairs ................................................................ 2-9

Special Hazards ....................................................................................................... 2-9

Battery ............................................................................................................... 2-9

Tracks (Track dumpers) .................................................................................. 2-9

Electric energy ................................................................................................... 2-9

Safety Guidelines while using Internal Combustion Engines ................................. 2-11

Guidelines for running the engine .................................................................... 2-11

Guidelines for fueling the engine ..................................................................... 2-11

Operation ........................................................................................................................... 3

Table of contents

T-2 BA 1001/1501/2001 US - Edition 2.3 * * Ba12001us2_3IVZ.fm

Table of contents

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

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

1001/1501/1501S operating equipment up to serial number AC ... ......................... 3-6

1001/1501/1501S operating equipment from serial number AB ... .......................... 3-7

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

Putting the machine into operation .......................................................................... 3-9

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

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

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

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

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

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

Parking checklist .............................................................................................. 3-11

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

Preheating/start switch: overview .................................................................... 3-12

Accelerator pedal: overview ............................................................................. 3-12

indicators and warning lights: overview .......................................................... 3-13

Before starting the engine ................................................................................ 3-15

Starting the engine: general ............................................................................. 3-15

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

When the engine has started ... ....................................................................... 3-16

Engine warm-up ............................................................................................... 3-16

Jump-starting the engine (supply battery) ....................................................... 3-16

Special instructions for traveling on public roads ............................................. 3-18

Moving off ........................................................................................................ 3-18

Hydraulic brake ................................................................................................ 3-19

Mechanical brake ............................................................................................. 3-19

Hazard warning system ......................................................................................... 3-19

Driving on slopes ................................................................................................... 3-20

Specific safety instructions .............................................................................. 3-20

Driving on slopes with a loaded dump bucket ................................................. 3-21

Driving on slopes with an empty dump bucket ................................................ 3-21

Driving across slopes ....................................................................................... 3-21

Parking the machine ........................................................................................ 3-21

Loading the machine ....................................................................................... 3-22

Seat adjustment ..................................................................................................... 3-23

Weight adjustment ........................................................................................... 3-23

Horizontal adjustment ...................................................................................... 3-23

Backrest adjustment ........................................................................................ 3-23

Seat belt ................................................................................................................. 3-24

Engine cover .................................................................................................... 3-25

Working with the machine ...................................................................................... 3-26

General safety instructions .............................................................................. 3-26

High-tip dump bucket operation (1001 + 1501H + 1501S) .................................... 3-27

Swivel dump bucket operation ............................................................................... 3-28

Loader unit (2001 SLE) .......................................................................................... 3-29

Information on working with the loader unit (if equipped) ...................................... 3-31

Rollbar .................................................................................................................... 3-31

Towing 1001/1501/1501 S/2001 ............................................................................ 3-32

Opening the high-pressure circuit 1001/1501/1501 S ..................................... 3-32

Releasing the hydraulic parking brake 1001/1501/1501 S .................................... 3-32

Opening the high-pressure circuit 2001 ................................................................. 3-33

Releasing the hydraulic parking brake 2001 .......................................................... 3-33

Articulated steering locking bar .............................................................................. 3-34

Locking the control levers ...................................................................................... 3-34

Lifting the machine ................................................................................................. 3-35

Loading and transporting the machine ............................................................ 3-36

BA 1001/1501/2001 US - Edition 2.3 * Ba12001us2_3IVZ.fm T-3

Table of contents

Strapping down the machine ........................................................................... 3-37

Battery master switch 1001 – 1501 ....................................................................... 3-37

Troubleshooting................................................................................................................ 4

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

Maintenance ...................................................................................................................... 5

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

Front dump bucket maintenance strut 1001 ...................................................... 5-1

Maintenance strut, model 1501 ............................................................................... 5-2

Maintenance strut 2001 ........................................................................................... 5-3

Fuel system ............................................................................................................. 5-4

Specific safety instructions ................................................................................ 5-4

Refueling ........................................................................................................... 5-4

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

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

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

Fuel prefilter with water separator ..................................................................... 5-6

Replacing the fuel filter ...................................................................................... 5-7

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

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

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

Engine and hydraulics cooling system ................................................................... 5-10

Checking/filling up coolant ............................................................................... 5-10

Specific safety instructions .............................................................................. 5-11

Air filter ................................................................................................................... 5-13

Replacing the filter ........................................................................................... 5-14

V-belt ..................................................................................................................... 5-14

Checking V-belt tension ................................................................................... 5-15

Retightening the V-belt .................................................................................... 5-15

Hydraulic system ................................................................................................... 5-16

Specific safety instructions .............................................................................. 5-16

Checking the hydraulic oil level ....................................................................... 5-18

Filling up hydraulic oil ...................................................................................... 5-19

Changing hydraulic oil ..................................................................................... 5-20

Fouling indicator for hydraulic oil filter ............................................................. 5-20

Replacing the hydraulic oil filter element ......................................................... 5-20

Important information for the use of biodegradable oil .................................... 5-21

Checking hydraulic pressure lines ................................................................... 5-22

Specific safety instructions .............................................................................. 5-22

Tires ....................................................................................................................... 5-23

Inspection work ................................................................................................ 5-23

Wheel change .................................................................................................. 5-24

Electric system ....................................................................................................... 5-25

Specific safety instructions .............................................................................. 5-25

Service and maintenance work at regular intervals ......................................... 5-25

Instructions concerning specific components .................................................. 5-26

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

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

General maintenance work .................................................................................... 5-27

Cleaning .......................................................................................................... 5-27

General instructions for all areas of the machine ............................................ 5-27

Exterior of the machine .................................................................................... 5-28

Engine compartment ....................................................................................... 5-28

Screw connections and attachments ............................................................... 5-28

Pivots and hinges ............................................................................................ 5-28

T-4 BA 1001/1501/2001 US - Edition 2.3 * * Ba12001us2_3IVZ.fm

Table of contents

Engine/machine fluids and lubricants (1001 and 1501) ......................................... 5-29

Engine/machine fluids and lubricants (2001) ......................................................... 5-31

Maintenance plan 1001 – 1501: overview ............................................................. 5-33

Maintenance plan 2001: overview ......................................................................... 5-36

Lubrication points 1001: overview .......................................................................... 5-40

Lubrication points 1501: overview .......................................................................... 5-41

Lubrication points 1501S: overview ....................................................................... 5-42

Lubrication points 2001: overview .......................................................................... 5-43

Specifications (1001 – 1501) ............................................................................................6

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

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

Travelling drive ......................................................................................................... 6-2

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

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

Work hydraulics ....................................................................................................... 6-2

Loader unit............................................................................................................... 6-2

Drive specifications.................................................................................................. 6-3

Electric system (up to AC000101) ........................................................................... 6-3

Fuse box ............................................................................................................ 6-3

Relays ................................................................................................................ 6-4

Electric system (from AB150001H/150002D) .......................................................... 6-4

Fuse box ............................................................................................................ 6-4

Relays ...................................................................................................................... 6-5

Tyres 1001/1501/2001 ....................................................................................... 6-5

Noise levels ............................................................................................................. 6-5

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

Dimensions model 1001 .......................................................................................... 6-7

Dimensions model 1501 .......................................................................................... 6-8

Dimensions model 1501S ........................................................................................ 6-9

Specifications (2001) ........................................................................................................6

Engine .................................................................................................................... 6-10

Travelling drive ....................................................................................................... 6-11

Brakes .................................................................................................................... 6-11

Steering system ..................................................................................................... 6-11

Work hydraulics ..................................................................................................... 6-11

Loader unit ............................................................................................................. 6-12

Drive specifications ................................................................................................ 6-12

Electric system ....................................................................................................... 6-12

Fuse box .......................................................................................................... 6-12

Relays .............................................................................................................. 6-13

Tires ....................................................................................................................... 6-14

Noise levels ............................................................................................................ 6-14

Coolant compound table ........................................................................................ 6-14

Tyres ...................................................................................................................... 6-15

Noise levels ............................................................................................................ 6-15

Coolant compound table ........................................................................................ 6-15

Dimensions model 2001 ........................................................................................ 6-16

BA 1001/1501/2001 US - Edition 2.3 * Ba12001us2_3SIX.fm I-1

Index

Numerisch

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

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

Air filter ................................................................................................ 5-13

Biodegradable oil ................................................................................ 5-21

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

Crane-handling bracket ....................................................................... 3-35

Driving on public roads ....................................................................... 3-18

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

Fastening the seat belt ........................................................................ 3-24

Fluids and lubricants .................................................................. 5-29, 5-31

Important information

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

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

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

Machine

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

Loading and transporting ............................................................. 3-36

Maintenance

Air filter ......................................................................................... 5-14

Biodegradable oil ......................................................................... 5-21

Checking the coolant level ........................................................... 5-11

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

Checking the hydraulic oil level .................................................... 5-18

Cleaning ....................................................................................... 5-27

Electric system ............................................................................. 5-25

Engine and hydraulics coolingsystem ......................................... 5-10

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

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

Filling up coolant .......................................................................... 5-11

Filling up hydraulic oil ................................................................... 5-19

Fluids and lubricants ........................................................... 5-29, 5-31

Fuel system .................................................................................... 5-4

General maintenance work .......................................................... 5-27

Hydraulic pressure lines ............................................................... 5-22

Hydraulic system .......................................................................... 5-16

Instructions concerning specific components .............................. 5-26

Maintenance plan ................................................................ 5-33, 5-36

Pivots and hinges ......................................................................... 5-28

Replacing the fuel filter .................................................................. 5-7

Screw connections ....................................................................... 5-28

Service and maintenance work at regular intervals ..................... 5-25

Tyres ............................................................................................ 5-23

V-belt ............................................................................................ 5-14

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

Before starting the engine ............................................................ 3-15

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

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

Description of 1501S components (overview) ................................ 3-3

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

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

Parking the machine ..................................................................... 3-21

Seat belt height adjustment .......................................................... 3-24

Starting the engine ....................................................................... 3-15

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

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

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

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

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

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

Rollbar ................................................................................................. 3-31

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

Seat adjustment ..................................................................................3-23

Backrest adjustment .....................................................................3-23

Horizontal adjustment ................................................................... 3-23

Weight adjustment ........................................................................ 3-23

Seat belt ..............................................................................................3-24

Specifications ...............................................................................6-1, 6-10

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

Coolant compound table .....................................................6-14, 6-15

Dimensions ............................................................. 6-7, 6-8, 6-9, 6-16

Electric system ...............................................................6-3, 6-4, 6-12

Engine ...................................................................................6-1, 6-10

Noise levels ..................................................................6-5, 6-14, 6-15

Starting aid .......................................................................................... 3-16

Telltales ............................................................................................... 3-13

Tyres ................................................................................................... 5-23

Index

I-2 BA 1001/1501/2001 US - Edition 2.3 * * Ba12001us2_3SIX.fm

Index

BA 1001/1501/2001 US – Edition 2.3 * 12001b110.fm 1-1

Introduction

1 Introduction

1.1 Important information on this Operator's Manual

Please store the Operator's Manual in the storage bin under the engine cover.

This Operator's Manual contains important information on how to work safely, correctly

andeconomicallywiththemachine.Therefore,itaimsnotonlyatnewoperators,butitalso

serves as a reference for experienced ones. It helps to avoid dangerous situations and

reduce repair costs and downtimes. Furthermore, the reliability and the service life of the

machine will be increased by following the instructions in the Operator's Manual. This is

why the Operator's Manual must always be kept at hand on the machine.

Your own safety, as well as the safety of others, depends to a great extent on how the

machine is moved and operated. Therefore, carefully read and understand this Operator's

Manual prior to the first drive. This Operator's Manual will help to 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

preparedforpossibledangeroussituations,asitwillbetoolateforitduringoperation.Asa

rule, keep the following in mind:

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

Operationalsafety andreadiness ofthe machinedo notonly depend on your skill,but also

on maintenance and servicing of the machine. This is why regular maintenance and

serviceworkisabsolutelynecessary.Extensivemaintenanceandrepairworkmustalways

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 answerany further questions regarding the

machine or the Operator's Manual.

Abbreviations/symbols

• This symbol stands for a list

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

☞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.

1-2 BA 1001/1501/2001 US – Edition 2.3 * * 12001b110.fm

Introduction

1.2 Brief description

The model 1001/1501/2001 dumpers are self-propelled work machines.

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

This machine is a versatile and powerful helper for moving earth, gravel and debris on

construction sites and elsewhere. The main components of the machine are:

• Rollbar

• Hydraulic swivel dump bucket or front dump bucket

• Yanmar three cylinder diesel engine

• Sturdy steel sheet chassis

1.3 Operator Qualifications

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.

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