Whether the operating hydraulics pressure on a DW90 is set right is something only the factory data can settle, and that data fills this 265-page Wacker Neuson DW90 service manual PDF, OEM document 1000333465, covering the DW60, DW90 and DW100 site dumpers. Separate hydraulics diagrams handle the DW60 and the DW90/DW100, while the wiring diagrams split into Tier III and Tier IV versions, down to a serial number break on the DW60 harness. Strand lists for every loom, from seat console to cabin, let you chase a circuit by wire number and color, and an SPN diagnosis code list decodes what the display is flashing at you. Fit the 12 V/100 Ah battery, confirm the 12 V/3.2 kW starter, and know the fuel pump rides on fuse F5 at 5 A. Guess a relief pressure and you can cook a pump. Bookmarked and keyword searchable, this PDF ends with your dumper hauling again.
What's Inside This Wacker Neuson DW60, DW90, DW100 Manual
| System | Pages | Key Topics |
|---|---|---|
| Operation | 9-22 | Information on This Service Manual, Identification of Warnings and Dangers, Explanation of Symbols and Abbreviations (Conversion Table) |
| Engine | 129-162 | Perkins Engine 854F-E34TTF (Engine Overview, Engine Exhaust Aftertreatment System, Representation with Auxiliary-Flow Diesel Particulate Filter, Engine Block Overview, Representation with Separate Intake-Manifold Pressure Sensor and Temperature Sensor, Turbocharger, Replacing the Oxygen Sensor, Check the Water Pump, Fuel System, Engine Malfunctions) |
| Hydraulic System | 163-180 | Hydraulic Pump (Diagram, Standard Operating Pump), Steering Valve, Priority Valve, Main Control Block |
| Electrical System | 181-222 | Ohmic Law; Power, Measuring Equipment, Measuring Methods, Cable Color Coding, Relays (Use, Mode of Function, Alternator, Starter), Lights Wiring Harness |
| Diagrams | 223-234 | Hydraulics Diagram, Hydraulics Diagram DW60/DW60P/DW60 Lrc, Hydraulics Diagram DW90/DW100, Wiring Diagram, Wiring Diagram Tier Iii, Wiring Diagram Tier Iv |
| Options | 235-265 | Immobilizer, Diagnosis Code List |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Screw in screws B gap to the housing | 34 mm (1.33 in) | p. 20 |
| Battery | 12 V/100 Ah | p. 34 |
| Battery (optional) | 12 V/120 Ah | p. 34 |
| Starter | 12 V/3.2 kW | p. 33 |
| Fuel pump fuse (F5) | 5A | p. 35 |
| Hydraulic hose identification code example | SLHYDR2SC16PN180PD180L1950D0 | p. 31 |
| Hydraulic reservoir capacity | 78.5 liters | p. 28 |
| Hydraulic reservoir capacity (middle of sight glass) | 55 liters | p. 29 |
| Fastening screw B torque | 8 Nm (6 ft.lbs.) | p. 70 |
| Hydraulic hose replacement interval | 6 years | p. 107 |
| Wheel nut tightening torque | 450 Nm | p. 109 |
| Jack lift capacity | 5000 kg | p. 109 |
Wacker Neuson DW60, DW90, DW100 Common Problems This Manual Covers
Wacker Neuson DW90 dumper engine cranks but won't start after multiple attempts in cold weather
Check the battery first: it should be a 12 V/100 Ah unit holding full charge, per the spec on page 34. Verify fuse F5 for the electric feed pump, rated 5A on page 35, then bleed air from the fuel lines. Test the 12 V/3.2 kW starter last; slow cranking usually traces back to the battery.
Manual Section: Engine MalfunctionsHydraulic system dead, skip won't tip and steering feels heavy right after startup
Check the hydraulic oil level at the sight glass before anything else; the reservoir holds 60 liters, per page 49. Verify the parking brake is fully released, because the brake valve blocks hydraulic function while applied. If oil and brake check out, test the pressure limiting valve; operating hydraulics should hold 240 bar maximum.
Manual Section: Hydraulic System MalfunctionsStuck in high gear on the road, won't shift down to low range for loading
Check the speed-select solenoid wiring before condemning the drive motor. Run a continuity test on the coil and connector using the measuring methods on page 181, and inspect the plug for corrosion or backed-out pins. Compare the circuit against the wiring diagram on page 192. Travel drive pressure must never exceed 450 bar during testing.
Manual Section: Electrical System p. 181Diagnostic lamp keeps flashing on startup and the engine refuses to crank or start
Read the stored fault before swapping parts; the engine electronics block starting until the active error clears. Match the code against the SPN diagnosis list starting on page 239. Check the 12 V/100 Ah battery under load first, because low supply voltage triggers phantom electronic faults and repeat no-start lockouts.
Manual Section: Diagnosis Code List (SPN) p. 239Temperature gauge climbing into the red and coolant boiling over on long uphill hauls
Check the coolant level cold and top up; the system holds 16 liters, per page 48. Inspect hoses and clamps for seepage, then blow debris out of the radiator core with compressed air. If the level keeps dropping, run a pressure leakage check on the cooling system before blaming the water pump.
Manual Section: Cooling System TroubleshootingFrequently Asked Questions
What are the torque specifications for Wacker Neuson DW90 wheel nuts?
The wheel nuts on the Wacker Neuson DW90 should be tightened to 450 Nm (332 ft.lbs). After changing a wheel, you must check the wheel nuts for tightness after 10 operating hours and retighten them if necessary. p. 109
What is the torque specification for Wacker Neuson DW60 hydraulic fittings?
The torque for metric hose fittings (light execution, DKOL) varies by nominal diameter. For example, a 05 nominal diameter fitting requires 15 Nm (11 ft.lbs), while a 32 nominal diameter fitting requires 220 Nm (162.3 ft.lbs). p. 36
How do I reset the maintenance meter on a Tier IV Wacker Neuson dumper?
The maintenance meter can be reset using the WANDA diagnostic tool. You must comply with the documentation provided for that specific tool. p. 127
What are the replacement specifications for the battery?
The standard battery is 12 V/100 Ah. A higher-capacity 12 V/120 Ah battery is available as an option. p. 33
What is the engine oil capacity for the Perkins engine (Tier III)?
The engine oil capacity for the Tier III diesel engine is 8.0 liters (2.1 gallons). p. 48
Is this Wacker Neuson DW60 manual a PDF I download?
You get a 265-page searchable PDF that downloads instantly after checkout. Open it on your laptop, tablet, or phone, and bring it right to the shop floor.
Does this Wacker Neuson DW60 manual allow printing?
Yes, printing is unrestricted: a single page, a chapter, or the lot, on letter or A4.
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