1001 Operators Manual DUMPER

User manual
Dumper
1001/1501/2001
Edition: 01 / 2007
Spare part No.: 1000103795
Language: English
Contents
Introduction ............................................................................................................................................................. 10
1 Warranty ....................................................................................................................................................... 10
1.1Type plate ............................................................................................................................................... 11
1.2Instructions for ordering spare parts ...................................................................................................... 11
2 Safety ........................................................................................................................................................... 12
2.1Safety rules ............................................................................................................................................. 13
2.2Use ......................................................................................................................................................... 16
2.3EC- Declaration of Conformity 1001 ....................................................................................................... 17
2.4EC-Declaration of Conformity 1501 ......................................................................................................... 18
2.5EC- Declaration of Conformity ................................................................................................................ 19
3 Description................................................................................................................................................... 20
3.1Technical specifications ......................................................................................................................... 20
Dimensions 1001 .................................................................................................................................... 20
Main specifications 1001 ........................................................................................................................ 20
Dimensions 1501 .................................................................................................................................... 21
Dimensions 1501 S ................................................................................................................................ 22
Main specifications 1501 S ..................................................................................................................... 22
Dimensions 2001 .................................................................................................................................... 23
Dimensions 2001 SLE ............................................................................................................................ 24
Main specifications 2001 SLE ................................................................................................................ 24
9707033_User manual_en
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Contents
Engine 1001 ........................................................................................................................................... 25
Engine 1501/1501 S ............................................................................................................................... 25
Engine 2001/2001SLE ............................................................................................................................ 25
Drive gear ............................................................................................................................................... 26
Brakes Dumper 1001/1501/1501 S ......................................................................................................... 26
Brakes Dumper 2001 .............................................................................................................................. 26
Steering .................................................................................................................................................. 26
Working hydraulics ................................................................................................................................. 26
Hydrauliktank .......................................................................................................................................... 27
Tires ........................................................................................................................................................ 27
Articulated frame steering structure ........................................................................................................ 27
Noise emission ...................................................................................................................................... 27
Vibrations ................................................................................................................................................ 27
Fire extinguisher ..................................................................................................................................... 27
Adhesive labels ..................................................................................................................................... 28
Label position ......................................................................................................................................... 28
4 Sub-assembly identification 1001/1501 ....................................................................................................... 32
Sub-assembly identification 1501 S ....................................................................................................... 33
Sub-assembly identification 2001 .......................................................................................................... 34
Sub-assembly identification 2001 SLE ................................................................................................... 35
4.1 Operating equipment 1001/1501/1501 S up to serial number AB..... ......................................................... 36
Operating equipment 1001/1501/1501 S from serial number AB..... ..................................................... 37
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Contents
Operating equipment 2001 / 2001SLE ................................................................................................... 38
Arrangement of the fuses in the fuse box Dumper 1001/1501/1501 S from serial number AB.... ......... 39
Arrangement of the fuses in the fuse box Dumper 2001 ....................................................................... 39
Arrangement of the fuses in the fuse box Dumper 1001/1501/1501 S up to serial number AB.... ........ 39
4.2 Drivers seat + rollover bar + overhead guard Dumper 2001 ..................................................................... 40
Standard drivers seat ............................................................................................................................ 40
Drivers seat with ROPS roll bar ............................................................................................................. 40
Overroll Bar ROPS ................................................................................................................................. 40
Overhead guard FOPS .......................................................................................................................... 40
5 Lifting the dumper ........................................................................................................................................ 41
6 Loading and transport .................................................................................................................................. 42
7 Towing device ............................................................................................................................................. 42
8 Loader unit (2001 SLE) ................................................................................................................................ 43
Information on working with the loader unit ............................................................................................ 44
9 Towing the dumper ...................................................................................................................................... 45
9.1Open high-pressue circuit 1001/1501/1501 S ........................................................................................ 45
9.2Loosen spring-loaded brake 1001/1501/1501 S .................................................................................... 45
9.3Opening the high-pressure circuit 2001 ................................................................................................. 46
9.4Releasing the spring-loaded brake 2001 .............................................................................................. 46
10 Inspections before start-up .......................................................................................................................... 47
10.1 Visual inspection ................................................................................................................................. 47
10.2Check engine oil level ......................................................................................................................... 47
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Contents
10.3 Check level of hydraulic oil ................................................................................................................. 47
10.4 Check coolant level ............................................................................................................................. 48
10.5 Refuelling ............................................................................................................................................. 48
10.6 Safety measures before start-up ......................................................................................................... 48
11 Starting the machine .................................................................................................................................... 49
11.1 Starting assistance (starting with an outside battery) ........................................................................... 50
12 Driving the dumper ...................................................................................................................................... 52
13 Hydraulic operation of the bucket 1501S / 2001 / 2001SLE ........................................................................ 53
Hydraulic operation of the bucket 1001 / 1501 ....................................................................................... 53
14 Switching off the dumper ............................................................................................................................. 54
15 Care and maintenance ................................................................................................................................. 55
15.1 General ................................................................................................................................................ 55
15.2 Maintenance plan ................................................................................................................................. 57
16 Daily maintenance ....................................................................................................................................... 60
16.1 Daily visual and leak checks ............................................................................................................... 60
16.2 Engine ................................................................................................................................................. 60
Check engine oil level ........................................................................................................................... 60
Check coolant level ............................................................................................................................... 60
Checking pre-filter and water separator ................................................................................................. 60
Cleaning the air filter ............................................................................................................................... 61
Refuelling ................................................................................................................................................ 61
16.3 Hydraulics ............................................................................................................................................ 61
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Contents
Checking the hydraulic oil level ............................................................................................................. 61
17 Weekly maintenance or every 50 operating hours ..................................................................................... 62
17.1 Engine ................................................................................................................................................. 62
Check engine mounts ............................................................................................................................ 62
V-belt tension .......................................................................................................................................... 62
Replacing engine oil and filter ............................................................................................................... 62
Battery .................................................................................................................................................... 62
Fuel filter and water separator ................................................................................................................ 62
Clean the radiator fins ............................................................................................................................. 63
17.2 Hydraulics ............................................................................................................................................ 63
Hydraulic pump ...................................................................................................................................... 63
Clean the hydraulic cooler fins ............................................................................................................... 63
Change Hydraulic OiI Filter (Combination Filter) 2001 / 2001 SLE ......................................................... 63
Change Hydraulic Oil Filter (Combination Filter) 1001/1501/1501 S ...................................................... 64
Lubrication plan 1001 / 1501 ................................................................................................................... 65
Lubrication plan 1501 S .......................................................................................................................... 66
Tyre pressure 1001/1501/1501 S/2001 ................................................................................................... 67
Lubrication plan 2001 .............................................................................................................................. 67
Additional lubrication points on the 2001 SLE ....................................................................................... 68
18 Maintenance every 250 operating hours ..................................................................................................... 69
18.1 Engine ................................................................................................................................................. 69
Replace the engine oil and oil filter ....................................................................................................... 69
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Contents
Replace the fuel filter .............................................................................................................................. 69
Check motor speed and exhaust system .............................................................................................. 69
18.2. Hydraulics ........................................................................................................................................... 69
Check hydraulic oil and hydraulic oil filter .............................................................................................. 69
18.3 Electrical system ................................................................................................................................. 69
18.4 Winter operation .................................................................................................................................. 69
19 Maintenance every 500 operating hours ..................................................................................................... 70
19.1 Engine ................................................................................................................................................. 70
Replace the air filter ............................................................................................................................... 70
Check valve play .................................................................................................................................... 70
Check cooling system and hoses for leaks .......................................................................................... 70
Check electrical connections ................................................................................................................. 70
Check pre-heating system ..................................................................................................................... 70
19.2 Hydraulics ............................................................................................................................................ 70
Check primary valves ............................................................................................................................ 70
Replace hydraulic oil and filter 1501S/2001 ........................................................................................... 70
Replace hydraulic oil and filter 1001/1501 ............................................................................................. 70
20 Maintenance every 1000 operating hours ................................................................................................... 72
20.1 Engine ................................................................................................................................................. 72
Check generator and starter ................................................................................................................... 72
Clean fuel tank ........................................................................................................................................ 72
Replace fuel filter .................................................................................................................................... 72
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Contents
Check water pump ................................................................................................................................. 72
Replace air filter ..................................................................................................................................... 72
Replace engine oil and oil filter ............................................................................................................. 72
20.2 Tyres .................................................................................................................................................... 72
20.3 Brakes ................................................................................................................................................. 72
21 Maintenance after longer lay-up .................................................................................................................. 73
21.1 Preparation for laying up ..................................................................................................................... 73
21.2 Start-up after laying up ......................................................................................................................... 73
22 Lubricants table ........................................................................................................................................... 74
23 Malfunctions ................................................................................................................................................. 75
A Safety instructions for the operation of earth-moving machinery .............................................................. A1
- VII -
Contents
Introduction
This manual and the written supplementary sheets must be kept in the vehicle within easy
reach at the place provided!
This manual contains detailed instructions on the proper operation and use, care and maintenance
and the security regulations necessary for the operation of the vehicle.
- Before first using the vehicle, obtain instructions from trained expert personnel and read the
operating instructions carefully.
- Road safety, reliability and working life primarily depend on fault-free operation and
maintenance.
- LIFTON assumes no liability within the meaning of the Product Liability Act for damage or
consequential losses resulting from the improper use and handling of the products supplied by us.
- Please note that claims cannot be derived from the contents of these operating instructions,
the illustrations and details contained therein in particular such of a design nature nor shall such
give occasion for complaint.
- LIFTON reserves the right to implement technical changes and/or introduce improvements
without being obliged to install or fit the same to vehicles already manufactured.
- Since we are continuously applying our efforts to improve our products, it is possible that your
vehicle contains improvements that could not be taken into account when these operating
instructions were printed.
- The vehicle described in this manual corresponds with the technical level and security
provisions applicable at the time of printing.
- Subject to technical amendments.
If you have any further questions, please dont hesitate to contact your LIFTON distributor.
1 Warranty
Warranty claims may be asserted only against the LIFTON distributor.

Moreover, the directions given in this instruction manual must be complied with.
The warranty and handling of warranty claims are subject to the general guidelines
of the Professional Association of the Austrian Mechanical Engineering Industry in
the version applicable at the time of printing of this manual.
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Contents
1.1 Type plate
The type plate is mounted on the front right of the cowling.
1.2 Instructions for ordering spare parts
Only use original LIFTON spare parts!

The complete part number, name and the quantity of the
parts needed must be entered in each order.
The type and production number of the machine (type plate) must
be specified for each order.
NOTICE: Any incorrect deliveries resulting from incomplete

details shall be the responsibility of the ordering
party. Please prepare telephone orders carefully.
In order to avoid time-consuming inquiries and
possible faulty deliveries, an order shall contain
clearly legible details of the address, post code,
mode of shipment and destination.
Please order spare parts only via your LIFTON distributor!
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Contents
2 Safety
WARNING: The following safety rules should be read carefully before

starting up the vehicle.
All the security regulations set out here and otherwise applicable must
be complied with.
Incorrect behaviour and the unawareness of sources of danger during the

operation of the vehicle can cause injuries.
In this description, such sources of risk are marked with
CAUTION.
Incorrect behaviour and an unawareness of causes of risk during

operation and maintenance can cause damage.
In this description, such sources of risk are marked with
WARNING.
Notices which if ignored can lead to interruptions to business operations

are marked in this description by
NOTICE.
This manual does not contain the safety and accident-prevention

regulations contained in national and regional legislation. These can be
found in the enclosed brochure published by the Civil Engineering
Professional Association.
The safety regulations must be kept in such a way that they are clearly
visible and available for consultation by the operating personnel at any
time.
Read these operating instructions repeatedly until you are familiar

with all the safety instructions, operating elements, sub-assemblies
and functions of the machine.
All the adhesive labels concerning safety (notices and warnings) must
be clearly legible. Remove dirt.
They must be replaced by new adhesive labels once they are no longer
legible!
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Contents
Use the vehicle carefully and cautiously so as to avoid

endangering both yourself and your colleagues.
Once you have read these operating instructions carefully,
practise handling the machine in an open space where there can
be no danger to other persons or property.
The operating instructions must be kept with the machine. The
toolbox under the cowling is the intended storage place.
2.1 Safety rules
The drivers safety and that of the persons within his field of work
are dependent on the drivers skills. For this reason, he must know
the functions of the operating elements.
Each machine has its performance limits:
Before starting up the dumper, the driver must be acquainted with

its characteristics, in particular with the speed, the braking and
driving system, the steering and control levers, the safety
equipment and instructions, and the vehicles stability.
WARNING: The DUMPER is designed and built exclusively for

use with original working equipment or working
equipment approved by the manufacturer.
When driving on roads, the vehicle must be equipped according

to the road traffic regulations and comply with traffic legislation. If
it is not fitted with lighting, the vehicle may only be driven on
building sites or when visibility is sufficient.
Adjust your driving speed to local visibility conditions.
The speed of the vehicle must always be adjusted to the

conditions of the road and the ground and to visibility conditions.
Use assistance where road visibility is insufficient or in the case of
obstacles.
The dumpers speed must always be kept so low that the dumper
is safe against tipping over. This is particular the case on
uneventerrain, at the edge of pits, in curves and in the event of an
emergency braking.
Particular caution is required when working on slopes. On firm soil

the dumper may be driven up to an angle of 20% (1 in 5) in any
direction. If the wheels can be expected to sink in on one side, the
maximum angle is accordingly smaller. Angles above 20% may
only be driven when the vehicle is loaded with the hopper pointing
up the hill, i.e. in reverse when going downhill.
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Contents
When travelling downhill at an angle of over 20 % with an empty hopper,

the hopper must be pointing downhill.
When leaving the vehicle

- Switch off the engine
- Remove the ignition key
- Secure against unauthorised use
Unauthorised persons are not allowed to use the machine.
With the exception of the driver, no-one is permitted to be on the dumper.

PASSENGERS PROHIBITED.
Use the towing ring provided to tow the vehicle.
Before starting work, ensure that the operating area, the steps and the
handles are free of oil, dirt, ice and loose objects.
Risk of injuries from slipping and the like.
Use the handles provided for climbing on and off.
Before and during work in the dark, check that the lighting equipment is
operating correctly.
Before starting the dumper, ensure that no children are in the area of
danger.
Only operate the dumper from the drivers seat.
Handle the dumper carefully and cautiously until you are fully familiar with
it.
Take note of all movements by machines and vehicles in your area of

work.
The area of risk (working area) must be kept free of persons.
Before starting the dumper, check that the cowling is closed and locked.
Use correct protective clothing:

Helmet
Working gloves
Solid working shoes
Reflective clothing
If necessary also
Ear protectors
Goggles and the like
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Contents
When travelling downhill with a full hopper, travel slowly and reduce the engine
speed by slowly releasing the accelerator pedal. When the diesel engine is at
tick-over speed, the dumper is braked hydraulically. The centre of gravity of the
pay load moves forwards as a result of the incline. In the event of doubt, travel
downhill in reverse gear.
When parking, activate the hand-brake. If possible, do not park the dumper on
an incline. If this should be necessary, use a wheel chock or something similar.
When leaving the dumper, check that the hopper is in lowered position.
Avoid braking sharply or suddenly changing direction on wet, muddy or

slippery surfaces. Do not exceed the payload. (see adhesive label on the
middle of the hopper). With light and loose material, the max. pay load is
reached when the hopper is heaped full. When heavy material is loaded, the
hopper should only be filled up to the rim of the hopper. Do not permit the load
to project over the sides.
Keep the floor plates of the dump body clean to ensure that the bulk material
slips easily out of the dump body. Load only flowing material.
Lift sticking or frozen material only towards the front and with the dumper being
aligned straight in driving direction on even ground. Make sure that the material
is really coming off during dumping before the dump body is fully upright,
ohterwise the dumper may tilt.
Never drive too close to a pit since there is the risk that the edge of the pit will
collapse as a result of the wheel pressure. If the edge is sufficiently secured and
a barrier prevents the edge collapsing, the dumper may be driven closer to the
edge.
Never tip material into a pit in which people are present. If the driver cannot see
into the pit, he must be assisted by a person who can see into the pit.
Always ensure that the brakes are in perfect condition.
Diesel fuel is inflammable. Never refuel when the engine is running or

overheated or in proximity to an open flame.
The dumper may be operated only by sufficiently trained personnel authorized

by the construction company. The drivers must wear working clothes suitable
for building sites and all weather and must be familiar with the contents of this
instruction manual. If the dumper is driven on public roads, the driver must have
the relevant driving licence and the vehicle must be approved for road traffic
use.
Check if the traffic equipment and the lighting system are working properly.
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Contents
It is forbidden to drive with the bucket raised or slewed. Only load a

flowing load material. It is forbidden to empty sticky or frozen material
lateral or when the dumper is located at an angle across a slope (see
adhesive label on the middle of the dashboard).
CAUTION: Danger of tipping
The sign OUT OF ORDER must be attached clearly visibly and legibly
on a vehicle during repairs or on adjustments.
It is forbidden to open the cowling when the engine is running.

There is a risk of injuries from rotating parts and a risk of burns.
Inform yourself about first aid measures and the location of the
- First-aid box
-Fire extinguisher
Where are the security devices in and on the vehicle?

- What is their purpose?
- How are the operated?
- Are they in working order?
When changing engine oil, use a large collection tank. This prevents oil
escaping and damaging the environment.
Maintenance work should only be carried out when the motor is switched
off. Remove the ignition key. In the event of a risk of rolling, the wheels
should be secured with chocks. In the case of water-cooled engines, the
filler stopper for the radiator should only be half opened when the engine
is warm; this allows the steam pressure to escape. Only then may the
stopper be completely opened.
The battery cables must be disconnected (minus cable first) when

working on the electrical system or carrying out welding work.
Before starting up the machine, check the steering and brakes for defects
and proper operation.
If substances harmful to the environment and/or persons escape from the

dumper, the necessary measures must be taken immediately (e.g. if
hydraulic oil escapes: apply oil bonding agent, place collection tank
underneath, have the leak stopped, if necessary remove contaminated
earth and dispose of appropriately).
2.2 Use
The compact dumper is suitable and designed for the transport of the
usual bulk goods arising on building sites and for concrete.
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Contents
2.3 EC- Declaration of Conformity 1001
EG-Konformittserklrung
EC-Declaration of Conformity
Dclaration de conformit
im Sinne der EG-Maschinenrichtlinie 98/37/EG, Anhang II A

in addition to the EC machine directives Annex
dans lesprit des directives du conseil relatives aux machines Annexe
Hiermit erklren wir, da der Kompakt-Allraddumper
We declare, that the compact-dumper
Nous dclarons, que le dumper compact
Typ 1001 Fahrgestell-Nr. . . . . . . . . . . . . . . . . .
type serial-no.
type numra de srie.
folgenden einschlgigen Bestimmungen entspricht: 98/37/EG

fulfills the following directives: 89/336EWG
est en conformit avec des prescriptions suivant: 2000/14/EG
Angewendete harmonisierte europische Normen EN 292-1 1991

Harmonized standards applied EN 292-2 1995
Normes euopen harmonises appliques EN 474-1 1994
EN 474-6 1996
Garantierter Schalleistungspegel LWA . . . . . . . . . . . . . . . . . . . . . . . . . . .101

Guarantee weighted Sound Power Level
Niveau sonore garanti de la puissance
Gemessener Schallleistungspegel LWA . . . . . . . . . . . . . . . . . . . . . . . . .94

Measured weighted Sound Power Level
Niveau sonore mesur de la puissance
Freiwilligen Baumusterprfung: Baumusterprfungsbescheinigung-Nr.:

Voluntary type-examination Eximination certificate No.:
Effectuer lexamen de type volontaire Attestation de type n:
Tredegar,
........................................................ .........................................................
Ort, Datum / Place, date / Lieu, date Lee Morris / Managing Director
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Contents
2.4 EC-Declaration of Conformity 1501

Typ 1501 Fahrgestell-Nr. . . . . . . . . . . . . . . . . .
type serial-no.
type numra de srie.


EN 474-6 1996



Tredegar,
........................................................ .........................................................
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Contents
2.5 EC- Declaration of Conformity

Typ 2001 Fahrgestell-Nr. . . . . . . . . . . . . . . . .
type serial-no.
type numra de srie.


EN 474-6 1996



Tredegar,
........................................................ .........................................................
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Contents
3 Description
3.1 Technical specifications
Dimensions 1001
Main specifications 1001

Useful load 1000 kg

Empty weight 1130 kg (1085 kg)
Volume of dump dump body 415 litres level
525 litres heaped
275 litres water standard
Driving speed 14 km/h
Turning radius 3200 mm outs (3100)
Ascending capacity 45 % theoretical
Safe incilnation 20 % in all driving positions
with narrow tires max. admissible lateral inclination 10 %
( )= with narrow tires

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Contents
Dimensions 1501
Useful load 1500 kg

Empty weight 1226 kg
800 litres heaped
Turning radius 3300 mm outs
19
Contents
Dimensions 1501 S
Main specifications 1501 S
Main specifications 1501 S
Useful load 1500 kg

800 litres heaped
20
Contents
Dimensions 2001
Useful load 2000 kg

1210 litres heaped
21
Contents
Dimensions 2001 SLE
Main specifications 2001 SLE
Main specifications 2001 SLE
Useful load 2000 kg

950 litres heaped
Volume of bucket 145 litres level
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Contents
Engine 1001
Engine Dumper 1001
up to serial number AB.... from serial number AB....
Model YANMAR 3TNE74-NSR YANMAR 3TNV76-XNSV
Typ water cooled water cooled
3-cyl. diesel engine 3-cyl. diesel engine
Stroke 1006 cm 1116 cm
Power to DIN 12,1 kW (16,5 HP) 17 kW (23,1 HP)
Engine speed 2200 U/min 3000 U/min
Battery 12V / 50 Ah 12V / 50 Ah
Diesel tank 15 l 15 l
Engine oil 2,25 l 2,25 l
Cooling water 4l 4l
Engine 1501/1501 S
Engine Dumper 1501/1501 S
up to serial number AB.... from serial number AB....
Model YANMAR 3TNE74-NSR YANMAR 3TNV76-XNSV
Typ water cooled water cooled
3-cyl. diesel engine 3-cyl. diesel engine
Stroke 1006 cm 1006 cm
Power to DIN 14 kW (19,04 HP) 17 kW (23,1 HP)
Engine speed 2500 U/min 3000 U/min
Battery 12V / 50 Ah 12V / 50 Ah
Diesel tank 15 l 15 l
Engine oil 2,25 l 2,25 l
Cooling water 4l 4l
Engine 2001/2001SLE
Engine Dumper 2001/2001SLE
Model YANMAR 3TNV82-A

Typ water cooled
3-cyl. diesel engine
Stroke 1006 cm
Power to DIN 21,9 kW (21,8 HP)
Engine speed 3000 U/min
Battery 12V / 50 Ah
Diesel tank 27 l
Engine oil 5l
Cooling water 8l
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Contents
Drive gear
Hydrostatic drive gear with automatic control via a self-regulating
axial piston pump and four hydraulic wheel engines.
Twin-Lock traction system, electrical direction switch, permanent
4-wheel
Drive Gear drive.
Maximum operating pressure

1001 1501/1501 S 2001
360 bar 360 bar 420 bar
Brakes Dumper 1001/1501/1501 S

Pedal-operated hydrostatic drive brake, spring-loaded brake at
the 2 brake wheel motors as auxiliary brake and parking brake,
operated via hand brake valve.
Brakes Dumper 2001

Hydrostatic drives, spring-loaded brake at all 4 wheel motors as
auxiliary brake and parking brake, operated via hand brake valve.
Steering
Hydrostatic articulated frame steering with emergency steering
characteristics
Working hydraulics
Working hydraulics
1001 1501/1501 S 2001
Gear pumping capacity 25 l/min 25 l/min 25 l/min
Operating pressure 170 bar 170 bar 175 bar
1001/1501/1501 S:
Double-lever control valve, dump body tilting by double-action
cylinder, dump body lifting with parallel guiding system via two
double-action cylinders.
2001:
Single-lever crossing control valve, dump body tilting via double-

acting cylinder, dump body swivelling via two double-acting
cylinders, combination filter for operating hyraulics and traversing
drive.
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Contents
Hydrauliktank
Hydraulic tank
1001 1501/1501 S 2001

20l 20l 28l
Tires
Tires
1001 1501/1501 S 2001

10.00/75x15 10.00/75x15 10.00/75x15
narrow tires
6.00x16
Articulated frame steering structure
Two-part frame connected to an articulated pendulum joint,

sheet steel compact design structure; driver seat located
centrally; maintenance-friendly, folding and lockable engine
cowling; dashboard with operating and warning displays,
operating hourmeter, horn and ignition lock.
Noise emission
Noise emission
1001 1501/1501S 2001

Acoustic power (LWA) 101 101 101
Sound level (LPA) 85 85 85
WARNING: No changes may be made to the vehicle that result in an

increase in the noise emissions!
Vibrations
According to vibration measurements, the dumper complies with

Directive 89/392/EEC
Fire extinguisher
The location and operation of the fire extinguishers and fire-fighting

facilities must be known.
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Contents
Adhesive labels
WARNING: All adhesive labels concerning safety (notices and

warnings) must be clearly legible. Remove dirt.
Replace with new labels if not legible.
Label position
1x dump body centre Dumper: 1001/1501/1501 S
at Dumper 1501 an 1501 S, useful load 1500 kg
1x engine bonnet Dumper: 2001

at Dumper 2001, useful load 2000kg
1x dump body edge left 1,2 m vehicle width, Dumper: 1001
1x dump body edge left Dumper: 1501/1501 S
1x dump body edge left 1 m vegicle width, Dumper: 1001
1x dump body edge right, Dumper: 1001/1501
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1x dump body edge right, Dumper: 1501 S
1x dump body edge right, Dumper: 2001
2x dump body (1x li; 1x re.)

1x engine bonnet rear
1x front chassis left Dumper: 2001
1x front chassis right Dumper: 2001
1x engine bonnet front

1x fan case
1x engine bonnet front, Dumper: 1001/1501/1501 S

1x near exhaust, Dumper: 1001/1501/1501 S
1x engine front, Dumper: 2001
1x dump body left, Dumper: 1001/1501/1501 S

1x dump body right, Dumper: 1001/1501/1501 S
1x front chassis left, Dumper: 2001
1x front chassis right, Dumper: 2001
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Contents
1x front chassis right, Dumper: 1001/1501

1x swing bracket right, Dumper: 1501 S
1x swing bracket left, Dumper: 2001
1x engine bonnet
2x rear chassis
1x engine bonnet, Dumper: 1001/1501/1501 S

1x engine bonnet, Dumper: 2001
acoustic power: 104 dB
1x diesel tank
1x hydraulic tank
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Contents
1x engine bonnet
1x engine bonnet Dumper: 1501S/ 2001
1x engine bonnet Dumper: 1001/1501
2x wing
2x dump body
1x rear chassis right, Dumper: 2001
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Contents
4 Sub-assembly identification 1001/1501
Baugruppenbezeichnung 1001/1501
1 rear chassis 8 engine bonnet

2 front chassis 9 parallel guiding system
3 lifting arm 10 dump body
4 articulated pendulum joint 11 lifting cylinder
5 driver's seat 12 tilting cylinder
6 control panel 13 steering cylinder
7 tilting bracket
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Contents
Sub-assembly identification 1501 S
Baugruppenbezeichnung 1501 S
1 driver's seat 7 articulated pendelum joint

3 dump body 9 rear chassis
4 swivel centring 10 engine bonnet
5 awing bracket
6 tilting cylinder
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Contents
Sub-assembly identification 2001
Baugruppenbezeichnung 2001
1 rear chassis 8 engine bonnet

2 front chassis 9 swivel bracket
3 swing bracket 10 dump body
4 articulated pendelum joint 11 swing cylinder
5 driver's seat 12 tilting cylinder
7 bucket 14 rollover bar
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Sub-assembly identification 2001 SLE
Baugruppenbezeichnung 2001 SLE
1 lift frame 5 fastening mount

2 lift ram 6 articulation (large)
3 bucket ram 7 articulation (small)
4 bucket
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Contents
4.1 Operating equipment 1001/1501/1501 S up to serial number AB.....
6 7 8 9 10 11 12 13
Betriebseinrichtungen 1001/1501/1501 S up to serial number AB.....
1 accelerator 9 pilot lamp motor temperature

2 parking brake 10 pilot lamp fuel reserve
3 key switch I ignition 11 free
II preheating 12 pilot lamp hydraulic oil filter
III starting 13 pilot lamp preheating
4 direction switch 14 operating hours meter
5 horn 15 tank indicator
6 pilot lamp charge 16 lever "tilt/lower dump body"
7 pilot lamp motor oil pressure 17 lever "lift/lower dump body"
8 pilot lamp parking brake 18 handle for horizontal seat adjustment
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Contents
4.1 Operating equipment 1001/1501/1501 S from serial number AB.....

13 8 10
14 9
15 11
13 12
13 13
17
3
6 16
5
4
7
1
20 2
19
18
Betriebseinrichtungen 1001/1501/1501 S from serial number AB.....
1 accelerator 10 pilot lamp parking brake

2 main brake 11 pilot lamp motor temperature
3 parking brake 12 turn indicator telltale
4 key switch I ignition 13 free
II preheating 14 pilot lamp hydraulic oil filter
5 direction switch 16 operating hours meter
6 horn 17 tank indicator
7 indicator 18 lever "tilt/lower dump body"
8 pilot lamp charge 19 lever "lift/lower dump body"
9 pilot lamp motor oil pressure 20 handle for horizontal seat adjustment
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Contents
Operating equipment 2001 / 2001SLE
6 7 8 9 14 15 16 17 10 11 12 13
Betriebseinrichtungen 2001
1 driving pedal 12 pilot lamp hydraulic oil filter

2 parking brake 13 dummy
3 key switch I ignition 14 pilot lamp full headlight beam
II preheating 15 not assigned
4 commutator switch 17 pilot lamp flasher
5 flasher switch - horn 18 strap for longitudinal shifting of seat
6 pilot lamp charge 19 control lever for dump body
7 pilot lamp motor oil pressure 20 operating hours meter
8 pilot lamp parking brake 21 fuel gauge
9 pilot lamp engine temperature 22 hydrostatic braking pedal
10 pilot lamp fuel reserve 23 light switch
11 not assigned
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Contents
Arrangement of the fuses in the fuse box Dumper 1001/1501/1501 S up to serial number AB....
Arrangement of the fuses in the fuse box Dumper 1001/1501/1501 S up to serial number AB.....
No. Capacity Function
(A)
1 30 stop solenoid, relay timer stop solenoid
2 7,5 horn
3 7,5 controller 5
4 7,5 pump solenoid valve
5 7,5 light switch
6 empty
7 empty
8 7,5 control lamps
9 empty
10 empty
11 empty
Arrangement of the fuses in the fuse box Dumper 1001/1501/1501 S from serial number AB....
Arrangement of the fuses in the fuse box Dumper 1001/1501/1501 S from serial number AB.....
F10 F9 F8 F7 F6 F5 F4 F3 No. Capacity Function
(A)
1 50 main fuse
2 40 main fuse
3 10 stop solenoid, relay timer stop solenoid
4 15 pump solenoid valve
5 10 horn, parking break, break light
F1 6 15 indicators
7 15 high beam light
F2 8 10 low beam light
9 10 side marker lamp
10 10 warning signal flasher
Arrangement of the fuses in the fuse box Dumper 2001
Arrangement of the fuses in the fuse box Dumper 2001
No. Capacity Function

(A)
1 10 warning signal flasher 30
2 7,5 side marker lamp, license plate light
3 7,5 low beam light
4 10 high beam light
5 7,5 warning beacon
6 7,5 traveling gear
7 10 relay stop solenoid
8 20 stop solenoid 30
9 empty
10 10 horn, stop light
11 10 bracket, control lamp, fuel level control + security relay
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Contents
4.2 Drivers seat + rollover bar + overhead guard Dumper 2001
The drivers seat is fitted with the following adjustment

possibilities to adjust sitting position:
CAUTION: Only adjust the seat when the vehicle is at a

standstill!
Standard drivers seat
Longitudinal adjustment of seat position

Raising the front left lever (14, see operating equipment, Sec.
4.1) can be used to adjust to adjust the seat horizontally
(forwards and backwards). If the lever is released, it catches in
one of the lock-in positions provided.
Weight adjustments
The weight is adjusted by turning the hand screw on the rear of
the seat back. An indicator on the rear serves as check, and
should point to zero when the seat is under load.
Drivers seat with ROPS roll bar
National regulations may require the presence of a roll bar.

In this case, the standard drivers seat must be replaced by a
seat fitted with a lap seat belt (to ISO 6683).
The seat is horizontally adjusted by raising the lever

(14, see operating equipment, Sec. 4.1) at the front and by
shifting the seat.
The weight setting is by means of a crank. The drivers

weight set is shown in a display window.
The height of the seat can be adjusted by pushing the lever

behind the back of the seat upwards.
Overroll Bar ROPS
When the overroll bar is swing open on the dumper, the

seat belt provided at the seat must always be fastened.
The seat belt must not be used without the overroll bar.
Overhead guard FOPS
Where the dumper may be exposed to falling debris hazards,

the overhead guard must be fitted. The guard is fitted to the
ROPS bar.
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Contents
5 Lifting the dumper
Appropriate lifting belts must be used to lift the dumper. When

lifting the dumper, the articulation lock must be swivelled into
position and secured by means of the spring cotter.
hook of crane 1001:

supporting strap Take the lifting belts into the supporting strap.
stop eye
slew in articulation prop

1501/1501 S:
hook of crane Don't take the lifting belts into the supporting strap.
stop eye
slew in articulation prop
2001 / 2001 SLE:

Fix the lifting belts at the stop eye situated at the rear frame and
thread the strap through the bucket edge.
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Contents
6 Loading and transport
Unladen dumpers can be driven backwards slowly over a loading ramp

onto the lorry or trailer, or can be loaded using a crane (see Sec. 5 Lifting
the dumper). The dumpers engine must be switched off.
Tie the dumper tightly to the loading surface. There are two rings located
on the front frame of the dumper and a bolt on the rear frame for this
purpose.
7 Towing device
The dumper is equipped with a towing device but is not a tractor machine
and cannot be used as such on difficult terrain.
If the dumper is used for towing on the building site, the bucket must
contain a ballast amounting to 25% of the working load. However, the
device towed plus the ballast in the bucket must not exceed the
dumpers working load. The towing bolt of the towing device must be
secured using a locking key.
WARNING: Load material only with the skip and the dumper in a straight
position! Damage may result if the loader unit hits the skip!
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Contents
8 Loader unit (2001 SLE)
The loader unit has been designed for raising loose material up to
300 kg.
The 2001 SLE is not suitable for excavating or pushing heavy material.
Bear in mind the following when using the 2001 SLE:
Skip must be lowered when loading.
Always lower the loader unit before dumping out or rotating
the skip.
Do not use the loader unit on slopes.
Other persons must stay clear of the dumper when working
Bucket must be in a horizontal position when pushing or
picking up material (see mark on bucket ram).
Dumper must be in a straight position when pushing or
picking up material (no steering).
Never use the loader unit as a crane.
Lower the bucket onto the skip when driving the dumper.
Warning: Load material only with the skip and the dumper
in a straight position!
Damage may result if the loader unit hits the
skip!
Bucket teeth towards the rear side of the skip. Avoid

dumping out the bucket too fast otherwise the material can
be thrown beyond the skip. Empty the bucket slowly! (lever
to the left) Check whether the loader unit is lowered before
rotating the skip. The skip can be dumped out to the right or
left, or to the front through the lowered arms of the loader
unit. Avoid dumping material onto the loader unit. Raise the
bucket only with the skip in a lowered and straight position.
For light grading work, empty the skip and rotate it to the
side if it is not required for working. This gives you good
visibility of the bucket. Reverse when grading, and press
and hold the lever downwards and to the front (no float
position).
The bucket has not been designed for transporting

material. No excavating!
The bucket of the 2001 SLE is not comparable with

a wheel loader bucket.
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Contents
Information on working with the loader unit
The loader unit bucket is no earthmoving tool! Load only bulk material.
The loader unit has not been designed for higher forces.
Always engage 1st speed and do not steer the wheels when driving
against a pile of material. Always move the bucket flat on the ground
before picking up material.
When penetrating into a pile with the bucket, fully dump in the bucket
(lever to the left). Avoid spinning the wheels: this can cause damage to
the drive, or the wheels to dig into the ground on loose ground.
Raise the bucket out of the material (lever to the rear). If there is too much
material in the bucket, reverse a little to remove a little material from the
bucket.
Raise the bucket until you can see it over the front edge of the skip.
Avoid losing material by carefully dumping out the bucket (lever to the
right) and by raising the whole loader unit at the same time (lever
diagonally to the rear right).
Keeping the bucket in a parallel position requires a little practice.
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Contents
9 Towing the dumper
If the dumper is to be towed, the high-pressure circuit on the hydrostatic

pump must be opened and the spring-loaded brakes released on both
rear wheel engines
9.1 Open high-pressue circuit 1001/1501/1501 S
2 At the left side of the pump below the floor plate there is one
1
high-pressure control valve each at the top and at the bottom.
Procedure:
* Loosen castellated nut width across 14 (item 2) and turn
it out to the end of the screw.
* Turn in bolt by means of a 4 mm Allen key (item 1) until
you feel a noticeable resistance. Then make another
half turn.
WARNING: Turning in further will damage the valve!
* Retighten castellated nut width across 14 (item 2).
Now the device can be towed slowly (2 km/h at max.) over a

short distance (1 km at max.). Then the valves have to be
activated again. To this end proceed in reverse order (turn
out screw to stop).
9.2 Loosen spring-loaded brake 1001/1501/1501 S
3 * To loosen the spring-loaded brake (1)dismantle the

two extractors (2) attached at the rear axle box. To this
end remove the hexagon bolt (3) M 12x35 (SW19).
4 * Take off the plastic plug (4) in the centre of the wheel
motor face.
* Place extractor on the wheel motor face and fix it by

means of bolt M12x35.
1
2
* Tighten bolt at 42 Nm until wheel revolves freely.
1 2 3
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Contents
9.3 Opening the high-pressure circuit 2001
1 At the (left side of) the pump below the floor plate there is one
high-pressure control valve each at the top and at the bottom.
2
Procedure:
Loosen lock nut width across 14 part 2 and turn it
out till the end of the screw.
Turn in screw with hexagon socket head width across
4 part 1 until it is flush with the nut
* Retighten castellated nut width across 14 (item 2).
Now the device can be towed slowly (2 km/h at max.) over a short
distance (1 km at max.). Then the valves have to be activated again. To
this end proceed in reverse order (turn out screw to stop).
9.4 Releasing the spring-loaded brake 2001
To loosen the spring-loaded brakes (1)

remove the extractor (2) fixed at the front wing.
To this end remove the hexagon head screw (3)
M12x35 (width across 19).
2
Remove the plastic stoppers (4) in the middle of the front end of the wheel
engine.
Place the withdrawal device with the front end on the wheel engine and
fix using screw M12x55.
Tighten screw with 42 Nm until the wheel rotates freely.

3
1 3
2
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Contents
10 Inspections before start-up

Inspections before start-up prevent malfunction during operations.
Consequently, they must never be ignored.
10.1 Visual inspection
Check:
Pressure hoses, hose connections and hydraulic cylinder seals
for oil leaks. Radiator for water leaks Engine for water and oil leaks
Tightness of battery terminals
10.2 Check engine oil level
The oil level is to be checked using the Dipstick when the machine
is standing horizontally and the engine switched off.
NOTICE: The notches on the Dipstick show the minimum and

maximum oil levels.
If necessary, top up with engine oil. For this purpose, open the oil
cap and fill in engine oil from a clean container.
WARNING: The quality of the engine oil is shown on the list of

lubricants. Only use engine oil of the same quality.
10.3 Check level of hydraulic oil
Check the level of the hydraulic oil at the inspection window on the
left side when the engine cowling is open.
(at Dumper 1001/1501/1501 S lower the first boom)
To this purpose, the bucket must be in direction of travel, the

bucket lowered and the dumper standing flat in the direction of
travel.
The inspection glass must be covered with oil up to upper edge.

If necessary, top up hydraulic oil. For this purpose, open the red
cap of the return filter and top up the hydraulic oil from a clean
container, and close the lock again.
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Contents
WARNING: Only use hydraulic oil of the same quality.
10.4 Check coolant level
CAUTION: Only check the coolant level when the engine is cold.
If necessary, top up with coolant. For this purpose, turn the radiator cap
anti-clockwise and remove.
WARNING: If coolant is added, ensure the correct mixture of water and

anti-freeze.
10.5 Refuelling
In order to prevent the formation of condensation before the next start-up,

refuel after every working operation until the tank is full.
When refuelling, ensure that fuel does not overflow.
WARNING: Never run the fuel tank empty, since otherwise the fuel
system must be bled.
10.6 Safety measures before start-up
When climbing onto the machine, always use both handles and the
non-slip tread. Keep the tread and pedals free of mud, oil, ice and other
residues.
Carry out the necessary checks every day before starting work (see Sec.
15 Daily maintenance)
Before climbing on the machine, check whether both directions of travel

are unobstructed, so that the dumper can be set in movement without
danger.
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Contents
11 Starting the machine
The driver must be sitting in the drivers seat and the seat adjusted
to his body (springs, position, back see Sec. 4.2 Drivers seat).
All switches and control levers must be set to neutral position.
Insert the ignition key in the ignition and turn.
Starting procedure:
Stage 1: Ignition on
NOTICE: The control lamps for oil pressure and charging must
come on lamp test
Stage 2: Preheating, hold the key in position until the

preheating control lamp goes out (approx. 10
seconds for cold engine).
Stage 3: Start
Release the ignition key as soon as the engine is running.
NOTICE: The ignition key returns to position automatically.
Do not turn the start engine longer than 10 seconds during each
starting attempt.
If the engine does not start, wait 30 seconds before a new attempt
to start, to allow the battery to recover.
During operation, leave the ignition key at the on position. If the key
is returned to the 0 position, the motor switches off.
WARNING: The control lamps (oil pressure and charging) must

be extinguished.
WARNING: If they are not extinguished, or if one of these lamps

comes on during operation, switch off the engine and
have the cause determined by the service personnel
or the workshop.
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Contents
11.1 Starting assistance (starting with an outside battery)
If the battery is empty, a suitable start aid cable connected to another

battery (12 V) can be used as starting assistance.
WARNING: The only safe method to bridge an empty battery is to have the
following procedure carried out by 2 persons. This is necessary
in order to remove the start aid cable without the driver having
to leave the drivers cabin while the engine is running.
CAUTION: Do not attempt to connect the charging battery with a start aid
cable if it is frozen. This can cause a fracture or an explosion.
Comply with these instructions in the given sequence and
completely as set out, in order to avoid personal injuries.
Check before connecting that the start aid battery is also a 12 V battery.
Check the start aid cable and terminals for damage, rust, etc.
1. Set the ignition keys of both vehicles to off and ensure that the operating
levers of both vehicles are in the neutral position, and that the vehicles are
not in contact with each other.
2. Unscrew the filler stoppers of the battery and check that the acid solution
is at the right level. In addition, place a clean cloth over the open filler
openings to prevent the acid solution boiling over.
CAUTION: If acid splashes onto your skin, eyes or clothes, rinse them
immediately with plenty of water.
3. Connect the two positive terminals (+) of the two batteries using one start
aid cable. Check that the cable and the terminal are firmly fixed.
CAUTION: Never try to connect the start aid cable directly to the starter
motor ignition switch, and instead always connect it to the
positive terminal (+) of the dumper battery.
The connection between the negative poles (-) using the start
aid cable should always be made last.
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Contents
4. Connect the start aid cable to the negative terminal (-) of the
battery of the dumper to be started.
5. Finally connect the start aid cable to the negative terminal (-) of
the battery of the vehicle providing assistance.
Check that the cable and terminals are firmly fixed.
Rotate the terminals of the start aid cable several times around the
battery terminals to establish a good electrical contact.
6. Now start the dumper. If it does not start immediately, start the
engine of the vehicle providing assistance in order to avoid an
excessive load on the start aid battery.
7. Once the dumper is running smoothly, have a further person

- release the start aid cable from the battery of the started engine,
first the cable from the negative terminal (-) and then from the
positive terminal (+), and
- release the start aid cable from the battery of the vehicle providing
starting assistance, first from the negative terminal (-) and then from
the positive terminal (+).
Ensure that cables never short-circuit each other (come into

contact).
Ensure that the dumpers dynamo has sufficient time to recharge

the battery before operating the dumper or switching the engine
off.
The cloth must be removed and the filler stoppers replaced.
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Contents
12 Driving the dumper
1. Release the hand-brake by pulling up the lever to unlock it and

then pushing it forwards.
2. Select the desired direction using the direction switch.
3. After selecting direction, accelerate, and the dumper will begin to

travel once the motor speed reaches approx. 1300 rpm.
4. If the accelerator is released, the dumper brakes automatically

until it comes to a stop. Accelerating and releasing the accelerator
should take place slowly in order to avoid jerky travel of the
dumper.
5. For quick deceleration actuate the brake pedal.
6. Use the hand-brake to stop the dumper on an incline.
7. Do not change direction of travel (forwards-reverse) while moving.
8. Observe the control lamps during operation. If a control lamp

should light up, bring the vehicle to a standstill and determine the
cause.
9. In emergencies, use the hand brake.
10. Travel slowly on difficult terrain.
WARNING: The safety instructions on driving, in particular on sloping

terrain, must be complied with!
WARNING: Point 5. is only for the Dumper 2001
Only for dumper 2001

If the cooling water temperature is less than 5C the cold starting unit of
the diesel engine is active. This unit causes a reduction of white smoke
and pollutant emission. While this function is active the diesel engine runs
at a higher engine speed. As soon as the cooling water temperature
exceeds 5C the cold starting unit is switched off automatically and the
engine speed is lowered to normal level.
WARNING: Always let the dumper warm up until the diesel engine has
reached its operating temperature. If the dumper is started without this
warm-up period it may drive off automatically upon loosening of the
parking brake!
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Contents
13 Hydraulic operation of the bucket 1501S / 2001 / 2001SLE
The control levers for activating the bucket swing tipping

returning the bucket are located to the left of the drivers seat.
Do not drive the dumper with the bucket raised.
The bucket may only be emptied lateral with flowing load material.
Observe if the material is sliding uniformly before fully raiseing the
bucket (see adhesive label on the dashboard).
If material sticks in the bucket, it may only be emptied when the

bucket is lowered and the dumper is in straight-ahead driving
position.
Hydraulic operation of the bucket 1001 / 1501

The control levers for dump body motions lift - lower - tilt - tilt back
are arranged to the left of the drivers seat.
Never drive with lifted dump body.
Lift and empty the dump body on a plain surface only when the
dumper is aligned straight in travelling direction (see label at the
right dump body edge)
Material adhering in the dump body may be removed only with

lowered dump body and the dumper aligned straight in travelling
direction.
If the material shall be dumped into a pit, a solid stop (beam) is
required to support the front wheels.
Never approach the pit with only the brake!
When the lifted and filled dump body shall be lowered, the control
lever may be operated only carefully to ensure slow lowering of
the dump body.
WARNING: Lowering the bucket too quickly and causing it to hit
against the frame can damage the dumper and cause
it to tip over!
Do not overstrain the engine during the first 50 operating hours.

Ensure that you do not always drive the dumper at full speed, but
instead drive at a variety of engine speeds.
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Contents
14 Switching off the dumper
- Switch the direction switch to neutral position.
- Activate the hand-brake.
- Lower the bucket.
- Let the engine run in neutral for a short while.
- Turn the ignition key to the 0 position, stopping the engine. Remove
the key when leaving the dumper.
- Chock the wheels with wedges or the like on steep terrain.
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Contents
15 Care and maintenance
15.1 General
The working condition and the working life of machinery is influenced to a considerable extent by care
and maintenance.
Cleaning: in the first 3 months, wash only with cold water (no high pressure or steam-jet washing), after the
first 3 months ensure a minimum distance of 30 cm between the spray jets and the vehicle, do not use
water of a temperature exceeding 60 C or any aggressive detergents.
For this reason, compliance with the prescribed maintenance work is in the interest of any machine owner.
The maintenance activity is imposed as an obligation by the manufacturer. Failure to comply may lead to
restrictions of the warranty.
Maintenance work concerning the engine is set out in the engine operating instruction.
If lubricants are used that do not correspond with the manufacturers recommendations, all warranty claims
shall expire.
Before carrying out maintenance or repair work on your machine, determine the precise details of the
damage incurred.
Before starting maintenance or repair works, lower the working equipment to the ground. Insert locking
and safety levers.
- Release the residual pressure in the hydraulic system
- Allow the engine to cool (hot radiator water)
If work is to be carried out when the machine is raised, secure it appropriately (supports).
If maintenance or repairs are carried out in an enclosed space, ensure sufficient ventilation.
Dispose of oil filters, oil, etc. in accordance with the environment protection laws.
When working on or underneath the dumper, place a warning notice on the seat or easily visible and
legible in the crawler excavator.
Remove the ignition key.
Never work on the electrical equipment at humid places or with damp hands (gloves).
When working on the electrical equipment, disconnect the negative terminal (-) from the battery.
Always replace sealing elements that have been removed (O-rings, flange seals, etc.) with new ones.
When tightening screws, secure them against twisting.
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Contents
After all maintenance or repair work, clean the vehicle of all dirt and oil
residues. Danger of slipping!
The hours specified for the maintenance interval correspond with the
hours on the operating hour meter.
WARNING: Smoking and the use of open light is forbidden during

maintenance and repair work. Fire risk!
WARNING: The operating pressure of the hydraulic system may only be

set by trained expert personnel. In the event of faults
caused by unauthorised changes to operating pressure, all
the manufacturers warranty obligations shall automatically
expire.
NOTICE: The system must be bled after maintenance work on the

hydraulic system. Starting the dumper without bleeding
results in damage to the pumps.
Bleed the cylinders when first or subsequently mounting them on the

machine as follows in order to avoid damage to components resulting
from trapped air.
1. Extend the piston rod slowly and completely, without exercising

any pressure at the end of the stroke.
2. Move the cylinder slowly through at least 5 complete working
cycles (out/in) before starting up the machine for normal work.
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Contents
15.2 Maintenance plan
Maintenance activity every 10 h every 50 h every 250 h every 500 h every 1000 h
Structural component (daily) (weekly) (6 months) (12 months) (18 months)
ENGINE
Leakage O
Visual inspection O
Fixing screws, tight fit O
Engine speed O
Exhaust system O
Tappet clearance O
Oil level O
Motor oil O <>(1) <> <>

Motor oil filter <>(1) <> <>
Fuel level O
Preliminary filter with water separator O
Fuel tank X
Fuel filter O <>
V-belt: condition and tension O
Dynamo, starter O
Electrical connections O
Preheating system O
Battery fluid O
Cooling agent O
Radiator fins X
Water pump O
Cooling system and hoses O
Air filter O/X O/X <> <>
- check - replace
X - clean (1) - replace first
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Contents
Structural component (daily) (w eekly) (6 months) (12 months) (18 months)
HYDRAULIC UNIT
Fixing screws, Hydraulic pumps O
Leakage (lines, pumps, cylinders) O
Hydraulic oil level O

Radiator fins oil cooler X
Filter element combination filter <>(1) O <> <>
Primary and secondary pressure control valve O

Hydraulic oil O <>(1) <>
Ventilation filter and sieve O O
Ventilation filter in filler cap O O
ELECTRICAL SYSTEM
Pilot lamps O
Function of system O
Fixing O
TRAVELLING GEAR
Wheels after work O
Wheel nuts O
Wheel bearings O
Oil change axles filling level up to overflow <>

Leakage O
Brake system O
- check - replace
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Contents
Structural component (daily) (w eekly) (6 months) (12 months) (18 months)
GENERAL
Hydraulic fittings and hoses O
Bolts O
Lighting equipment O
Leakage check, visual inspection O

Check of effectiveness of parking brake O
Functional check of steering system O
Check of access are treads clean O/X

Lubricate lubrication points
O O O O
(acc. to lubrication chart)
Clearance of pin and bush supports O
Fixing of lines O
Control elements (exact function) O

Piston rods O
- check - replace
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Contents
16 Daily maintenance
16.1 Daily visual and leak checks
See also maintenance plan, Sec. 14.2
* Check operating elements for exact movement

* Hydraulic fittings
* Pressure hoses, pressure connections and hydraulic cylinder seals for
oil leaks
* Radiator for water leaks
* Engine for water and oil leaks
* Firm mounting of battery terminals
* Control lamps
16.2 Engine
Check engine oil level
The oil level must be checked using a measuring rod when the machine
is standing horizontally and the engine is switched off.
Also check the quality of the oil; if the oil is particularly dirty, change the
oil before expiry of the interval.
NOTICE: The notches of the oil measuring rod show the minimum and
maximum oil levels.
If necessary, top up with engine oil. For this purpose, open the oil cap
and fill in engine oil from a clean container.
WARNING: The quality of the engine oil is shown on the list of lubricants.
Only use engine oil of the same quality.
Check coolant level
CAUTION: Only check the coolant level when the engine is cold.
If necessary, top up with coolant. For this purpose, turn the radiator cap
anti-clockwise and remove.
WARNING: If coolant is added, ensure the correct mixture of water and

anti-freeze.
Checking pre-filter and water separator
If the indicator rings rises, the tank must be drained (condensation)
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Contents
Cleaning the air filter
Open filter casing and clean the dust cyclone.

Unscrew the filter cartridge and remove the cartridge.
Clean the cartridge with low air pressure (3-5 bar)
WARNING: If the control lamp on the dashboard lights up, the air
filter must be cleaned immediately.
Important when working with high concentrations of
dust.
Refuelling
In order to prevent the formation of condensation before the next

start-up, refuel after every working operation until the tank is full.
When refuelling, ensure that fuel does not overflow.
WARNING: Never run the fuel tank empty, since otherwise the
fuel system must be bled.
16.3 Hydraulics
Checking the hydraulic oil level
Check the level of the hydraulic oil at the inspection window on the
left side when the engine cowling is open.
To this purpose, the bucket must be in direction of travel, the

bucket lowered and the dumper standing flat in the direction of
travel.
The inspection glass must be covered with oil up to upper edge.

If necessary, top up hydraulic oil. For this purpose, open the red
cap of the return filter and top up the hydraulic oil from a clean
container, and close the lock again.
WARNING: The hydraulic oil quality is shown in the list of

lubricants. Only use hydraulic oil of the same quality.
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Contents
17 Weekly maintenance or every 50 operating hours
NOTICE: The following work must be carried out in addition to the

daily maintenance work, see also maintenance plan, Sec.
14.2.
17.1 Engine
Check engine mounts
See engine operating instructions.
V-belt tension
Check the V-belt tension according to the engine operating instructions.

Replace the belt if there are cracks or other damage.
CAUTION: Do not check when the engine is running.
Replacing engine oil and filter
See engine operating instructions.
The first filling of engine oil and oil filter must be replaced especially after
the first 50 hours.
The further oil change intervals are contained in the engine operating
instructions.
Dispose of used oil in accordance with the environment protection laws.
Battery
The manufacturers instructions must be followed for the maintenance of

the battery. Check the acid level in the battery.
The battery is located in the chassis at the right rear.
When replacing the battery, dispose of the old battery in accordance with
the environment protection laws.
NOTICE: The battery acid level must be between the minimum and
the maximum marks. Only top up battery acid with distilled
water.
Fuel filter and water separator
If the indicator ring rises, the container must be emptied (condensation).

If dirty, clean the sieve.
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Clean the radiator fins
Remove dirt, dust, leaves, etc. from the radiator fins. Clean at
shorter intervals in higher concentrations of dust.
Check and replace if necessary the cooling water hose and
cooling clamps.
17.2 Hydraulics
Hydraulic pump
Check the mounting screws.

Check the hydraulic system (lines, pumps, cylinders, etc.) for oil
leaks.
Clean the hydraulic cooler fins
Remove dirt, dust, leaves, etc. from the radiator fins. Clean at
shorter intervals in higher concentrations of dust.
Change Hydraulic OiI Filter (Combination Filter) 2001 / 2001 SLE
1 The return filter must be replaced exceptionally after the first 50

hours. The further filter change intervals are contained in the
operating instructions.
2
* Screw off black cover (1) (width across 27).
3 * Pull insert part (2) upward and out.
* Replace filter element (3).
* Put insert part (2) back in place.
* Tighten cover (1) manually.
Dispose of oil filter as provided by the environmental law.
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Change Hydraulic Oil Filter (Combination Filter) 1001/1501/1501 S
The return filter must be replaced exceptionally after the first 50

hours. The further filter change intervals are contained in the
operating instructions.
* Screw off black cover (1) (width across 27).

* Pull insert part (2) upward and out.
* Replace filter element (3).
* Put insert part (2) back in place.
* Tighten cover (1) manually.
Dispose of oil filter as provided by the environmental law.
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Contents
Lubrication plan 1001 / 1501
Before starting any maintenance work with the dump body tilted,
fold down the red maintenance support by removing the pin and
tilting up the dump body. The support will retain the dump body
in case it starts dropping.
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Lubrication plan 1501 S
64
Contents
Lubrication plan 2001
Tyre pressure 1001/1501/1501 S/2001
Check the tire pressure visually every day. Test the tire pressure
by means of pressure gauge once a week.
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Contents
Additional lubrication points on the 2001 SLE

Before carrying out maintenance work with the skip
dumped out, fold down the red maintenance prop
by removing the pin and dumping out the skip.
The prop prevents the skip from being lowered.
Apply grease to the 9 lubrication points on either side

of the machine!
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18 Maintenance every 250 operating hours
NOTICE: The following work is to be carried out in addition to the

weekly and the 50-perating-hour maintenance work, see
also maintenance plan, Sec. 14.2.
18.1 Engine
Please refer to the engine operating instructions for the maintenance

work
Replace the engine oil and oil filter
See engine operating instructions

Dispose of the used oil and filter in accordance with the environment
protection laws.
Replace the fuel filter
Dispose of the filter in accordance with the environment protection laws.
Check motor speed and exhaust system
See engine operating instructions
18.2. Hydraulics
Check hydraulic oil and hydraulic oil filter
If the filter must be replaced, dispose of it in accordance with the

environment protection laws.
18.3 Electrical system
Check the fixing of the cable harness and battery. Tighten if necessary
and secure against twisting.
18.4 Winter operation
* Before the cold weather starts, check the battery acid for frost
protection. Switch to winter diesel if necessary. Check engine coolant for
frost protection.
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Contents
NOTICE: The following work should be carried out in addition

to the weekly, the 50 and the 125-250 operating hour
maintenance work, see also maintenance plan, Sec.
14.2.
19.1 Engine
Please refer to the engine operating instructions for the

maintenance work
Replace the air filter
Open the cap, unscrew the filter cartridge, remove the cartridge
and replace with a new cartridge. Clean the dust separator.
Check valve play
For the adjustment of the valve play, see engine operating

instructions.
Check cooling system and hoses for leaks
Check electrical connections
Check pre-heating system
19.2 Hydraulics
Check primary valves
Readjust if necessary.
Replace hydraulic oil and filter 1501S/2001
The hydraulic oil should only be changed when warm (approx. 40

degrees C). Before changing the oil, the bucket must be in
direction of travel, the bucket tipped in central position and the
dumper aligned straight in the direction of travel.
Replace hydraulic oil and filter 1001/1501
The hydraulic oil should only be changed when warm (approx. 40

degrees C). Before changing the oil, the bucket must be in
direction of travel, the bucket tipped in and the dumper aligned
straight in the direction of travel.
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Contents
* Open the return filter (SW27).
* Place an oil tank with a capacity of at least 30 l under the opening.
* Unscrew the oil drain screw (SW17).
* Open the intake filter (horizontal) (SW27) and replace the filter cartridge.
* Remove the return filter (upper side of the hydraulic tank).
* Rinse out hydraulic tank if necessary.
* Close the stopper screw.
* Replace the vent filter element in the return filter.
* Top up with clean hydraulic oil via filter unit (filtration 16 mm) until the
inspection glass is covered up to the top edge.
* Insert a new return filter cartridge and close the cap properly.
WARNING: Dispose of used oil environmentally.
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Contents
NOTICE: The following work should be carried out in addition

to the weekly, the 50, the 125-250 and the 500
operating hour maintenance work, see also
maintenance plan, Sec. 14.2.
20.1 Engine
Please refer to the engine operating instructions for the

maintenance work
Check generator and starter
Clean fuel tank
Replace fuel filter
Dispose of filter in accordance with the environment protection

laws.
Check water pump
Replace air filter
Replace engine oil and oil filter
Dispose of engine oil and oil filter in accordance with the

environment protection laws.
20.2 Tyres
Check tyres for wear and damage, replacing if necessary.
20.3 Brakes
Functional test for efficiency of foot brake, parking brake and
auxiliary brake. If the braking action has become insufficient,
please contact the manufacturer.
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Contents
21 Maintenance after longer lay-up
21.1 Preparation for laying up
* Carefully clean and dry all parts of the machine.
NOTICE: If possible, do not leave machines standing in the open.

If it cannot be avoided, the machine should be parked on
wooden boards and covered with a tarpaulin.
* Lubricate all lubrication points
* Replace engine oil
* Grease the piston rods of the hydraulic cylinders
* Disconnect the earth cable from the battery or remove the battery and
store in a protected place
* Check the frost protection capacity of the coolant
21.2 Start-up after laying up
* Wipe grease from piston rods
* Install or connect battery
* Start engine and run without load
WARNING: When laid-up, the machine should be started and run without
load once a month.
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Contents
22 Lubricants table
Lubrication point Lubricant
Engine oil Fina Kappa 10 W 40 CF - 4 / SG
BP Energol SHF 46
Hydraulic oil
Fina Hydrav TSX 46
All lubrication points BP Energrease L 21 M
Temperature range of engine oil
from - 25 C to + 40 C outside temperature
Notice: All the greases specified are suitable from - 25 C to + 40 C
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Contents
23 Malfunctions
Defect Cause Rectification
ENGINE
Engine cannot be started No fuel Refuel
Battery power insufficient Charge battery, replace
Fuel filter contaminated Clean fuel filter
Pre-glow system defective Replace pre-glow system

(Service workshop)
Fuel line leakage Replace fuel line
Insufficient engine power Air filter contaminated Clean air filter
Engine not at operating temperature Warm up engine
Engine overheated Check cooling system
INDICATOR LAMPS
Engine oil pressure indicator Oil pressure too low Stop engine immediately, check oil
lamp comes on during level and top up if necessary
operation
If oil level is correct, oil pump is
defective
(service workshop)
Temperature display rises Oil level too low Top up oil

above 100 C
Cooling water level too low Top up coolant
Fan blades rotate too slowly Re-tension V-belt
Air filter contaminated Clean air filter
Charge monitor lamp comes Generator not charging properly Re-tension V-belt
on during operation
Parking brake pilots lamp lightsOil level in the tank of the main braking Refill oil
up during operation cylinder is too low
Pilot lamp for hydraulic oil filter Oil filter clogged Change oil filter
lights up and audible warning
signal is given when engine is Switch at filter defective Change witch
warm
Fuel reserve pilot lamp lights Too little fuel Refill fuel
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Contents
Defect Cause Rectification
S E A L I N G S, H O S E S
Oil, fuel spots below the engine Loose hose connections Tighten hose connection
Sealings and/or hoses damaged Change sealings and/or hoses

and check and refill oil level,
if necessary
Oil loss in hydraulic system Loose hose fittings Tighten hose fittings, check
hydraulic oil level, top up if
necessary
Sealings, hoses, or piping damagedChange sealings, hoses, piping

Rohrleitungen beschdigt (service workshop)
STATIC DISPLACEMENT DRIVE

Driving not possible Solenoid valve for forward and Check electric switch and contacts
reverse defective or without current (franchised workshop)
No supply pressure Check by means of pressure

gauge (approx. 18 bars are
required)
(franchised workshop)
Parking brake applied Loosen parking brake
Steering not possible Defective steering system Franchised workshop
Defective steering cylinder Franchised workshop
Dumper doesn`t lift load Primary pressure relief valve Check pressure with pressure
adjusted too low gauge -> setting 170 bar
(franchised workshop)
Overloaded Dump material
Cylinders are lowering too fast Sets of seals soiled or defective Franchised workshop
Excessive leakage at spool valve Franchised workshop
Hydraulic oil foaming out of the tank Air in the system Retighten suction hoses
venting system
Dump body was lowered with Remove oil traces (no dump body
engine at standstill motion with engine at standstill)
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Contents
Fault Cause Remedy
HYDRAULIK SYSTEM
Dumper cannot lift load Primary pressure valve set too low Check pressure using pressure
.-> set value 175 bar
(authorised workshop)
Overloaded Tip out material
Cylinder falls too quickly Gasket set contaminated or Authorised workshop

defective
Excessive leak on the distributing Authorised workshop

regulator
Hydraulic oil bubbles out of the Air in the system Tighten intake hosesn
tank vent
Bucket was lowered with the Remove traces of oil (do not move
engine switched off bucket when the engine is
switched off)
75
Safety instructions
A Safety instructions for the operation of earth-moving machinery
1 Preface
The following are designated as earthmoving machinery:
- excavators,
- loaders,
- excavator-loaders,
- bulldozers,
- dump trucks,
- scrapers,
- graders,
- pipe-laying machines,
- trench cutting machines,
- compactors and
- special-purpose earthmoving machines.
Instructions on the safe operation of earthmoving machinery are given below.
When operating and servicing earthmoving machinery, the respective national safety instructions,
e.g. in the Federal Republic of Germany the accident prevention regulations for earthmoving
machinery (VBG 40), vehicles (VBG 12) and the safety regulations for vehicle maintenance (ZH 1/
454), must also be observed.
As a supplement to the operating instructions, the statutory regulations for public road transport
and for accident prevention must be observed. Such regulations may, for example, also relate to
the handling of hazardous substances or the wearing of personal protective gear.
In addition, existing safety requirements must also be observed for special locations (tunnels,
galleries, quarries, pontoons, contaminated areas etc.).
2 Intended use
2.1 Earthmoving machinery must be operated only under the intended operating conditions provided
by the manufacturer in the operating instructions.
2.2 The use is as intended when the earthmoving machine is used with the corresponding operating
devices in accordance with the European or national safety regulations or for other work for which
it is suitable according to the manufacturers instructions.
2.3 Changes to the safety systems of the earthmoving machine by the owner without the prior consent
of the manufacturer are inadmissible.
2.4 Spare parts must comply with the technical requirements specified by the manufacturer.
-A1-
Safety instructions
3 General information
3.1 Earthmoving machinery must be operated or serviced independently only by persons
- who are physically and mentally suited,

- who are instructed in the operation or servicing of the earthmoving machine and have furnished
proof of their capacity to do so to the contractor,
- and who can be expected to perform the tasks assigned to them reliably.
The statutory minimum age must be observed.
3.2 Any working method prejudicial to safety must be avoided.
3.3 The legal load of earthmoving machinery must not be exceeded.
3.4 The earthmoving machine must be operated only in a safe, serviceable state.
3.5 The operating instructions issued by the manufacturer must be observed for operation, servicing,
repair, assembling and transport.
3.6 The contractor must supplement safety regulations where necessary with special instructions
adapted to local operating conditions.
3.7 Operating instructions and safety-relevant instructions must be in safekeeping by the operators
seat. In the case of earthmoving machinery without cabs, they may be kept at the application site.
3.8 The operating instructions and the safety instructions must be present in full and in a legible state.
3.9 Safety devices on earthmoving machinery must not be disabled during machine operation.
3.10 Protective working gear must be worn during machine operation. Rings, scarves and open jackets
must be avoided. Goggles, safety footwear, safety helmets, protective gloves, reflective
waistcoats, ear plugs etc. may be needed for specific operations.
3.11 Prior to beginning work, information on first aid and on emergency services (ambulance, fire
service, helicopter) is essential.
It must be checked that a first-aid kit complying with the regulations is present.
3.12 The location and operation of fire extinguishers on the earthmoving machine and the local fire-
alarm and fire-fighting facilities must be known.
3.13 Loose parts, e.g. tools or other accessories, must be secured on the earthmoving machine.
3.14 Doors, windows, covers, flaps etc. must be secured against inadvertent closing when in opened
state.
-A2-
Safety instructions
4 Hazard zone
4.1 All persons must keep out of the hazard zone of earthmoving machinery.
The hazard zone is the surrounding area of the earthmoving machine in which persons may be
reached by operation-induced movements of the earthmoving machine, its operating devices and
its attachments or by swinging-out loads, by falling material or by falling operating devices.
4.2 The machine operator may work with the earthmoving machine only if no person is within the
hazard zone.
4.3 The machine operator must give a warning signal if persons are exposed to danger.
4.4 The machine operator must stop working with the earthmoving machine if persons fail to leave the
hazard zone despite a warning.
4.5 No person may have access to the pivot range of earthmoving machinery with centre pivot
steering when the engine is running.
4.6 An adequate safety clearance (min. 500 mm) must be kept from fixed components, e.g. structures,
quarry faces, scaffolding or other machines, to prevent the risk of crushing.
4.7 If the safety clearance cannot be observed, the area between fixed components and the operating
range of the earthmoving machine must be closed off.
4.8 If the machine operator has a restricted view of his driving and operating area due to deployment-
induced influences, he must be assisted by a marshaller or the driving and operating area must
be secured by a fixed barrier.
5 Stability
5.1 Earthmoving machinery must be used, driven and operated in such a way that its stability or its
security against overturning is guaranteed.
5.2 The machine operator must adapt the travelling speed to local conditions and keep the operating
device as close as possible to the ground when driving over sloping or uneven terrain.
5.3 In the case of earthmoving machinery fitted with additional stabilising devices to increase stability,
the manufacturers operating instructions must be observed.
5.4 Earthmoving machinery must be kept sufficiently far away from the edge of quarries, trenches,
stockpiles and slopes to prevent any risk of overturning.
5.5 Earthmoving machinery must be secured against inadvertent movement or slippage when working
close to the edges of excavations, shafts, ditches, trenches and slopes.
-A3-
Safety instructions
6 Operation
6.1 General
6.1.1 Machine operators must be appointed by the contractor to operate or service the earthmoving
machine.
6.1.2 Operating devices (adjusting components) may be activated only by the operator or from the
operators console.
6.1.3 The steps and areas provided must be used for access to the machine. They must be kept in a
non-slip state.
6.1.4 For earthmoving machinery fitted with quick-change devices for mounting and discharging the
operating device, of which locking mechanism is not clearly visible from the operators workplace
(design, soiling), the following additional safety measures are essential:
- The firm fit of the operating device at the connection of the quick-change device must be
controlled directly by the operator or another person.
- If this is not feasible, the operating device must be lifted only to such an extent that the firm fit
can be checked by rearward tilting and dumping.
All persons must keep out of the hazard zone during this test run.
6.2 Transport of persons
6.2.1 Apart from the machine operator, no persons may be transported on earthmoving machinery
unless special places have been provided for this purpose by the manufacturer.
These special places must be equipped with fixed seats and securing devices to prevent
persons from falling from the earthmoving machine.
6.2.2 No one may mount or alight from earthmoving machinery except with the prior consent of the
machine operator and when the machine is stationary.
6.3 Driving
6.3.1 Prior to starting up the earthmoving machine, the operators seat, the mirror and the adjustable
parts must be set in such a way as to ensure operational safety.
6.3.2 The safety belt must be applied when earthmoving machinery is fitted with a ROPS system or a
TOP protective structure.
6.3.3 The windows must be clean, and free from condensation and ice.
-A4-
Safety instructions
6.3.4 Cold-start aids (ether) must not be used near sources of heat or open flames or on poorly
ventilated premises.
6.3.5 The roadways must be designed so as to ensure smooth, safe operation, i.e. they must be
adequately wide with the lowest possible gradient and laid on a base with a good bearing
capacity.
6.3.6 The bearing capacity of bridges, basement ceilings, vaulting etc. must be checked before driving
over them.
6.3.7 The clearance dimensions of underpasses, tunnels etc. must be checked prior to driving into
them.
6.3.8 On high gradients and slopes, the load must be kept towards the incline if possible to increase
stability.
6.3.9 The engine must not be out of gear when driving downhill. Prior to driving down the slope, the
gear suited to the terrain must be selected and no gear change made while driving downhill.
6.3.10 Slopes on driveways must be designed to ensure that earthmoving machinery can be safely
braked.
6.3.11 Extensive reversing should be avoided.
6.3.12 Earthmoving machinery must not be driven on the public highway unless an operating and driving
licence compatible with the national traffic legislation is available.
6.3.13 Outside the public transport area, e.g. on construction sites, traffic regulations should be applied
analogously. This point should also be taken into account there with respect to the driving licence.
6.4 Loading, unloading
6.4.1 The machine operator must not swing the operating devices across occupied driving, operating
and working places of other machines unless they are secured with fall-over protective structures
(FOPS).
6.4.2 If the required protection above the drivers cab is not present, the driver of that vehicle must
leave the drivers stand when swinging across it is necessary.
6.4.3 The vehicles must be loaded in such a way that they are not overloaded and cannot lose any
material while being driven. They must be loaded from the lowest possible height.
6.4.4 The unloading locations must be designed to ensure that extensive reversing is avoided as fast
as possible.
6.4.5 Earthmoving machinery must not be operated at dumping sites unless appropriate measures have
been taken to prevent inadvertent movement or overturning.
-A5-
Safety instructions
6.5 Marshallers
6.5.1 Marshallers must be clearly recognisable, e.g. through special clothing. They must be within the
visual range of the machine operator.
6.5.2 During their marshalling activity, marshallers must not be given other tasks which might distract
them from their functions.
6.6 Deployment with risk of falling objects
6.6.1 When there is a risk of heavy objects falling, earthmoving machines must not be used unless their
operators stand is fitted with a protective roof (FOPS); in the case of excavators a protective
windscreen (FGPS) must also be present.
6.6.2 Close to earth and rock walls, excavators should be set up and operated in such a way that the
operators stand and the steps leading to it are on the side of the earthmoving machine away from
the wall.
6.6.3 Demolition work must not be done with earthmoving machinery unless it is assured that persons
are not at risk.
6.6.4 Prior to carrying out demolition work with excavators, e.g. demolishing with demolition pendulums,
the weight of the pendulum must be coordinated with the load capacity of the machine and the
boom length.
6.6.5 The highest point of the operating device of the earthmoving machine should be above the
component to be demolished.
6.7 Operation in areas carrying underground lines
6.7.1 Prior to carrying out excavation work with earthmoving machinery, a check must be made in the
area to be excavated for underground lines which might present a risk to persons.
6.7.2 If underground lines are present, their location and course must be determined by agreement with
the owner or operator of the line and the necessary safety measures must be stipulated and taken.
6.7.3 The course of lines in the construction site zone must be clearly marked under supervision prior to
earthmoving work being commenced. If the location of lines cannot be determined, exploratory
trenches must be dug, if necessary by hand.
6.7.4 If underground lines or their protective coverings are contacted or damaged inadvertently, the
machine operator must stop work immediately and notify the supervisor.
6.8 Operation close to overhead electric lines
6.8.1 When working with earthmoving machinery close to overhead electric lines and contact lines, a
safety clearance dependent on the voltage rating of the overhead line must be kept between such
lines and the earthmoving machine and its operating devices to prevent a voltage transfer. This
also applies to the clearance between such lines and attachments or slung loads.
-A6-
Safety instructions
6.8.2 The following safety clearances are applicable in Germany:
Voltage rating Safety clearance

up to 1000 V 1.0 m
more than 1 kV to 110 kV 3.0 m
more than 110 kV to 220 kV 4.0 m
more than 220 kV to 380 kV
or for unknown voltage rating 5.0 m
6.8.3 All working movements of earthmoving machinery, e.g. the boom positions, the swinging of
cables and the dimensions of slung loads must be taken into account, as must ground
irregularities through which the earthmoving machine is tilted and thus comes closer to overhead
lines.
Wind may make overhead lines and operating devices swing out, reducing the clearance.
6.8.4 If adequate clearance from electrical transmission lines and contact lines cannot be maintained,
the contractor must implement other safety measures against voltage transfer by agreement with
the owner or operator of the lines. This may be done, for example, by
- switching off the current,

- moving the overhead line,
- cabling or
- limiting the working range of earthmoving machinery.
6.8.5 In the event of a voltage transfer, the following rules must be observed:
- Do not leave the operators cab.

- Warn other persons not to approach or touch the machine.
- If possible, bring the operating device or the entire earthmoving machine out of the hazard
zone.
- Have the current switched off.
- Never leave the machine until the contacted/damaged line has been switched off.
6.9 Operation below ground and in enclosed areas
If earthmoving machinery is used below ground or in enclosed areas, adequate ventilation must
be provided and the valid regulations must be observed.
6.10 Stoppages
6.10.1 Prior to breaks or finishing work, the operator must move the earthmoving machine to level ground
with an adequate bearing capacity and secure it from movement.
The operating devices must be set down or secured in such a way that no inadvertent movement
is possible.
-A7-
Safety instructions
6.10.2 The operator must not leave the earthmoving machine unless the operating devices are set down
or secured
6.10.3 Earthmoving machines must be parked only where they present no obstacle, e.g. to public
highway or site traffic. If necessary they must be secured by warning devices such as warning
triangles, warning cords, flashing or warning lamps.
6.10.4 Prior to leaving the operating stand, the operator must set all control devices to neutral and apply
the brakes.
6.10.5 Before leaving the earthmoving machine, the operator must first switch off the driving motors and
secure them against unauthorised starting.
6.11 Lifting-gear deployment
6.11.1 Lifting-gear deployment covers the lifting, transporting and lowering of loads by means of a
slinging aid (cable, chain etc.), with the assistance of persons being required for slinging and
releasing the load.
This means, for example, the lifting and lowering of pipes, shaft rings or containers with
earthmoving machinery.
6.11.2 Earthmoving machinery must not be used in lifting-gear deployment unless the prescribed safety
devices are present and fully functioning.
For hydraulic excavators, for example, these are:
- safe slinging facility for a load-bearing device,

- working load table,
and in addition for hydraulic excavators with a legal working load of more than 1000 kg or a
overturning moment of more than 40 000 Nm
- overload warning system,

- open-circuit monitoring system(s) at boom lifting cylinder(s).
6.11.3 Loads must be slung in such a way that they cannot slip or fall out.
6.11.4 Persons involved in guiding the load and riggers must remain within the visual field of the machine
operator.
6.11.5 The machine operator must keep loads as close as possible to the ground and prevent their
swinging.
6.11.6 Earthmoving machinery must not be driven with a slung load unless the roadway is as even as
possible.
-A8-
Safety instructions
6.11.7 When earthmoving machinery is in lifting-gear deployment, riggers may approach the boom only
with the consent of the machine operator and only from the side. The machine operator must not
give his consent unless the earthmoving machine is stationary and the operating device is not
being moved.
6.11.8 No damaged or inadequately dimensioned slinging aids (cables, chains) must be used.
Protective gloves must always be worn when working with slinging aids.
7 Assembly, servicing, repair (maintenance)
7.1 Earthmoving machinery must not be assembled, converted or dismantled except under the
direction of qualified personnel appointed by the contractor and with the manufacturers operating
instructions being observed.
7.2 Work on such components as

- braking,
- steering,
- hydraulic and
- electrical systems
of the earthmoving machine must be performed by specially trained skilled personnel only.
7.3 Stability must be ensured at all times including during maintenance work.
7.4 The operating devices must be secured from moving by being set down on the ground or with
equivalent measures, e.g. supporting sleeves or jacks. If necessary, the superstructure of
excavators must be secured against swivelling.
7.5 In the case of earthmoving machinery with centre pivot steering, the pivot joint must be positively
locked when work is being done in that area.
7.6 When installing and dismantling counterweights, they must be placed only at the locations
prescribed by the manufacturer.
7.7 For jacking up earthmoving machinery, lifting gear must be used in such a way as to prevent any
slippage. Tilted positions of the lifting gear or their inclined application are inadmissible.
7.8 Lifted earthmoving machinery must be secured by shoring up, e.g. with diagonal stacks of planks
or squared timbers or with jacks.
Earthmoving machinery which is lifted with operating devices, must be supported immediately
after being lifted. No work may be done under raised earthmoving machinery which is held in
place only by the hydraulic system.
-A9-
Safety instructions
7.9 Prior to replacing the bucket scrapers of scraper vehicles or scraper-dozers, the scraper buckets
must be set down on a non-tilting, unbreakable base.
7.10 Maintenance and repair work on scraper buckets must be done only when the closing flap is
secured.
7.11 Prior to any maintenance and repair work, the driving motors must be stopped.
Only maintenance or repair work which cannot be carried out with a drive is exempt from these
requirements. It must be ensured that the drive can be stopped immediately in any hazardous
situation prior to beginning such work.
7.12 In the case of earthmoving machinery with a combustion engine, the battery must be disconnected
prior to any work on the electrical system or any arc welding.
7.13 When disconnecting the battery, first the negative and then the positive pole must be
disconnected. Reconnection is done in the reverse sequence.
7.14 The battery must be covered with insulating material if any maintenance work is done in its vicinity.
No tools may be laid down on the battery.
7.15 In the case of electrically driven earthmoving machinery, the electrical systems and where
necessary the mobile connection lines must be switched off and secured against inadvertent or
unauthorised switching on.
7.16 Protective devices of moving machine parts must not be opened or removed unless the drive has
been stopped and secured against unauthorised starting.
Protective devices are, for example, motor compartment flaps, doors, guards, housings.
7.17 On completion of assembly, maintenance or repair work, all protective devices must be correctly
mounted again.
7.18 Welding work on load-bearing parts of earthmoving machinery, e.g. lattice booms, lifting cranks,
must be carried out in accordance with the recognised rules of welding technology.
7.19 No welding or drilling may be carried out on roll-over, tipp-over or fall-over protective structures
(ROPS, TOPS, FOPS).
7.20 Modifications, e.g. welding on the hydraulic or compressed air system, must not be undertaken
except with the authorisation of the manufacturer.
- A 10 -
Safety instructions
7.21 The control pressure, dynamic pressure and internal tank pressure must be reduced before
starting work on the hydraulic system.
7.22 Only those hoses and lines prescribed by the manufacturer may be used.
7.23 Hydraulic hoses and lines must be skilfully laid and installed.
7.24 Smoking and the use of open flames are forbidden during refuelling.
8 Recovery, towing, transport
8.1 The recovery and towing of earthmoving machinery must be done with adequately dimensioned
towing devices only.
8.2 The towing points or blocks prescribed by the manufacturer, e.g. lugs, hooks, must be used.
8.3 The towing vehicle must be driven slowly. All persons must keep out of the range of towing
devices.
8.4 During loading and transport, earthmoving machinery and any necessary auxiliary devices must
be secured against inadvertent movement.
8.5 The travelling gear and crawler unit of earthmoving machinery must be cleaned of mud, snow and
ice to such an extent that ramps can be negotiated without a risk of slippage.
8.6 Low-loader access ramps must be fitted with wooden planks before being negotiated by tracked
vehicles.
8.7 Before the actual transport, the route to be covered should be inspected to ensure that the roads
are wide enough, bridge and underpass openings large enough, and roads, tracks and bridges
are strong enough.
9 Supervision
9.1 The prescribed deadlines for recurring tests must be observed.
9.2 Before starting his work, the machine operator must also check as specified by the manufacturer
that safety, driving and operating devices, e.g. overload warning system, brakes, steering,
lighting, are fully functioning.
When mounting operating devices on quick-change systems, the firm fit of the operating device
must be checked by moving it in all directions. During this process, all persons must keep out of
the hazard zone.
- A 11 -
Safety instructions
9.3 Hydraulic hoses must be replaced as soon as the following damage is noticeable:
- damage to the outer layer through to the intermediate layer,

- brittleness in the outer layer,
- distortions in pressurised or unpressurised state not conforming with the original shape of the
installed hose,
- leakages,
- damage to the hose fittings or to the connection between fittings and hose,
- storage damage (the shelf life of the hose should not exceed 2 years),
- damage resulting from exceeding the standard service life (the service life under normal
conditions should not exceed 6 years).
9.4 The coolant level must be checked only when the lid is cool; the lid must be turned carefully to
reduce the pressure.
9.5 The machine operator must report any recorded defects without delay to the supervisor and, in the
event of a change of operator, to the operator replacing him.
9.6 In the event of defects endangering the operational safety of the earthmoving machine, it must be
taken out of operation until the defects have been rectified.
- A 12 -
Safety instructions
- A 13 -
Neuson Limited
Crown Business Park
Tredegar
Gwent South Wales NP22 4EF
Phone (+44) 1495 723083
Fax (+44) 1495 713941
e-Mail: office@liftondumpers.com
www.neusonkramer.com
Neuson Baumaschinen GmbH

Haidfeldstrae 37
A-4060 Linz-Leonding
Austria
Tel.: (+43) 732 90 5 90 - 0
Fax: (+43) 732 90 5 90 - 200
e-mail: verkauf@neuson.com
www.neusonkramer.com

1001 Operators Manual DUMPER

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User manual

1.1Type plate ............................................................................................................................................... 11

1.2Instructions for ordering spare parts ...................................................................................................... 11

2.1Safety rules ............................................................................................................................................. 13

2.3EC- Declaration of Conformity 1001 ....................................................................................................... 17

2.4EC-Declaration of Conformity 1501 ......................................................................................................... 18

2.5EC- Declaration of Conformity ................................................................................................................ 19

3.1Technical specifications ......................................................................................................................... 20

Dimensions 1001 .................................................................................................................................... 20

Main specifications 1001 ........................................................................................................................ 20

Dimensions 1501 .................................................................................................................................... 21

Main specifications 1501 ........................................................................................................................ 21

Dimensions 1501 S ................................................................................................................................ 22

Main specifications 1501 S ..................................................................................................................... 22

Dimensions 2001 .................................................................................................................................... 23

Main specifications 2001 ........................................................................................................................ 23

Dimensions 2001 SLE ............................................................................................................................ 24

Main specifications 2001 SLE ................................................................................................................ 24

Engine 1001 ........................................................................................................................................... 25

Engine 1501/1501 S ............................................................................................................................... 25

Engine 2001/2001SLE ............................................................................................................................ 25

Drive gear ............................................................................................................................................... 26

Brakes Dumper 1001/1501/1501 S ......................................................................................................... 26

Brakes Dumper 2001 .............................................................................................................................. 26

Working hydraulics ................................................................................................................................. 26

Articulated frame steering structure ........................................................................................................ 27

Noise emission ...................................................................................................................................... 27

Fire extinguisher ..................................................................................................................................... 27

Adhesive labels ..................................................................................................................................... 28

Label position ......................................................................................................................................... 28

4 Sub-assembly identification 1001/1501 ....................................................................................................... 32

Sub-assembly identification 1501 S ....................................................................................................... 33

Sub-assembly identification 2001 .......................................................................................................... 34

Sub-assembly identification 2001 SLE ................................................................................................... 35

4.1 Operating equipment 1001/1501/1501 S up to serial number AB..... ......................................................... 36

Operating equipment 1001/1501/1501 S from serial number AB..... ..................................................... 37

Operating equipment 2001 / 2001SLE ................................................................................................... 38

Arrangement of the fuses in the fuse box Dumper 2001 ....................................................................... 39

Standard drivers seat ............................................................................................................................ 40

Drivers seat with ROPS roll bar ............................................................................................................. 40

Overroll Bar ROPS ................................................................................................................................. 40

Overhead guard FOPS .......................................................................................................................... 40

5 Lifting the dumper ........................................................................................................................................ 41

6 Loading and transport .................................................................................................................................. 42

7 Towing device ............................................................................................................................................. 42

8 Loader unit (2001 SLE) ................................................................................................................................ 43

Information on working with the loader unit ............................................................................................ 44

9 Towing the dumper ...................................................................................................................................... 45

9.1Open high-pressue circuit 1001/1501/1501 S ........................................................................................ 45

9.2Loosen spring-loaded brake 1001/1501/1501 S .................................................................................... 45

9.3Opening the high-pressure circuit 2001 ................................................................................................. 46

9.4Releasing the spring-loaded brake 2001 .............................................................................................. 46

10 Inspections before start-up .......................................................................................................................... 47

10.1 Visual inspection ................................................................................................................................. 47

10.2Check engine oil level ......................................................................................................................... 47

10.3 Check level of hydraulic oil ................................................................................................................. 47

10.4 Check coolant level ............................................................................................................................. 48

10.5 Refuelling ............................................................................................................................................. 48

10.6 Safety measures before start-up ......................................................................................................... 48

11 Starting the machine .................................................................................................................................... 49

11.1 Starting assistance (starting with an outside battery) ........................................................................... 50

12 Driving the dumper ...................................................................................................................................... 52

13 Hydraulic operation of the bucket 1501S / 2001 / 2001SLE ........................................................................ 53