Wacker Neuson 2503

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OM 25-3503 us – Edition 4.1 * 2503_3503b530.fm 5-37

Maintenance

Oil grades for the hydraulic system, depending on temperature.

Hydrau-

lics oil

grade

Ambient temperature

HVLP

°C-20-15-10-5 0 5 1015202530354050

ISO VG32

ISO VG46

ISO VG68

°F-4 5 14233241505968778695104122

1. According to DIN 51524 section 3

Main Page

Table of Contents3
Introduction13
Important Information on this Operator's Manual13
Machine Overview14
Brief Description15
Traveling Drive15
Operating Hydraulics15
Cooling System15
Cabin15
Fields of Application, Attachments16
Use: Attachment16
Regulations20
EC Declaration of Conformity 250321
EC Declaration of Conformity 350322
Type Labels and Component Numbers23
Other Signs and Symbols (up to AG01597)25
Other Signs and Symbols (from AG01598)29
Overview of Safety Labels29
Symbols30
Safety Labels34
Fire Extinguisher39
Safety Instructions41
Safety Symbols Found in this Manual41
Warranty42
Disposal42
Designated Use42
Preparing to Use the Machine43
Conditions for Use43
User Training and Knowledge43
Preparing for Use43
Information on Visibility44
Modifications and Spare Parts44
Operator and Technician Qualifications and Basic Responsibilities44
User/Owner Responsibility44
Repair Person Qualifications44
Safety Instructions Regarding Operation45
Preparing for Use45
Starting and Stopping45
Work Area Awareness46
Danger Zone Awareness46
Operating the Machine46
Carrying Passengers46
Mechanical Integrity47
Traveling47
Operator Protection System48
TOPS Rollbar (up to Serial No. AF01416)48
ROPS Rollbar48
Traveling Without TOPS Rollbar (up to Serial No. AF01416)48
Traveling Without ROPS Rollbar48
Shatter Protection (Option)49
Work Range and Restricted Visibility49
Applications with Lifting Gear50
General Information50
Operation with Lowered TOPS Rollbar (up to Serial No. AI00966)50
Operation with Lowered ROPS Rollbar50
Attachments50
General Information Regarding Attachments50
Installation Notes51
Trailers51
Hammer Operation52
Safety Instructions52
Working with a Hammer52
Transport and Towing53
Towing53
Transporting53
Safety Guidelines for Maintenance53
General Maintenance Notes53
Personal Safety Measures54
Preparing for Maintenance and Repair Work54
Performing Maintenance and Repairs55
Special Hazards55
Electrical Energy55
Underground Electric Lines56
Overhead Electric Lines56
Gas, Dust, Steam, Smoke57
Safety Instructions Regarding Internal Bombustion Engines57
Hydraulics57
Noise58
Msds58
Tracks58
Battery59
Safety Guidelines While Using Internal Combustion Engines59
Running the Engine59
Fueling the Engine59
Dual Power Option60
Operation61
Cabin Overview64
Instrument Panel Overview67
Putting into Operation68
Safety Instructions68
Putting into Operation for the First Time68
Running-In Period68
Check Lists69
Start-Up Checklist69
Operation Checklist70
Parking Checklist70
Driving the Excavator71
Preheating Start Switch71
Throttle71
Automatic Engine Speed Setting72
Indicator Lights and Warning Lights Tier III (Overview)72
Indicator Light (Red) - Hydraulic Oil Filter72
Indicator Light (Red) - Alternator Charge Function72
Indicator Light (Red) - Engine Oil Pressure72
Fuel Level Indicator73
Hour Meter73
Display Element 3503 Tier IV74
Meaning of Displays and Symbols 3503 Tier IV76
Multifunctional Display (Tier IV Only)79
Menu Structure of Display Setting79
Before Starting the Engine82
Starting the Engine82
Procedure82
Starting with the Immobilizer (Option)83
Starting with the Immobilizer - Internal Transponder (Option)84
Starting at Low Temperatures85
When the Engine Has Started85
Jump-Starting the Engine (Supply Battery)85
Special Instructions for Machine Travel on Public Roads87
Starting Machine Travel87
Drive Levers87
High Speed89
Hydraulic Brake90
Mechanical Brake90
Stabilizer Blade as a Parking Brake90
Machine Travel on Slopes90
Stabilizer Blade93
Parking the Machine94
Parking the Machine on Slopes95
Light System96
Working Lights96
Roof Lights (Option)96
Interior Light97
Rotating Beacon (Option)97
Travel Signal (Option)97
Socket97
Protective Structures98
Definition of the Term "Protective Structure98
Mechanical Integrity98
Definition of Fops/Front Guard Levels99
Responsibility for Machine Equipped with Protective Structures99
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 Exits107
Emergency Exit for Cabin Equipped with Protective Front Guard Structure107
Cabin Heating and Ventilation108
Summer/Winter Operation108
Ventilation108
Washer System109
Washer System Reservoir109
Seat Adjustment110
Weight Adjustment111
Horizontal Adjustment111
Backrest Adjustment111
Seat Belt112
Front Window114
Door115
Entry and Exit117
Safety Instructions Regarding Entry and Exit117
Engine Cover118
Valve Compartment Cover118
Towing the Machine119
Important Information Regarding Towing119
Crane Lifting the Machine120
Important Information Regarding Loading120
Loading and Transporting the Machine122
Tying down the Machine123
Removing the Cabin/Canopy123
Installing the Cabin/Canopy126
Machine Operation128
General Safety Instructions128
Wacker Neuson Vario (Option)129
Control Levers/Iso Controls: Overview131
Control Lever on the Left132
Auxiliary Hydraulics132
Boom Swivel Controls133
Hammer Operation (Option)133
Control Lever on the Right136
Lowering the Boom with the Engine Stopped136
Changeover Valve for SAE/ISO Controls (Option)137
Control Lever on the Left137
Control Lever on the Right137
Directional Valve Position138
Directional Valve138
Control Lever with Proportional Controls (Option): Overview139
Function139
Measures to be Taken in Case of Malfunctions140
Diagnosis Display140
Control Lever on the Left141
Auxiliary Hydraulics (Proportionally Controlled)141
Boom Swivel Controls (Proportionally Controlled)141
Hammer Operation (Proportionally Controlled)142
Adjusting Control Response142
Characteristic Curve Status Indicator142
Lowering the Boom with the Engine Stopped143
Rotating the Upper Carriage144
Swivel Unit Brake144
Functional Check of Swivel Unit Brake145
Tilting the Upper Carriage (Option 3503)147
Operation (from Serial No. AG02695)148
Releasing the Pressure on the Operating Hydraulics148
Releasing Pressure148
Pressure Release with Proportional Controls (Option)148
Re-Equipping Attachments149
Specific Safety Instructions149
Removing a Bucket150
Installing a Bucket150
Mechanical Quickhitch (Option)151
Hydraulic Quickhitch (Option)152
Picking up an Attachment153
Setting down an Attachment155
Powertilt (Option 3503)157
Re-Equipping158
Installing the Powertilt Unit158
Removing the Powertilt Unit158
Connection159
Operation160
Control Lever on the Left (Powertilt)160
Control Lever on the Right (if Equipped with Auxiliary Hydraulics and Proportional Controls)160
Connections for Auxiliary Hydraulics160
Grab Operation161
Safe Load Indicator (Option)162
Safety Feature "Hose Burst Valve" (Option)162
Working with the Excavator163
Inadmissible Work Procedures163
Excavator Work Position165
Bucket Position When Digging165
Excavating Trenches166
Loading166
Grading166
Excavating Trenches Sideways166
Working Alongside Trenches167
Stabilizer Blade at Rear167
Further Recommendations for Digging168
Loading Vehicles168
Freeing the Machine168
Grading169
Exhaust Gas Treatment (Tier IV)169
Indication of Load171
Particulate Matter Catalyst Indicator Lights171
Regeneration Push Button172
Automatic Regeneration Mode173
Manual Regeneration174
Malfunctions175
Hydraulics176
Malfunctions of the Powertilt Unit177
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 Messages180
Maintenance183
Safety-Relevant Parts183
Fuel System184
Refueling184
Stationary Fuel Pumps184
Draining Fuel185
Diesel Fuel Specification185
Bleeding the Fuel System186
Water Separator186
Engine Lubrication System187
Checking the Oil Level187
Adding Engine Oil188
Engine and Hydraulics Cooling System189
Specific Safety Instructions189
Checking the Coolant Level/Adding Coolant190
Checking the Coolant Level191
Adding Coolant192
Draining Coolant192
Air Filter193
Replacing the Filter194
V-Belt196
Hydraulic System196
Specific Safety Instructions196
Checking the Hydraulic Oil Level197
Adding Hydraulic Oil198
Important Information on the Use of Biodegradable Oil199
Checking Hydraulic Pressure Lines200
Tracks201
Checking Track Tension201
Setting the Tracks202
Maintenance of Joint Rod (Lifting Eye) and Load Hook203
Traveling Drive204
Electrical System204
Specific Safety Instructions204
Servicing and Maintenance at Regular Intervals204
Instructions Concerning Specific Components205
Alternator205
Battery206
General Maintenance207
Cleaning207
General Instructions for All Areas of the Machine207
Inside the Cabin208
Cleaning the Seat Belt208
Exterior of the Machine208
Engine Compartment208
Threaded Fittings and Attachments209
Pivots and Hinges209
Lubrication Points209
Lubrication Points on Slewing Cylinder/Ball Bearing Race of Live Ring210
Lubrication Points on the Stabilizer Blade211
Additional Lubrication Points on Slewing Stabilizer Blade (Option 3503)211
Lubricating the Teeth of the Live Ring211
Lubricating the Teeth of the Live Ring VDS212
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 Time215
Preparatory Work before Taking out of Service215
Permanently Putting out of Operation215
Putting into Operation Again216
Fluids and Lubricants217
Additional Oil Change and Filter Replacement (Hydraulic System)218
Maintenance Overview225
Maintenance Plan (Tier IV)225
Technical Datac231
Model 2503231
Engine231
Hydraulic System231
Stabilizer Blade231
Operating Hydraulics231
Tracks232
Model 3503232
American Tier III Engine232
American Tier IV Engine232
Hydraulic System233
Stabilizer Blade233
Operating Hydraulics233
Tracks233
Model 3503 VDS234
Engine Tier III (Option)234
Engine Tier IV (Option)234
Hydraulic System234
Stabilizer Blade235
Operating Hydraulics235
Tracks235
Operating Range (2503/3503/3503 VDS)235
Rotation Speed of Upper Carriage (2503/3503/3503 VDS)235
Electrical System236
Fuse Box in Cabin236
Noise Levels236
Rotating Beacon (Option)236
Roof Lights (Option)236
Vibration237
Coolant Compound Table239
Powertilt (Option 3503)240
Weights240
Dimensions Model 2503241
Dimensions Model 3503242
Dimensions Model 3503 VDS243
Lift Capacity Table 2503244
Lift Capacity Table 3503245
Lift Capacity Table 3503 Vario246
Lift Capacity Table 3503 VDS247
Safety Instructions Stability Tables248
Foreword254
Safety Alerts254
One-Call First255
A Word to the User/Operator255
Follow a Safety Program256
Prepare for Safe Operation259
Start Safely263
Operate Safely265
Shut down Safely272
Load and Unload the Machine Safely272
Perform Maintenance Safely273
Final Word to the User278

Table of Contents

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