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Wacker Neuson
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2503
Wacker Neuson 2503 User Manual
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1-2
OM 25-3503 us – Edition 4.1 * * 2503_3503b110.fm
Introduction
1.2
Machine overview
1
Boom light
2
Boom
3S
t
i
c
k
4
Rubber tracks
5
Travel gear
6
Stabilizer blade
7
Cabin
8
Valve cover
9
Handhold
Fig. 1:
Machine outside views
6
9
14
13
13
15
8
7
1
14
13
Exhaust pipe
14
Lifting eye/tie-down point
15
Lubrication point for track tension
16
Engine cover
2
3
4
5
5
7
16
13
15
Table of Contents
Table of Contents
3
Introduction
13
Important Information on this Operator's Manual
13
Machine Overview
14
Brief Description
15
Traveling Drive
15
Operating Hydraulics
15
Cooling System
15
Cabin
15
Fields of Application, Attachments
16
Use: Attachment
16
Regulations
20
EC Declaration of Conformity 2503
21
EC Declaration of Conformity 3503
22
Type Labels and Component Numbers
23
Other Signs and Symbols (up to AG01597)
25
Other Signs and Symbols (from AG01598)
29
Overview of Safety Labels
29
Symbols
30
Safety Labels
34
Fire Extinguisher
39
Safety Instructions
41
Safety Symbols Found in this Manual
41
Warranty
42
Disposal
42
Designated Use
42
Preparing to Use the Machine
43
Conditions for Use
43
User Training and Knowledge
43
Preparing for Use
43
Information on Visibility
44
Modifications and Spare Parts
44
Operator and Technician Qualifications and Basic Responsibilities
44
User/Owner Responsibility
44
Repair Person Qualifications
44
Safety Instructions Regarding Operation
45
Preparing for Use
45
Starting and Stopping
45
Work Area Awareness
46
Danger Zone Awareness
46
Operating the Machine
46
Carrying Passengers
46
Mechanical Integrity
47
Traveling
47
Operator Protection System
48
TOPS Rollbar (up to Serial No. AF01416)
48
ROPS Rollbar
48
Traveling Without TOPS Rollbar (up to Serial No. AF01416)
48
Traveling Without ROPS Rollbar
48
Shatter Protection (Option)
49
Work Range and Restricted Visibility
49
Applications with Lifting Gear
50
General Information
50
Operation with Lowered TOPS Rollbar (up to Serial No. AI00966)
50
Operation with Lowered ROPS Rollbar
50
Attachments
50
General Information Regarding Attachments
50
Installation Notes
51
Trailers
51
Hammer Operation
52
Safety Instructions
52
Working with a Hammer
52
Transport and Towing
53
Towing
53
Transporting
53
Safety Guidelines for Maintenance
53
General Maintenance Notes
53
Personal Safety Measures
54
Preparing for Maintenance and Repair Work
54
Performing Maintenance and Repairs
55
Special Hazards
55
Electrical Energy
55
Underground Electric Lines
56
Overhead Electric Lines
56
Gas, Dust, Steam, Smoke
57
Safety Instructions Regarding Internal Bombustion Engines
57
Hydraulics
57
Noise
58
Msds
58
Tracks
58
Battery
59
Safety Guidelines While Using Internal Combustion Engines
59
Running the Engine
59
Fueling the Engine
59
Dual Power Option
60
Operation
61
Cabin Overview
64
Instrument Panel Overview
67
Putting into Operation
68
Safety Instructions
68
Putting into Operation for the First Time
68
Running-In Period
68
Check Lists
69
Start-Up Checklist
69
Operation Checklist
70
Parking Checklist
70
Driving the Excavator
71
Preheating Start Switch
71
Throttle
71
Automatic Engine Speed Setting
72
Indicator Lights and Warning Lights Tier III (Overview)
72
Indicator Light (Red) - Hydraulic Oil Filter
72
Indicator Light (Red) - Alternator Charge Function
72
Indicator Light (Red) - Engine Oil Pressure
72
Fuel Level Indicator
73
Hour Meter
73
Display Element 3503 Tier IV
74
Meaning of Displays and Symbols 3503 Tier IV
76
Multifunctional Display (Tier IV Only)
79
Menu Structure of Display Setting
79
Before Starting the Engine
82
Starting the Engine
82
Procedure
82
Starting with the Immobilizer (Option)
83
Starting with the Immobilizer - Internal Transponder (Option)
84
Starting at Low Temperatures
85
When the Engine Has Started
85
Jump-Starting the Engine (Supply Battery)
85
Special Instructions for Machine Travel on Public Roads
87
Starting Machine Travel
87
Drive Levers
87
High Speed
89
Hydraulic Brake
90
Mechanical Brake
90
Stabilizer Blade as a Parking Brake
90
Machine Travel on Slopes
90
Stabilizer Blade
93
Parking the Machine
94
Parking the Machine on Slopes
95
Light System
96
Working Lights
96
Roof Lights (Option)
96
Interior Light
97
Rotating Beacon (Option)
97
Travel Signal (Option)
97
Socket
97
Protective Structures
98
Definition of the Term "Protective Structure
98
Mechanical Integrity
98
Definition of Fops/Front Guard Levels
99
Responsibility for Machine Equipped with Protective Structures
99
Protective FOPS Structure/Small Screen - Category I (Option)
100
Protective FOPS Structure/Canopy - Category I (Option)
101
Protective Front Guard Structure Category I (Option)
103
Shatter Protection (Option)
105
Emergency Exits
107
Emergency Exit for Cabin Equipped with Protective Front Guard Structure
107
Cabin Heating and Ventilation
108
Summer/Winter Operation
108
Ventilation
108
Washer System
109
Washer System Reservoir
109
Seat Adjustment
110
Weight Adjustment
111
Horizontal Adjustment
111
Backrest Adjustment
111
Seat Belt
112
Front Window
114
Door
115
Entry and Exit
117
Safety Instructions Regarding Entry and Exit
117
Engine Cover
118
Valve Compartment Cover
118
Towing the Machine
119
Important Information Regarding Towing
119
Crane Lifting the Machine
120
Important Information Regarding Loading
120
Loading and Transporting the Machine
122
Tying down the Machine
123
Removing the Cabin/Canopy
123
Installing the Cabin/Canopy
126
Machine Operation
128
General Safety Instructions
128
Wacker Neuson Vario (Option)
129
Control Levers/Iso Controls: Overview
131
Control Lever on the Left
132
Auxiliary Hydraulics
132
Boom Swivel Controls
133
Hammer Operation (Option)
133
Control Lever on the Right
136
Lowering the Boom with the Engine Stopped
136
Changeover Valve for SAE/ISO Controls (Option)
137
Control Lever on the Left
137
Control Lever on the Right
137
Directional Valve Position
138
Directional Valve
138
Control Lever with Proportional Controls (Option): Overview
139
Function
139
Measures to be Taken in Case of Malfunctions
140
Diagnosis Display
140
Control Lever on the Left
141
Auxiliary Hydraulics (Proportionally Controlled)
141
Boom Swivel Controls (Proportionally Controlled)
141
Hammer Operation (Proportionally Controlled)
142
Adjusting Control Response
142
Characteristic Curve Status Indicator
142
Lowering the Boom with the Engine Stopped
143
Rotating the Upper Carriage
144
Swivel Unit Brake
144
Functional Check of Swivel Unit Brake
145
Tilting the Upper Carriage (Option 3503)
147
Operation (from Serial No. AG02695)
148
Releasing the Pressure on the Operating Hydraulics
148
Releasing Pressure
148
Pressure Release with Proportional Controls (Option)
148
Re-Equipping Attachments
149
Specific Safety Instructions
149
Removing a Bucket
150
Installing a Bucket
150
Mechanical Quickhitch (Option)
151
Hydraulic Quickhitch (Option)
152
Picking up an Attachment
153
Setting down an Attachment
155
Powertilt (Option 3503)
157
Re-Equipping
158
Installing the Powertilt Unit
158
Removing the Powertilt Unit
158
Connection
159
Operation
160
Control Lever on the Left (Powertilt)
160
Control Lever on the Right (if Equipped with Auxiliary Hydraulics and Proportional Controls)
160
Connections for Auxiliary Hydraulics
160
Grab Operation
161
Safe Load Indicator (Option)
162
Safety Feature "Hose Burst Valve" (Option)
162
Working with the Excavator
163
Inadmissible Work Procedures
163
Excavator Work Position
165
Bucket Position When Digging
165
Excavating Trenches
166
Loading
166
Grading
166
Excavating Trenches Sideways
166
Working Alongside Trenches
167
Stabilizer Blade at Rear
167
Further Recommendations for Digging
168
Loading Vehicles
168
Freeing the Machine
168
Grading
169
Exhaust Gas Treatment (Tier IV)
169
Indication of Load
171
Particulate Matter Catalyst Indicator Lights
171
Regeneration Push Button
172
Automatic Regeneration Mode
173
Manual Regeneration
174
Malfunctions
175
Hydraulics
176
Malfunctions of the Powertilt Unit
177
Engine Warning Lights (Tier IV Only)
178
Engine and Engine Oil Warning Lights (Tier IV Only)
178
Malfunctions (Display Element/Multifunctional Display - Tier IV Only)
179
Engine Error Messages
180
Maintenance
183
Safety-Relevant Parts
183
Fuel System
184
Refueling
184
Stationary Fuel Pumps
184
Draining Fuel
185
Diesel Fuel Specification
185
Bleeding the Fuel System
186
Water Separator
186
Engine Lubrication System
187
Checking the Oil Level
187
Adding Engine Oil
188
Engine and Hydraulics Cooling System
189
Specific Safety Instructions
189
Checking the Coolant Level/Adding Coolant
190
Checking the Coolant Level
191
Adding Coolant
192
Draining Coolant
192
Air Filter
193
Replacing the Filter
194
V-Belt
196
Hydraulic System
196
Specific Safety Instructions
196
Checking the Hydraulic Oil Level
197
Adding Hydraulic Oil
198
Important Information on the Use of Biodegradable Oil
199
Checking Hydraulic Pressure Lines
200
Tracks
201
Checking Track Tension
201
Setting the Tracks
202
Maintenance of Joint Rod (Lifting Eye) and Load Hook
203
Traveling Drive
204
Electrical System
204
Specific Safety Instructions
204
Servicing and Maintenance at Regular Intervals
204
Instructions Concerning Specific Components
205
Alternator
205
Battery
206
General Maintenance
207
Cleaning
207
General Instructions for All Areas of the Machine
207
Inside the Cabin
208
Cleaning the Seat Belt
208
Exterior of the Machine
208
Engine Compartment
208
Threaded Fittings and Attachments
209
Pivots and Hinges
209
Lubrication Points
209
Lubrication Points on Slewing Cylinder/Ball Bearing Race of Live Ring
210
Lubrication Points on the Stabilizer Blade
211
Additional Lubrication Points on Slewing Stabilizer Blade (Option 3503)
211
Lubricating the Teeth of the Live Ring
211
Lubricating the Teeth of the Live Ring VDS
212
VDS Lubrication Points (Option)
213
Powertilt (Option 3503)
214
Lubrication Points of Hydraulic Quickhitch (Option)
214
Maintenance When out of Service for a Longer Period of Time
215
Preparatory Work before Taking out of Service
215
Permanently Putting out of Operation
215
Putting into Operation Again
216
Fluids and Lubricants
217
Additional Oil Change and Filter Replacement (Hydraulic System)
218
Maintenance Overview
225
Maintenance Plan (Tier IV)
225
Technical Datac
231
Model 2503
231
Engine
231
Hydraulic System
231
Stabilizer Blade
231
Operating Hydraulics
231
Tracks
232
Model 3503
232
American Tier III Engine
232
American Tier IV Engine
232
Hydraulic System
233
Stabilizer Blade
233
Operating Hydraulics
233
Tracks
233
Model 3503 VDS
234
Engine Tier III (Option)
234
Engine Tier IV (Option)
234
Hydraulic System
234
Stabilizer Blade
235
Operating Hydraulics
235
Tracks
235
Operating Range (2503/3503/3503 VDS)
235
Rotation Speed of Upper Carriage (2503/3503/3503 VDS)
235
Electrical System
236
Fuse Box in Cabin
236
Noise Levels
236
Rotating Beacon (Option)
236
Roof Lights (Option)
236
Vibration
237
Coolant Compound Table
239
Powertilt (Option 3503)
240
Weights
240
Dimensions Model 2503
241
Dimensions Model 3503
242
Dimensions Model 3503 VDS
243
Lift Capacity Table 2503
244
Lift Capacity Table 3503
245
Lift Capacity Table 3503 Vario
246
Lift Capacity Table 3503 VDS
247
Safety Instructions Stability Tables
248
Foreword
254
Safety Alerts
254
One-Call First
255
A Word to the User/Operator
255
Follow a Safety Program
256
Prepare for Safe Operation
259
Start Safely
263
Operate Safely
265
Shut down Safely
272
Load and Unload the Machine Safely
272
Perform Maintenance Safely
273
Final Word to the User
278
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Wacker Neuson 2503 Specifications
General
Brand
Wacker Neuson
Model
2503
Category
Excavators
Language
English
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