Wacker Neuson ST11 Manual

OPERATION & MAINTENANCE
MANUAL
Compact Track Loader
ST11
Item 8009641121
Revision
Date
101
March 2022

PRELIMINARY INFORMATION
This manual is supplied together with the spare parts manual with each machine.
The manual was created and formulated in conformity with the EEC regulations and in particularwith
the UNI-ISO 6750 regulation.
The manual supplies information about the operation of the machine, with particular reference tothe
safety procedures to adopt during its use. Furthermore, it contains useful advice and information for its
maintenance.
The information supplied does not claim absolute working safety, but supplies a reliable basis for its
achievement.
Safety instructions and precautions to be applied in general or in particular are listed in each chapter
in correspondence to the operating specifications.
Please follow the instructions in this manual and scrupulously follow the recommendations.
Respecting the procedures will allow operating in absolute tranquillity and safety.
The company, in its constant search to improveits products,or for reasonsof constructive,technical-
functional and commercial requirements, reserves the right to modify the machine without the
obligation to timely update the sections of this publication involved.
Designs and texts may disagree more or less obviously with some technical characteristicsof the
machine; in this case, contact the manufacturer before proceeding.
In the manual, and if necessary on some parts of the machine, certain symbols are used, followed
according to the case by messages inherent to safety. For more attentive and easier reading of these,
follow the warnings as described below:
DANGER
Where this symbol appears, there is a high degree of danger and risk for the safety and life of the
operator or other persons. Use all the precautions and measures recommended in this manual and
dictated by common sense.
WARNING
This symbol, signals the presence of a potential danger which can be avoided by following and
respecting the instructions listed in this manual or using the right precautions.
The use of the machine is subordinate to reading and knowledge of this manualwith
particular reference to the information regarding safety.
This manual must always accompany the machine and must be kept within easy reach of the operator.
Other than providing instructions on the proper use of the machine, it guards against risks and dangers
deriving from improper use and not in conformity with the use for which it was intended.
CONSERVE THIS MANUAL FOR THE FUTURE REFERENCES
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Table of Contents
01
02
03
04
05
PRESENTATION OF THE MACHINE
GENERAL SAFETY REGULATIONS
OPERATER CONTROLS
EQUIPMENT AND ACCESSORIES
MAINTENANCE
4
10
15
29
34

01 – PRESENTATION OF THE MACHINE
The loading shovel has been designed and built for loading and unloading earth, gravel, sand, debris
and other loose material and is however suitable to operate in compliance with the features and
performance indicated in this manual.
It is a machine with Diesel internal combustion motorisation with hydrostatic transmission, joy-stick
type servo-controls for traversing and manoeuvre of the arms and the bucket.
Movement is obtained using four rubber tracks with suitable tread to operate inside without dam-
aging the floor.
The machine is equipped with an open or closed driver’s cabin with heating plant and an incorporated
protective structure against tipping ROPS and against falling objects FOPS – 1st level.
FOPS 2nd level protection can be supplied on request for heavy duty and/or particular use; bolt in
replacement of the 4 eye-bolts.
MACHINE IDENTIFICATION
The machine is fitted with a special plate carrying the
identification data of the machine, riveted to the left
front side of the frame.
For any queries always quote the type and serial
number stated on the plate.
For further explanations, please consult the modes
on the Spare Parts Manual attached to the machine.
Other accessories which can be installed in the machine
will be provided with their nameplate, which can be seen
from the external part of the accessory.
For further information consult the documentation related
to the specific element.
MAIN PARTS OF THE MACHINE
1. Loading bucket
2. Non-slip access steps
3. Safety bar
4. Lifting eye-bolts
5. Cabin ROPS-FOPS
6. Hydraulic oil tank
7. Cowling
8. Diesel tank (RIGHT and LEFT)
9. Lever arm
10. Bucket release and various equipment
11. Handle for ascent and descent
12. Auxiliary power take off (P.T.O)
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TECHNICAL DATA
ENGINE
Brand and model Kubota V1505T
Calibration Power at 2800 rpm HP/Kw 41/30
Cylinders Nº 4
Displacement cm31498
Cooling water
HYDRAULIC SYSTEM:
Hydrostatic drive with double axial piston pump and variable cylinders connected to two two-
speed geared motors, one for each track roller.
Negative braking system on the geared motors
Main variable-cylinder axial piston pump Lt/min 57.4 x 2
Auxiliary gear pump Lt/min 39 x 1
Total capacity Lt/min 153.8
Useful capacity for power take off (PTO) Lt/min 39 a 180 bar
Max. operating pressure bar 180
Hydraulic servo-controls with joy sticks for traversing and manoeuvre of arms and bucket.
Floating electrovalve to adjust the bucket to the ground
Safety electrovalve to block arm descent
Electro-valve for 2nd speed control
Heat exchanger for the cooling of the hydraulic oil.
Hydrostatic steering
FRAME:
Chassis in box-type sheet steel and shaped
RUBBER TRACKS:
Width mm 250
PERFORMANCE:
Weight when fully eupped (including
operator)
Kg 2220
Bucket capacity (SAE capacity m³ 0.245)
- 35% T.L. (*) ISO 14397/1-2 Kg 400
- 50% T.L. (*) ISO 14397/1-2 Kg 520
(*)T.L.= Tipping Load = Max loadpermitted by the machine withmaximum working radius at tipping limit.
Tear strength at tooth daN 930
Lifting force at floor level daN 1030
Transfer speed I/II Km/h 4.5÷10
Possible gradient % more than100
Specific ground pressure: - when empty Kg/cm20.33
- when loaded Kg/cm20.40
Autonomy About hours 8

OVERALL DIMENSIONS
TRANSPORT AND HANDLING
LOADING WITH RAMPS AND TRANSPORT BY TRUCK
The machine loading and unloading operations must be carried out on a compact and level
surface.
Check that the transport vehicle is in perfect condition. Apply the hand brake and insert safety
wedges at the front and rear of the rear axle tyres.
The vehicle engine must be off and the key removed from the ignition. The body must be level.
Position the machine at the rear of the truck, ensuring that the longitudinal axle coincides with that of
the truck.
Check that the ramps are suitable for the vehicle to be loaded. Only use homologated and/or
certified ramps.
Check that the ramps are perfectly clean and free of grease and that there is no risk whatsoever of
the tracks .
Check that the ramps are long enough to avoid problems during ascent and descent of the machine. The
length of the ramps must be such that their inclination with respect to the height of the truck loading
platform is between 15º and 16º.
Check that the ramps are properly coupled to the transport vehicle and appropriately
spaced.
The width of the ramp must be such as to allow comfortable passage of the tracks .
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The ascent and descent operations must always be carried out with the machine running and the
hydraulic oil at operating temperature.
Do not use the ramps as a gangway for crossing from one vehicle to the next.
For loading and unloading of the machine it is recommended to ascend in reverse gear and descend in
forward gear. In both cases it is recommended to keep the arm lowered and the bucket turned
downwards, parallel to the ramps. Block the eventual lowering of the loading platform with a truss or
other equipment.
Before ascending or descending, check perfect alignment between the tracks and the ramps. Do
not steer or adjust direction while on the ramps. If necessary, return to the point of departure,
repositioning correctly.
Caution of passage in the connection area between the ramps and the loading platform of
the truck; the steep slope must be negotiated by moving very slowly and withextreme caution.
Be twice as careful in the descent phase since the unbalance towards the bottomin this case is much
higher. It is recommended to lower the arms and turn the bucket forwards to allow eventual
emergency shutdown.
All the loading and unloading operations of the machine must be carried out and co- ordinated by
at least a second person who controls good progress of the operations.
TRANSPORT
Once the machine has been positioned on the load plane, lightly rest the bucket and proceed to
blocking the machine lengthwise by inserting wedges in front of and behind the track rollers.
For transversal and vertical blocking use belts to prevent lateral and vertical movement
owing to jolts during transport.
Measure and check the maximum height of the load. During transport always follow the road
regulations and the specific regulations in force in the various countries of transit.
LIFTING
Check that the cabin is correctly fixed to the frame before lifting the machine.
Use the 4 supplied eye-bolts to lift the machine, by fixing them to the special seats located on the roof
of the cabin.
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If the eyebolts are removed, close the four seats with the plastic caps supplied. Any
infiltration of water could seriously damage the electrical system of the right-hand
and left-hand dashboard.
Restrict the lifting area, prohibiting access to foreign personnel. Do not pass over persons or things and
ensure that the loading area is free of any obstacles (electric and telephone cables, etc.).
IT IS STRICTLY PROHIBITED TO WALK OR STAND UNDERTHE SUSPENDED LOADS.
- Use cables or chains with adequate capacity for the load to be lifted.
- Attach the ropes or chains to the previously bolted eye-bolts and proceed with lifting avoiding
sudden movements and dangerous machine swaying.
- During transport follow the instructions previously recommended.
PRESCRIPTIONS FOR CIRCULATION ON ROADS
For correct road circulation comply to all specified below.
1. Flashing lights.
2. Shovel blocking pin in maximum lifting position
3. Shovel sharp edge lateral and front protections.
4. Plate positioning.
5. Frame number punching area.
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PRESCRIPTIONS
- Working system commands must be blocked. Involuntary lifting of
arms is prevented by the hydraulic block inserted on start-up of the
machine.
- Disconnection and insertion is controlled by a button (ref. 4) on the
right command panel.
- Obligation for approved yellow flashing light. This functions even
when the use of a lighting device is not obligatory.
- Front loading shovel in max. lifting position and blocked to the frame using the special retainer.
- The shovel’s sharp edge must be protected by a special protection indicated with red and white
reflective stripes.
- The working lights must always be switched off.
- In each case the prescriptions inserted into the vehicle registration document and in the Highway
Code must be respected.
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02 – GENERAL SAFETY REGULATIONS
The plates applied, other than indicating the various manoeuvres for machine control and use, serve
to point out the risks connected with machine operation. An operator who wears glasses mustuse
them to read the plates.
Keep all the plates clean and legible paying particular attention to the safety warnings indicated.
Replace any damaged or missing plates, which may be obtained from the manufacturer on request.
GENERAL REGULATIONS
Carefully follow the safety warnings contained in the manual and applied on the vehicle; these signal a
potential danger and point out the precautions to take to prevent it. If the warning message is notfully
understood, ask for an explanation from your employer or from your authorised dealer.
- For the entire period of use of the machine, be aware of the possible dangers and take care to
prevent them.
- Inobservance of the regulations for use and maintenance make the machine dangerous to both
the operator and others.
- Do not use the machine until it has been mastered perfectly.
- Do not start any work before having ascertained that your own safety and that of others is safe-
guarded.
- The safety prescriptions are pointed out on the parts and/or controls through special adhesive
labels. Keep them clean or replace them when they become illegible.
- Clothing must be as suitable as possible for the job, and in particular, not loose-hanging; avoid
scarves and ties. Follow the regulations concerning the use of individual protection, in particular:
oRigid helmet
oHeadphones
oShoes
oGloves
sp
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SAFETY REGULATIONS FOR STARTING
The machine must only be driven by qualified staff that are at least 18 years old. Before getting
on, inspect the machine.
To enter or exit the cabin it is advisable to always turn towards the vehicle.
Use the steps and the handles. Do not jump and do not use the controls as supports.
Before starting the machine, check, adjust and lock the seat into position to ensure maxi- mum
driving comfort and ease of handling of the controls
It is recommended to hoot before starting to move and manoeuvre.
OPERATING SAFETY
Never operate the machine in closed environments, unless there is an efficient system for
suction and discharge of flue gas.
Before using the machine , ascertain that all the safety devices are in place and in working order. Poor
visibility may cause accidents. Keep the windows clean and use the lights for better visibility. Do not
use the vehicle in reduced visibility conditions.
Do not use the machine before the hydraulic system oil has reached the appropriate temperature. It is
recommended to drive the machine at 60-70% of its power for the first 100 hours.
Before starting to drive or activate the equipment, ensure that there is nobody in the sur-
rounding working area. Should anyone enter into the manoeuvring zone, stop the machine.
On carrying out work on site, the overall height and width of the machine must always be taken
into consideration. The loading limits of the land, floor, ramps, etc. on which is to be operated must be
known.
Whenever possible, avoid crossing or going over obstacles: large irregularities in the ground, rocks,
felled trunks, steps, ditches, jumps and paths may cause the machine to tip-over.
- During transport or operation in proximity of high-tension wires, the safety distance must be
respected.
- Do not transport persons on the machine.
- Do not use the bucket to lift or transport persons.
- For safety reasons, do not try to climb on or of the machine while it is moving.
- In case of fire, do not extinguish with water. First of all, use the fire extinguisher, smother the fire
with sand or earth, or better, cover the fire with a blanket or cloth.
- When driving the machine pay particular attention to the condition of the ground; moderate
speed in the case of rain, snow or ice.
The machine must be driven and manoeuvred only from the driver’s seat, in aseated position
with the safety bar lowered and with safety belts fastened.
EMERGENCY EXIT
In case of EMERGENCY the operator can use n. 2 escape routes. These are the front opening and
the rear window of the driver’s cabin.
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REARWINDOW:
To remove the glass pull the relative peg (ref. 1) positioned on the
central part of the rubber seal and remove the insert it includes.
Push the glasstowards the outside with force (ref. 2) and exit
from the vehicle.
The rear window safety exit is not suitable for use in environments where polar clothing
is required.
N.B.: In machines equipped with a front door, which also
becomes an emergency exit, act as follows:
-
Pull the special peg (ref. 3) positioned in the upper central part
of the glass seal, push the glass out using the feet (ref. 4) and
exit from the vehicle.
MOVEMENT ON SLOPES
Movement on slopes and craggy areas must be carried out with caution; a high risk exist for
the operator and whoever is working in the area. To limit risks to a minimum follow the
indications below.
- The loaded shovel must always be upstream, both in ascent and in descent.
- The empty shovel must always be downstream, both in ascent and in descent.
- The load must always be as low as possible.
- Avoid travelling over land where lateral and longitudinal slopes are both present.
- Never pass across slopes.
- Ascent and descent must be carried out by following the slope in a straight line and not at an
angle or in an oblique manner.
MOVEMENT
WITH LOADED SHOVEL
IN ASCENT
IN DESCENT
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SAFETY REGULATIONS FOR STOPPING AND PARKING
Never leave the machine with the engine running.
After leaving the driver’s seat, and after ascertaining that there are no persons near the machine,
slowly lower and rest the equipment on the ground. Set the controls in the rest position.
If possible, park the machine in an area where no other machines are operating and where there
is no vehicle traffic.
Select a solid and level surface. If this is not possible, arrange the machine in a position
transverse to the slope, ensuring that there is no danger of sliding.
In public places or when visibility is reduced, place barriers around the machine to keep persons
away.
MAKING THE LIFTING ARMS SAFE
If the machine malfunctions or blocks with the arm raised it is necessary to make them safe, by
bringing them to the ground.
This is a very delicate operation that must be carried out by following the indications below.
1. The operator must remain seated, with safety beltsfastened.
2. The area around the machine must be completely
cleared of people.
3. Move the key inserted in the ignition commutator to position “1”
(Ref. 2).
4. Press the lifting arms safety activation deactivation button (Ref.
4).
5. Successively press the lifting arms fluctuation button (Ref.5)
and the lifting arms descend immediately
WITH EMPTY SHOVEL
IN ASCENT
IN DESCENT
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ATTENTION
In case of EMERGENCY it is possible to block arm descent by pressing the same button again (Ref. 5).
This operation must be carried out exclusively to make the lifting arms safe.
FIRE-EXPLOSION PREVENTION REGULATIONS
Flames or sparks can cause the battery and fuel to explode and therefore set fire to the
machine. To avoid and prevent the causes please follow the advice given below.
Equip the machine with an extinguisher. After any use, reload or replace it. The extinguisher must
always be in perfect working order.
- Do not short-circuit the battery clamps with keys or metal objects; any sparks could initiate
flaming of the machine’s fuel, oils and lubricants.
- Do not weld, grind, smoke or light flames near to the battery or fuel tank.
- When replacing the battery follow the indications supplied in the relative chapter.
- Always keep the machine clean and check any type of leak that may occur.
- Check efficiency and integrity of the electric plant – possible cause of starting a fire.
- Always clean the machine well after use as deposits of inflammable debris, in contact with the
hot parts of the machine, could increase the fire risk. The risks increase if this debris is in contact
with the exhaust box or near to the hot parts of the engine.
Do not use the machine in environments where dusts and gas are present, or in a
generally inflammable atmosphere or when the machine’s exhaust pipe can come into contact
with inflammable substances.
DANGER OF FIRE-EXPLOSION
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03 – OPERATOR CONTROLS
DRIVER’S SEAT
The driver’s seat must not be adjusted while the vehicle is moving.
Danger of accidents!
Always fasten the seatbelts.
The driver’s seat is important for good health. Therefore it must be maintained integral.
The driver’s seat can be adjusted longitudinally using the special lever positioned low on the right
hand side.
SAFETY BELTS
FASTENING:
Sit properly in the driver’s seat, adjust the belt length, check thatit is not
twisted, then insert the clip Ainto the housing Buntil locked.
UNFASTENING:
Press the button Cand remove the belt from the fixed part placing it to
the right of the driver.
SAFETY BAR
Every machine is equipped with a safety bar that together with the safety belts and cabin in
compliance with ROPS and FOPS makes up the operator’s “safety girdle”.
The machine must always be driven with safety bar lowered and safety belts fastened.
FUNCTIONS OF THE SAFETY BAR
A - SAFETY BAR RAISED:
-Start-up of the diesel engine
-The servo-controls are deactivated
-The lifting arms are blocked
B - SAFETY BAR LOWERED:
-The diesel engine does not start-up
-The servo-controls are activated
-The arm control is deactivated.
For activation of the arm control
(ascent/descent) press the button (Fig.1 - ref.4)
ATTENTION
If the safety bar rises the hydraulic servo-controlsare
deactivated and the lifting arm blocked.
A
POSITION A
POSITION B
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CONTROL AND AUXILIARY INSTRUMENTS
CONTROL PANEL
Fig. 1
17
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1. FUELLEVELINDICATOR
Switching on of the warning light signals the entry into the use of reserve fuel, which allows
a residual autonomy of about 1 hour.
2. KEY IGNITION SWITCH
To start the machine proceed as follows:
a. Insert the key in the ignition switch (Ref. 2 of fig.1)
and turn clockwise to position “1” (panel on).
b. Wait for the spark-plug pre-heating warning light
(ref. 7.3) to switch off.
c. Continue to turn the key to position “3”, passing
position ”2” with a slight pressure. Thus starting has
been completed.
d. After starting, the key automatically returns to
position “1”.
e. In case of failed starting, turn the key back to position
“0” and repeat the operation from the
beginning.
3. POSITION PIVOTED SWITCH FOR POWER TAKE OFF (P.T.O.) CONTROL
INSERTED: Deactivates the commandon the RIGHT manipulator
4. LIFTING ARM SAFETY ACTIVATION AND DEACTIVATION SWITCH
ALWAYS insert with the engine switched on and the safety bar lowered. Press it again for d
deactivation.
5. 2-POSITION SWITCH WITH MECHANICAL INTERLOCK FOR ACTIVATION OF LIFTING ARM
FLUCTUATION FUNCTION
(ROUND LEVELLING; can only be activated with the button (ref.4) inserted.
This switch MUST only be used with the arms and bucket on the ground. Activation
with the arms raised consents to the immediate fall of the entire arms-bucket unit with
very serious risks.
6. ENGINE COOLING LIQUID HIGH TEMPERATURE ALARM BUZZER
The engine shuts down with the warning light switched on. Check the level of the cooling liquid
inside the radiator. Do not re-start until the cause of overheating has been identified.
7. CHECK AND CONTROL INSTRUMENTS
The following warning lights are housed in the instrument as well as the timer:
0
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2
3

1. – POWER TAKE OFF INSERTION WARNING LIGHT (PTO)
2. – POWER TAKE OFF INSERTION WARNING LIGHT (PTO)
3. – GLOW PLUGSPRE-HEATING INDICATOR
The warning light switches on after clockwise rotation of the key in the ignition block. The
machine must always be started-up after the warning light switches off.
4. – ENGINECOOLINGLIQUIDTEMPERATURE WARNINGLIGHT
The warning light signals anomalous functioning of the diesel engine cooling plant.
5. – GENERATORCHARGEINDICATOR
-OFF in normal operating position (goes off immediately after starting)
-When ON it signals malfunctioning in the battery recharging system.
6. – ENGINEOILPRESSUREINDICATOR
When this indicator comes on, it signalsmalfunctioning in the diesel engine lubrication system
-insufficient pressure or lack of oil. Immediately stop and identify the cause.
7. – AIR FILTER CLOGGED INDICATOR
When the indicator is on, it signals inefficiency of the suction system - filter cartridge
clogged.
8. – HYDRAULIC SERVO-CONTROL BLOCK WARNING LIGHT SWITCHED ON:
Hydraulic commands deactivated (safety bar raised). SWITCHED OFF:
Hydraulic commands activated (safety bar lowered).
9.– HEADLAMP INSERTION WARNING LIGHT
7.10– HOUR COUNTER
Signals the progressive working time. Functions with the engine running.
8 – 12V UNIPOLAR OUTLET
Allows low-tension fitting usage.
9 – EMERGENCY LIGHT SWITCH
Controls the simultaneous functioning of the four direction indicators.
Insert the switch every time a potential danger exists and in EMERGENCY situations.
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10 – FLASHLIGHT DEVICE SWITCH
Commands the device positioned above the cabin connected through a plug at the side of the
left working light. ALWAYS SWITCHED ON DURING CIRCULATION ON ROADS
11 – WORKING LIGHT SWITCH
Commands the working lights situated on the front part of the cabin.
12– AVAILABLE (WINDSCREEN WIPER COMMAND ON MACHINES EQUIPPED WITH CABINFRONT
DOOR)
13– AVAILABLE (HEATING FAN COMMAND SWITCH (2 SPEED) IN MACHINES EQUIPPEDWITH
HEATINGPLANT
14– 3-POSITION SWITCH FOR LIGHTING PLANT CONTROL(POSITION
ANDHEADLIGHTS)
15 – THREE-POSITION SWITCH FOR DIRECTION INDICATOR COMMAND
FORWARD:
CENTRAL:
BACKWARD:
turn left
neutral
turn right
16 – FUSE BOX
F1 – Switch and warning light protection fuse (7.5A)
F2 – Flashing light + working lights protection fuse (15A)
F3 – Heating fan protection fuse (10A)
F4 – Windscreen wiper protection fuse(10A)
F5 – Safety bar and services micro protection fuse(10A)
F6 – Acoustic warning + reverse gear warning protection fuse (7.5A)
F7 – Power take off (PTO) protection fuse (10A)
F8 – Alternator excitement protection fuse (5A)
F9 – Engine shutdown protection fuse +30 (15A)
F10 – Radio and emergency lights protection fuse +30 (10A)
F11 – Position lights right line protection fuse (5A)
F12 – Position lights right line Position lights right line + number plate light protection fuse (5A)
F13 – Headlights protection fuse (10A)
F14 – Protection fuse +15 and stop lights (5A)
17 – 12 V UNIPOLAR SOCKET FOR ATTACHMENT TO FLASHING LIGHT
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MACHINE START-UP AND SHUTDOW
-Operator correctly positioned inside the driver’s
cabin for use of the machine both in the transfer
phase and for working.
STARTING
- For proper starting follow the instructions described
above and as indicated below.
- Once the engine has started, gradually move the
accelerator (Ref. LA) lever to the idle position, at a
sufficiently low rpm and avoiding sudden acceleration,
until the hydraulic system has reached the operating
temperature (5 ÷10 min- utes depending on the
atmospheric conditions and climatic.
Start-up can only be carried out withthe safety
bar raised, Position “A”
Do not allow unauthorised persons to drive the machine. Remember that the responsibility for the
machine lies with the person who has received it.
Do not start using the machine until sure of its functioning. It is a good rule to practice in an
open and clear area when manoeuvres in which experience is lacking need to be carried out.
Concerning driving of the machine follow the instructions as described below, remembering which
is the front side of the machine.
STOPPING
To stop the engine it suffices to turn the key
(Fig.1 - ref. 2) anticlockwise.
It is advisable to idle the engine for a few
minutes before stopping the machine.
Remove the key whenever leaving the driver’s seat.
Never leave the machine running and unattended.
2
POSITIONA
POSITIONB
POSITIONB
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