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Operator's Manual

Track excavators

Machine models 2503/3503


Edition 2.3
Order no. 1000188382
Language EN
Documentation

Description Language Order no.

Operator's Manual EN 1000188382

Spare parts catalogue 2503 1000179989


De/En/Fr
3503 1000189534

Legend

Edition Issued

1.0 06/2008

1.1 03/2009

1.2 10/2009

2.0 01/2010

2.1 02/2010

2.3 05/2010

Copyright 2010 Wacker Neuson Linz GmbH, Linz-Leonding


Printed in Austria
All rights reserved
No part of this publication may be reproduced, translated or used in any form or by any means graphic, electronic
or mechanical including photocopying, recording, taping or information storage or retrieval systems without prior
permission in writing from the manufacturer.
The cover features the machine with possible optional equipment.

Translation of original Operator's Manual

Wacker Neuson Linz GmbH


Haidfeldstr. 37
A-4060 Linz-Leonding
Tel. +43 (0) 732 90 5 90-0
E-mail verkauf@wackerneuson.com
www.wackerneuson.com
Document: BA 25-3503 EN
Order no.: 1000188382
Edition: 2.3
Table of contents
I Table of contents

Table of contents
Introduction
Important information on this Operator's Manual ..................................................... 1-1
Machine overview .................................................................................................... 1-2
Brief description ....................................................................................................... 1-3
Travelling drive .................................................................................................. 1-3
Work hydraulics ................................................................................................. 1-3
Cooling system .................................................................................................. 1-3
Cab .................................................................................................................... 1-3
Fields of application, attachments ........................................................................... 1-4
Use: attachment ................................................................................................ 1-4
Regulations .............................................................................................................. 1-6
EC Declaration of Conformity 2503 ......................................................................... 1-7
EC Declaration of Conformity 3503 ......................................................................... 1-8
Type labels and component numbers ...................................................................... 1-9
Other signs and symbols (up to AG01597) ............................................................ 1-11
Other signs and symbols (from AG01598) ............................................................ 1-15
Overview of safety labels: ................................................................................ 1-15
Symbols ........................................................................................................... 1-16
Safety labels .................................................................................................... 1-18
Fire extinguisher .................................................................................................... 1-22
Safety instructions
Identification of warnings and dangers .................................................................... 2-1
Warranty .................................................................................................................. 2-1
Disposal ................................................................................................................... 2-1
Designated use and exemption from liability ........................................................... 2-2
General conduct and safety instructions .................................................................. 2-3
Organisational measures ................................................................................... 2-3
Selection and qualification of staff, basic responsibilities .................................. 2-4
Safety instructions regarding operation ................................................................... 2-5
Normal operation ............................................................................................... 2-5
Cab and protective structures ............................................................................ 2-7
Operation without cab/canopy ........................................................................... 2-7
Checks when reversing the machine ................................................................. 2-7
Applications with lifting gear .............................................................................. 2-8
Working with attachments ................................................................................. 2-9
Transport ........................................................................................................... 2-9
Working in the area of underground electric lines ............................................. 2-9
Working near overhead electric lines .............................................................. 2-10
Safety instructions for maintenance ....................................................................... 2-11
Warning of special hazards ................................................................................... 2-13
Electrical energy .............................................................................................. 2-13
Gas, dust, steam, smoke ................................................................................. 2-13
Hydraulics ........................................................................................................ 2-13
Noise ............................................................................................................... 2-14
Oil, grease and other chemical substances ..................................................... 2-14
Battery ............................................................................................................. 2-14
Tracks .............................................................................................................. 2-14
Protective structures .............................................................................................. 2-15
Hammer operation ................................................................................................. 2-15
Safety instructions ........................................................................................... 2-15
Working with a hammer ................................................................................... 2-16

BA 25-3503 EN - Ausgabe 2.3 *Ba2503_3503en2_3IVZ.fm I-1


Table of contents

Operation
Cab overview ........................................................................................................... 3-3
Instrument panel overview ....................................................................................... 3-5
Putting into operation ............................................................................................... 3-6
Safety instructions ............................................................................................. 3-6
Putting the machine into operation for the first time .......................................... 3-6
Running-in period .............................................................................................. 3-6
Check lists ......................................................................................................... 3-7
Start-up checklist ............................................................................................... 3-7
Operation checklist ............................................................................................ 3-8
Parking checklist ................................................................................................ 3-8
Driving the excavator ............................................................................................... 3-9
Preheating start switch ..................................................................................... 3-9
Throttle ............................................................................................................... 3-9
Automatic revs setting ............................................................................................ 3-10
Telltales and warning lights: overview ............................................................ 3-10
Before starting the engine ...................................................................................... 3-12
Starting the engine (general information) ............................................................... 3-12
Procedure ........................................................................................................ 3-12
Starting with the drive interlock (option) ................................................................. 3-13
Starting with the drive interlock internal transponder (option) ............................. 3-14
Starting at low temperatures .................................................................................. 3-15
When the engine has started ... ............................................................................. 3-15
Jump-starting the engine (supply battery) .............................................................. 3-15
Special instructions for driving on public roads ...................................................... 3-17
Moving off .............................................................................................................. 3-17
Drive levers ............................................................................................................ 3-17
High speed ............................................................................................................. 3-18
Hydraulic brake ...................................................................................................... 3-18
Mechanical brake ................................................................................................... 3-18
Driving on slopes ................................................................................................... 3-19
Specific safety instructions .............................................................................. 3-19
Driving on slopes ............................................................................................. 3-20
Stabiliser blade operation ...................................................................................... 3-21
Parking the machine .............................................................................................. 3-22
Parking the machine on slopes ........................................................................ 3-22
Light system ........................................................................................................... 3-23
Working lights .................................................................................................. 3-23
Roof lights (option) ........................................................................................... 3-23
Interior light ...................................................................................................... 3-24
Rotating beacon (option) ................................................................................. 3-24
Cab heating and ventilation ................................................................................... 3-24
Summer/winter operation ....................................................................................... 3-25
Washer system ...................................................................................................... 3-25
Tank for washer system ................................................................................... 3-26
Seat adjustment ..................................................................................................... 3-26
Weight adjustment ........................................................................................... 3-27
Horizontal adjustment ...................................................................................... 3-27
Backrest adjustment ........................................................................................ 3-27
Seat belt ................................................................................................................. 3-28
Emergency exit ...................................................................................................... 3-29

I-2 BA 25-3503 EN - Ausgabe 2.3 * *Ba2503_3503en2_3IVZ.fm


Table of contents

Emergency exit on machines equipped with protective Front Guard structures


(option) ............................................................................................................ 3-29
Front window ......................................................................................................... 3-30
Door ....................................................................................................................... 3-31
Exit through the door ............................................................................................. 3-33
Engine cover .......................................................................................................... 3-34
Valve compartment cover ...................................................................................... 3-34
Towing the track excavator .................................................................................... 3-35
Towing ............................................................................................................. 3-35
Crane handling the machine .................................................................................. 3-36
Loading and transporting the machine .................................................................. 3-37
Tying down the machine ........................................................................................ 3-38
Removing the cab/canopy ..................................................................................... 3-38
Installing the cab/canopy ....................................................................................... 3-40
Working with the machine ...................................................................................... 3-42
General safety instructions .............................................................................. 3-42
Wacker Neuson Vario (option) ............................................................................... 3-43
Control levers/ISO controls: overview .................................................................... 3-45
Left-hand side control lever ............................................................................. 3-46
Auxiliary hydraulics .......................................................................................... 3-46
Boom swivel controls ....................................................................................... 3-47
Hammer operation ........................................................................................... 3-47
Right-hand side control lever ........................................................................... 3-48
Lowering the boom with the engine stopped ................................................... 3-48
Changeover valve for SAE/ISO controls (option) .................................................. 3-49
Left-hand side control lever ............................................................................. 3-49
Right-hand side control lever ........................................................................... 3-49
Directional valve position ................................................................................. 3-50
Directional valve .............................................................................................. 3-50
Control lever with proportional controls (option): overview .................................... 3-51
Function ........................................................................................................... 3-51
Measures to be taken in case of malfunctions ................................................ 3-52
Left-hand side control lever ............................................................................. 3-52
Auxiliary hydraulics .......................................................................................... 3-53
Boom swivel controls ....................................................................................... 3-53
Hammer operation ........................................................................................... 3-54
Adjusting control response .............................................................................. 3-54
Lowering the boom with the engine stopped ................................................... 3-55
Rotating the upper carriage ................................................................................... 3-56
Swivel unit brake ............................................................................................. 3-56
Tilting the upper carriage (option) .......................................................................... 3-57
Releasing the pressure on the work hydraulics ..................................................... 3-58
Releasing pressure .......................................................................................... 3-58
Pressure release with proportional controls (option) ....................................... 3-58
Re-equipping attachments ..................................................................................... 3-59
Specific safety instructions .............................................................................. 3-59
Removing a bucket .......................................................................................... 3-60
Mounting a bucket ........................................................................................... 3-60
Mechanical quickhitch system (option) .................................................................. 3-61
Hydraulic quickhitch system (option) ..................................................................... 3-62
Operation ......................................................................................................... 3-63
Powertilt 3505 (option) ........................................................................................... 3-65
Re-equipping ................................................................................................... 3-66
Mounting the Powertilt unit .............................................................................. 3-66
Removing the Powertilt unit ............................................................................. 3-66
Connection ...................................................................................................... 3-67
Operation ......................................................................................................... 3-68

BA 25-3503 EN - Ausgabe 2.3 *Ba2503_3503en2_3IVZ.fm I-3


Table of contents

Left-hand side control lever (Powertilt) ............................................................ 3-68


Right-hand side control lever (if equipped with auxiliary hydraulics and proportional
controls) ........................................................................................................... 3-68
Connections for auxiliary hydraulics ...................................................................... 3-69
Grab operation ....................................................................................................... 3-69
Safe load indicator (option) .................................................................................... 3-70
Working with the excavator .................................................................................... 3-71
Working with the standard bucket .................................................................... 3-71
Inadmissible work procedures ......................................................................... 3-71
Excavator work position ................................................................................... 3-73
Bucket position when digging .......................................................................... 3-73
Excavating trenches ........................................................................................ 3-74
Loading ............................................................................................................ 3-74
Grading ............................................................................................................ 3-74
Excavating trenches sideways ......................................................................... 3-74
Working alongside trenches ............................................................................ 3-75
Stabiliser blade at rear ..................................................................................... 3-75
Further practical hints for digging .................................................................... 3-76
Loading vehicles .............................................................................................. 3-76
Freeing the machine ........................................................................................ 3-76
Grading .................................................................................................................. 3-77
Grading ............................................................................................................ 3-77
Troubleshooting
Engine trouble ......................................................................................................... 4-2
Hydraulics ................................................................................................................ 4-3
Malfunctions of the Powertilt unit ............................................................................. 4-3
Maintenance
Introduction .............................................................................................................. 5-1
Safety-relevant parts ................................................................................................ 5-1
Fuel system .............................................................................................................. 5-1
Fuel system .............................................................................................................. 5-2
Refuelling ........................................................................................................... 5-2
Stationary fuel pumps ........................................................................................ 5-2
Draining the fuel ................................................................................................. 5-3
Diesel fuel specification ..................................................................................... 5-3
Bleeding the fuel system .................................................................................... 5-3
Water separator ................................................................................................. 5-4
Engine lubrication system ........................................................................................ 5-5
Checking the oil level ......................................................................................... 5-5
Filling up engine oil ............................................................................................ 5-6
Engine and hydraulics cooling system ..................................................................... 5-7
Specific safety instructions ................................................................................ 5-7
Checking/filling up coolant ....................................................................................... 5-8
Checking the coolant level ................................................................................. 5-8
Filling up coolant ................................................................................................ 5-9
Draining coolant ................................................................................................. 5-9
Air filter ................................................................................................................... 5-10
Replacing the filter ........................................................................................... 5-11
V-belt ...................................................................................................................... 5-12
Checking V-belt tension ................................................................................... 5-12
Retightening the V-belt .................................................................................... 5-13
Hydraulic system .................................................................................................... 5-14
Specific safety instructions .............................................................................. 5-14
Checking the hydraulic oil level ....................................................................... 5-15
Filling up hydraulic oil ...................................................................................... 5-16
Important information for the use of biodegradable oil .................................... 5-17

I-4 BA 25-3503 EN - Ausgabe 2.3 * *Ba2503_3503en2_3IVZ.fm


Table of contents

Checking hydraulic pressure lines ................................................................... 5-18


Tracks .................................................................................................................... 5-19
Checking track tension .................................................................................... 5-19
Setting the tracks ............................................................................................. 5-20
Travelling drive ...................................................................................................... 5-21
Checking the oil level and filling up oil ............................................................. 5-21
Draining oil ....................................................................................................... 5-21
Maintenance of attachments ........................................................................... 5-21
Electrical system .................................................................................................... 5-22
Specific safety instructions .............................................................................. 5-22
Service and maintenance work at regular intervals ......................................... 5-22
Instructions concerning specific components .................................................. 5-23
Alternator ......................................................................................................... 5-23
Battery ............................................................................................................. 5-24
General maintenance work .................................................................................... 5-25
Cleaning .......................................................................................................... 5-25
General instructions for all areas of the machine ............................................ 5-25
Inside the cab .................................................................................................. 5-26
Cleaning the seat belt ...................................................................................... 5-26
Exterior of the machine .................................................................................... 5-26
Engine compartment ....................................................................................... 5-26
Screw connections and attachments ............................................................... 5-27
Pivots and hinges ............................................................................................ 5-27
Lubrication points ................................................................................................... 5-27
VDS lubrication points (option) ........................................................................ 5-28
Powertilt (option) .............................................................................................. 5-28
Lubrication points of hydraulic quickhitch (option) ........................................... 5-29
Maintenance if the machine is out of service for a longer period of time ............... 5-30
Preparatory work before taking the machine out of service ............................ 5-30
Putting the machine into operation again ........................................................ 5-30
Fluids and lubricants ............................................................................................. 5-31
Additional oil change and filter replacement (hydraulics) ................................ 5-32
Maintenance plan (overview) ................................................................................. 5-35
Specifications
Model 2503 .............................................................................................................. 6-1
Engine ............................................................................................................... 6-1
Hydraulic system ............................................................................................... 6-1
Stabiliser blade .................................................................................................. 6-1
Work hydraulics ................................................................................................. 6-1
Model 3503 .............................................................................................................. 6-2
Engine ............................................................................................................... 6-2
Hydraulic system ............................................................................................... 6-2
Stabiliser blade .................................................................................................. 6-2
Work hydraulics ................................................................................................. 6-2
Model 3503 VDS ...................................................................................................... 6-3
Engine ............................................................................................................... 6-3
Hydraulic system ............................................................................................... 6-3
Stabiliser blade .................................................................................................. 6-3
Work hydraulics ................................................................................................. 6-3
Electrical system ...................................................................................................... 6-4

BA 25-3503 EN - Ausgabe 2.3 *Ba2503_3503en2_3IVZ.fm I-5


Table of contents

Fuse box in cab ................................................................................................. 6-4


Noise levels .............................................................................................................. 6-4
Vibration .................................................................................................................. 6-5
Coolant compound table .......................................................................................... 6-5
Powertilt ................................................................................................................... 6-5
Dimensions model 2503 .......................................................................................... 6-6
Dimensions model 3503 .......................................................................................... 6-7
Dimensions model 3503 VDS .................................................................................. 6-8
Lift capacity table 2503 ............................................................................................ 6-9
Lift capacity table 3503 .......................................................................................... 6-10
Lift capacity table 3503 Vario ................................................................................. 6-11
Lift capacity table 3503 VDS .................................................................................. 6-12

I-6 BA 25-3503 EN - Ausgabe 2.3 * *Ba2503_3503en2_3IVZ.fm


Index
I Index

A M
Abbreviations .........................................................................................1-1 Machine
Air filter .................................................................................................5-10 Brief description .............................................................................. 1-3
Fields of application ........................................................................ 1-4
B
Loading and transporting .............................................................. 3-37
Biodegradable oil .................................................................................5-17 Overview ........................................................................................ 1-2
C Maintenance
Check lists .............................................................................................3-7 Air filter ......................................................................................... 5-11
Crane-handling the machine ................................................................3-36 Biodegradable oil .......................................................................... 5-17
Bleeding the fuel system ................................................................ 5-3
D Checking the coolant level ............................................................. 5-8
Designated use and exemption from liability .........................................2-2 Checking the engine oil level .......................................................... 5-5
Driving on public roads ........................................................................3-17 Checking the hydraulic oil level .................................................... 5-15
Driving the excavator .............................................................................3-9 Cleaning ....................................................................................... 5-25
F Electrical system .......................................................................... 5-22
Engine and hydraulics cooling system ........................................... 5-7
Fire extinguisher ..................................................................................1-22
Engine lubrication system .............................................................. 5-5
Fluids and lubricants ............................................................................5-31
Filling in engine oil .......................................................................... 5-6
H Filling up coolant ............................................................................ 5-8
Hammer operation ...............................................................................2-15 Filling up hydraulic oil ................................................................... 5-16
Heating ................................................................................................3-24 Fluids and lubricants .................................................................... 5-31
Hose burst valve (option) .....................................................................3-70 Fuel system .............................................................................5-1, 5-2
Hydraulic quickhitch system ................................................................3-62 General maintenance work .......................................................... 5-25
Hydraulic pressure lines ............................................................... 5-18
I Hydraulic system .......................................................................... 5-14
Important information Instructions concerning specific components ............................... 5-23
On this Operator's Manual ..............................................................1-1 Maintenance plan ......................................................................... 5-35
Instrument panel overview .....................................................................3-5 Pivots and hinges ......................................................................... 5-27
Interior light ..........................................................................................3-24 Screw connections ....................................................................... 5-27
L Service and maintenance work at regular intervals ...................... 5-22
Track maintenance ....................................................................... 5-19
Legal regulations ...................................................................................1-6
V-belt ............................................................................................ 5-12
Light system .........................................................................................3-23
Maintenance if the machine is out of service for a longer period of time ...
Lowering the boom with the engine stopped ............................. 3-48, 3-55
5-30
N
Noise levels ................................................................................1-11, 1-16
O
Operation .............................................................................................. 3-1
Before starting the engine ............................................................ 3-12
Cab overview .................................................................................. 3-3
Hammer operation ........................................................................ 3-54
Instrument panel overview ............................................................. 3-5
Moving off ..................................................................................... 3-17
Parking the machine ..................................................................... 3-22
Seat belt height adjustment .......................................................... 3-28
Starting the engine ....................................................................... 3-12
Vario (option) ................................................................................ 3-43
P
Powertilt
Maintenance ........................................................................3-67, 3-68
Operation ...................................................................................... 3-68
Preheating start switch .......................................................................... 3-9
Putting into operation ............................................................................ 3-2
Check lists ...................................................................................... 3-7
Putting the machine into operation for the first time ....................... 3-6
Safety instructions .......................................................................... 3-6

BA 25-3503 EN - Ausgabe 2.3 *Ba2503_3503en2_3SIX.fm I-7


Index

R
Refuelling ...............................................................................................5-2
Rotating beacon ...................................................................................3-24
Running-in period ..................................................................................3-6
S
Safe load indicator ...............................................................................3-70
Safety instructions .................................................................................2-1
General conduct .............................................................................2-3
Identification ....................................................................................2-1
Maintenance .................................................................................2-11
Operation ........................................................................................2-5
Special hazards ............................................................................2-13
Trailers and attachments ................................................................2-9
Transport ........................................................................................2-9
Seat adjustment ...................................................................................3-26
Backrest adjustment .....................................................................3-27
Horizontal adjustment ...................................................................3-27
Weight adjustment ........................................................................3-27
Seat belt ...............................................................................................3-28
Seat belt height adjustment .................................................................3-28
Signs and symbols ...............................................................................1-11
Specifications .........................................................................................6-1
Coolant compound table .................................................................6-5
Dimensions ...................................................................... 6-6, 6-7, 6-8
Electrical system .............................................................................6-4
Engine .............................................................................. 6-1, 6-2, 6-3
Noise levels ....................................................................................6-4
Vibration ..........................................................................................6-5
Work hydraulics ...................................................................... 6-2, 6-3
Starting aid ...........................................................................................3-15
T
Telltales ...............................................................................................3-10
Tilting the upper carriage .....................................................................3-57
Track maintenance ..............................................................................5-19
V
Ventilation ............................................................................................3-24
Ventilation, fresh air ......................................................................3-24
W
Warranty ................................................................................................2-1
Washer system ....................................................................................3-25
Tank ..............................................................................................3-26
Working
Freeing the machine .....................................................................3-76
Practical hints ...............................................................................3-76

I-8 BA 25-3503 EN - Ausgabe 2.3 * *Ba2503_3503en2_3SIX.fm


Introduction

1 Introduction
1.1 Important information on this Operator's Manual
Please store the Operator's Manual in the storage box at the rear of the seat.
This Operator's Manual contains important information on how to work safely, correctly
and economically with the machine. Therefore, it aims not only at new staff, but it also
serves as a reference for experienced staff. It helps to avoid dangerous situations and
reduce repair costs and downtimes. Furthermore, the reliability and the service life of the
machine will be increased by following the instructions in the Operator's Manual. This is
why the Operator's Manual must always be kept at hand in the machine.
Your own safety, as well as the safety of others, depends to a great extent on how the
machine is moved and operated. Therefore, carefully read and understand this Operator's
Manual prior to the first drive. This Operator's Manual will help to familiarise yourself more
easily with the machine, thereby enabling you to use it more safely and efficiently.
Prior to the first drive, carefully read chapter Safety Instructions as well, in order to be
prepared for possible dangerous situations, as it will be too late for it during operation. As a
rule, keep the following in mind:
Careful and prudent working is the best way to avoid accidents!
Operational safety and readiness of the machine do not only depend on your skill, but also
on maintenance and servicing of the machine. This is why regular maintenance and serv-
ice work is absolutely necessary. Extensive maintenance and repair work must always be
carried out by an expert with appropriate training. Insist on using original spare parts when
carrying out maintenance and repair work. This ensures operational safety and readiness
of your machine, and maintains its value.
Special equipment and superstructures are not described in this Operator's Manual.
We reserve the right to improve the technical standard of our machines without
adapting the Operator's Manual.
Modifying Wacker Neuson products and fitting them with additional equipment and
attachments not included in our delivery program requires Wacker Neuson's written
authorisation, otherwise warranty and product liability for possible damage caused by
these modifications shall not be applicable.
Subject to modifications and printing errors.
Your Wacker Neuson dealer will be pleased to answer any further questions regarding the
machine or the Operator's Manual.

Abbreviations/symbols
This symbol stands for a list
Subdivision within lists or an activity. Follow the steps in the recommended sequence
This symbol requires you to carry out the activity described
Description of the effects or results of an activity
n. s. = not shown
Opt = option
Stated whenever controls or other components of the machine are installed as an option.

This symbol shows the driving direction for better orientation in figures and
graphics.

BA 25-3503 EN Edition 2.3 *2503_3503b110.fm 1-1


Introduction

1.2 Machine overview

1 Boom light 2
2 Boom
3 Stick
4 Rubber tracks
5 Undercarriage
7
6 Stabiliser blade
3
7 Cab
8 Valve cover
9 Handle
9

5
13 Exhaust pipe
14 14 Eye hook for loading/tying down the
machine
15 Lubrication point for track tension
7 16 Engine cover

16 13

15

13

5
14 4
Fig. 1: Machine outside views

1-2 BA 25-3503 EN Edition 2.3 * *2503_3503b110.fm


Introduction

1.3 Brief description


Get informed on and follow the legal regulations of your country.
The machine can be equipped with a backhoe bucket, shovel bucket or grab for loosening,
picking up, transporting and dumping earth, rock and other material that is mostly trans-
ported without moving the machine.
A wide range of attachments accounts for the numerous applications of the machine,
among others hammer and grab applications. See chapter see chapter 1.4 Fields of
application, attachments on page 1-4 for further applications.
The main components of the machine are:
Undercarriage
Tracked travel gear
Stabiliser blade
Live ring
Upper carriage
TOPS (Tip Over Protective Structure) and ROPS (Roll Over Protective Structure)
tested canopy (open version) or
TOPS (Tip Over Protective Structure) and ROPS (Roll Over Protective Structure)
tested cab (closed version) option
FOPS (Falling Object Protective Structure) option
Water-cooled diesel engine
Hydraulic and electrical components
Boom

Travelling drive
The diesel engine permanently drives the twin axial variable displacement pump whose oil
flow is sent to a hydraulic motor.

Work hydraulics
The diesel engine also drives the joint gear pump for the work hydraulics. The oil flow of
this pump depends on the diesel engine speed only.

Cooling system
Coolant temperature is monitored with the telltale on the machine's instrument panel.

Cab
Modifying or carrying out improper repair work on the cab is dangerous. Do not modify the
cab. Repair work may be carried out by an authorised workshop only. If the cab has been
damaged, check it before resuming work and have it repaired if necessary. Please contact
your Wacker Neuson dealer for support. Failure to follow this precautionary measure can
lead to severe or fatal injury. The cab has been specially designed for your protection in
case of an accident.
Fasten your seatbelt, otherwise you can be thrown around or even outside the cab and
crushed. Therefore always fasten your seatbelt as you drive and work with the machine.
Tighten the seatbelt before taking up work with the machine.

BA 25-3503 EN Edition 2.3 *2503_3503b110.fm 1-3


Introduction

1.4 Fields of application, attachments


The attachments will decide in the first place how the excavator is used.

Caution!
In order to avoid damage to the machine, only the attachments listed below
have been certified for installation on the machine.
Please contact your Wacker Neuson dealer if you wish to use other attach-
ments.

Using tools of other manufacturers, or tools which have been released for other excavator
types, can reduce the machine's output and stability considerably, and can also cause
damage to the machine and injuries to the operator or the staff.
Always compare the weight of the attachment and its maximum payload with the indica-
tions in the lift capacity table. Never exceed the maximum payload stated in the lift capac-
ity table.

Notice!
Please refer to the Operator's and maintenance manual of the attachment manu-
facturer for using and carrying out maintenance on attachments such as hammers,
grabs etc.

Use: attachment

Description of attachment Capac- Excava- Remarks


Weight Item no.:
ity tor

14 kg - 1000004049 2503
Required for operation of Wacker Neuson
Complete quickhitch
quickhitch systems
27 kg - 1000018479 3503

38 kg 36 l 1000093539 2503
Bucket B = 260 mm
42 kg 36 l 1000093543 2503 For quickhitch

40 kg 43 l 1000093534 2503

44 kg 43 l 1000017122 2503 For quickhitch


Bucket B = 300 mm
56 kg 50 l 1000093755 3503

64 kg 50 l 1000017130 3503 For quickhitch

48 kg 59 l 1000093536 2503

52 kg 59 l 1000093542 2503 For quickhitch


Bucket B = 400 mm
64 kg 69 l 1000093756 3503

72 kg 69 l 1000017125 3503 For quickhitch

1-4 BA 25-3503 EN Edition 2.3 * *2503_3503b110.fm


Introduction

Description of attachment Capac- Excava- Remarks


Weight Item no.:
ity tor

54 kg 75 l 1000093535 2503

58 kg 75 l 1000093541 2503 For quickhitch


Bucket B = 500 mm
74 kg 88 l 1000093757 3503

82 kg 88 l 1000017127 3503 For quickhitch

63 kg 91 l 1000093537 2503

67 kg 91 l 1000017121 2503 For quickhitch


Bucket B = 600 mm
82 kg 107 l 1000093758 3503

90 kg 107 l 1000017134 3503 For quickhitch

71 kg 107 l 1000093538 2503

75 kg 107 l 1000093540 2503 For quickhitch


Bucket B = 700 mm
90 kg 127 l 1000093759 3503

99 kg 127 l 1000017128 3503 For quickhitch

92 kg 73 l 1000093462 2503
Offset bucket B = 850 mm short stick
96 kg 73 l 1000017105 2503 For quickhitch

94 kg 87 l 1000096529 2503

100 kg 87 l 1000017106 2503 For quickhitch


Offset bucket B = 1000 mm short stick
135 kg 111 l 1000096567 3503

142 kg 111 l 1000017131 3503 For quickhitch

147 kg 158 l 1000096568 3503


Offset bucket B = 1400 mm short stick
155 kg 158 l 1000017132 3503 For quickhitch

92 kg 73 l 1000093546 2503
Offset bucket B = 850 mm long stick
96 kg 73 l 1000093548 2503 For quickhitch

94 kg 87 l 1000096541 2503

100 kg 87 l 1000096542 2503 For quickhitch


Offset bucket B = 1000 mm long stick
135 kg 111 l 1000096569 3503

142 kg 111 l 1000096571 3503 For quickhitch

147 kg 158 l 1000096570 3503


Offset bucket B = 1400 mm long stick
155 kg 158 l 1000096572 3503 For quickhitch

BA 25-3503 EN Edition 2.3 *2503_3503b110.fm 1-5


Introduction

Description of attachment Capac- Excava- Remarks


Weight Item no.:
ity tor

55 kg 69 l 1000093460 2503
Ditch cleaning bucket B = 850 mm
59 kg 69 l 1000093335 2503 For quickhitch

64 kg 82 l 1000096528 2503
Ditch cleaning bucket B = 1000 mm
68 kg 82 l 1000096518 2503 For quickhitch

84 kg 117 l 1000096563 3503


Ditch cleaning bucket B = 1000 mm
102 kg 116 l 1000096549 3503 For quickhitch

75 kg 98 l 1000096540 2503
Ditch cleaning bucket B = 1200 mm
79 kg 98 l 1000096539 2503 For quickhitch

109 kg 166 l 1000096564 3503


Ditch cleaning bucket B = 1400 mm
130 kg 164 l 1000096550 3503 For quickhitch

14 kg - 1000020344 2503
Hammer console
27 kg - 1000070743 3503

1.5 Regulations
Requirements to be met by the driver
Earth moving machines may be driven and serviced only by persons who meet the follow-
ing requirements:
18 years or older
Physically and mentally suited for this work
Persons have been instructed in driving and servicing the earth moving machine and
have proven their qualifications to the contractor
Persons are expected to carry out work reliably.
They have been appointed by the contractor for driving and servicing the earth moving
machine.
Get informed on and follow the legal regulations of your country.

Warranty
Warranty claims can be made only if the conditions of warranty have been observed. They
are included in the General Conditions of Sales and Delivery for new machines and spare
parts sold by the dealers of Wacker Neuson Linz GmbH, Linz-Leonding (Austria). Further-
more, the instructions in this Operator's Manual must be observed.

1-6 BA 25-3503 EN Edition 2.3 * *2503_3503b110.fm


Introduction

1.6 EC Declaration of Conformity 2503

EC Declaration of Conformity
According to Machine Directive 2006/42/EC, appendix II A

Manufacturer
Wacker Neuson Linz GmbH
Haidfeldstr. 37
A-4060 Linz-Leonding

Product
Machine designation: Hydraulic excavator
Machine model: 2503
Serial no.: ______________
Output (kW): 19.4 kW
Measured sound power level:94 dB (A)
Guaranteed sound power level:94 dB (A)

Conformity assessment procedure


Notified body according to Directive 2006/42/EC, appendix XI:
Fachausschsse Bau und Tiefbau
Prf- und Zertifizierungsstelle im BG-PRFZERT
Landsberger Str. 309
D-80687 Munich
Distinguishing EU number 0036

Notified body according to Directive 2000/14/EC, appendix VI:


TV SD Industrie Service GmbH
Westendstr. 199
D-80686 Munich

Directives and standards


We hereby declare that this product corresponds to the relevant regulations and requirements of the following Directives and
standards:
2006/42/EC (old 98/37 EC), 2004/108/EC (old 89/336/EEC), 2002/44/EC, 2005/88/EC, 2000/14/EC;
DIN EN ISO 12100-1 and 2, DIN EN 474-1 and 5, DIN EN 14121,
DIN EN 3471, DIN EN 13510, EN ISO 3744, EN ISO 3746, DIN EN ISO 3449

Leonding,
Place, date Thomas Kck, Josef Erlinger,
Responsible for documentation Managing director

BA 25-3503 EN Edition 2.3 *2503_3503b110.fm 1-7


Introduction

1.7 EC Declaration of Conformity 3503

EC Declaration of Conformity
According to Machine Directive 2006/42/EC, appendix II A

Manufacturer
Wacker Neuson Linz GmbH
Haidfeldstr. 37
A-4060 Linz-Leonding

Product
Machine designation: Hydraulic excavator
Machine model: 3503
Serial no.: ______________
Output (kW): 23.7 kW
Measured sound power level:93.9 dB (A)
Guaranteed sound power level:95 dB (A)

Conformity assessment procedure


Notified body according to Directive 2006/42/EC, appendix XI:
Fachausschsse Bau und Tiefbau
Prf- und Zertifizierungsstelle im BG-PRFZERT
Landsberger Str. 309
D-80687 Munich
Distinguishing EU number 0036

Notified body according to Directive 2000/14/EC, appendix VI:


TV SD Industrie Service GmbH
Westendstr. 199
D-80686 Munich

Directives and standards


We hereby declare that this product corresponds to the relevant regulations and requirements of the following Directives and
standards:
2006/42/EC (old 98/37 EC), 2004/108/EC (old 89/336/EEC), 2002/44/EC, 2005/88/EC, 2000/14/EC;
DIN EN ISO 12100-1 and 2, DIN EN 474-1 and 5, DIN EN 14121,
DIN EN 3471, DIN EN 13510, EN ISO 3744, EN ISO 3746, DIN EN ISO 3449

Leonding,
Place, date Thomas Kck, Josef Erlinger,
Responsible for documentation Managing director

1-8 BA 25-3503 EN Edition 2.3 * *2503_3503b110.fm


Introduction

1.8 Type labels and component numbers


Serial number AG00580
The serial number is stamped on the machine chassis. It is also located on the type label.
The type label is located at the front right on the machine chassis (at cab level)
Type label information
Example:

Machine designation: ---------------


Model: ---------------
Fig. 1: Type label: location Model year: ---------------
CEE no.: ---------------
Output: ---------------
Serial no.: ---------------
Max. payload: ---------------
GWR: ---------------
Operating weight: ---------------
Front GAWR: ---------------
Transport weight: ---------------
Fig. 2: Type label Rear GAWR: ---------------
Version: ---------------
Other information see chapter 6 Specifications on page 6-1

Cab number
The type label (arrow) is located on the chassis of the cab, at the upper left beside the
door.

Fig. 3: Cab type label


Engine number
The type label (arrow) is located on the valve cover (engine).

Example: Yanmar 46557

Fig. 4: Diesel engine type label from serial number


AG00580

BA 25-3503 EN Edition 2.3 *2503_3503b110.fm 1-9


Introduction

Hydraulic quickhitch system (option)

Fig. 5: Type label (hydraulic quickhitch system)

Powertilt (option)

Fig. 6: Powertilt type label

1-10 BA 25-3503 EN Edition 2.3 * *2503_3503b110.fm


Introduction

1.9 Other signs and symbols (up to AG01597)


The following states signs and symbols which are not unequivocally comprehensible. They
do not contain explanatory text and are not explained in the following chapters.
Meaning
Machine is raised by the eye hooks
see chapter 3.35 Crane handling the machine on page 3-36
Location
On either side of the stabiliser blade, and on either side of the boom.

Fig. 7: Eye hooks

Meaning
Points for tying down the machine.
The mounting points are used for tying down the machine during loading and transport.
see chapter 3.37 Tying down the machine on page 3-38
Location
On either side of the stabiliser blade, and on either side of the undercarriage.
Fig. 8: Slinging points for tying down the machine

Meaning
Noise levels produced by the machine.
LWA = sound power level
Other information see chapter 6.5 Noise levels on page 6-4

93 Location
Next to the cab door
Fig. 9: Noise level indication

Meaning
This label shows the forwards driving direction.
Location
On either side of the undercarriage

Fig. 10: Direction indicator

Meaning
General indication of danger.
This label warns persons standing or working near the excavator of an existing danger
within the area of increased danger around the machine.
Location
On either side of the boom
Fig. 11: Danger label

Meaning
The CE mark means that the machine meets the requirements of the Machine Directive
and that the conformity procedure has been carried out. The machine meets all the health
and safety requirements of the Machine Directive.
Location
On the type label
Fig. 12: CE mark

BA 25-3503 EN Edition 2.3 *2503_3503b110.fm 1-11


Introduction

Meaning
Do not touch hot surfaces, wait for parts to cool down.
Location
In the engine compartment.

Fig. 13: Hot surface

Meaning
Fill in diesel fuel only!
Location
Next to the filler inlet.

Fig. 14: Diesel

Meaning
The tank contains hydraulic oil.
see chapter 5.6 Engine and hydraulics cooling system on page 5-7
Location
On the hydraulic oil tank

Fig. 15: Hydraulic oil

Meaning
Read the Operator's Manual before working with the machine!
Location
Inside the cab on the right-hand side lining

Fig. 16: Read the Operator's Manual

Meaning
Press the boom and the stabiliser blade into the ground as you leave the machine, remove
the ignition key and place chocks on the left and right under the tracks see Parking
checklist on page 3-8.
Location
Cab roof lining
Fig. 17: Parking the machine correctly

Meaning
Describes the throttle lever function.
see Throttle on page 3-9
Location
Fig. 18: Engine speed control Below the throttle lever
Meaning

10 Interval at which lubrication point must be lubricated.


Location
50 On upper carriage
9705016G

Fig. 19: Lubrication interval

1-12 BA 25-3503 EN Edition 2.3 * *2503_3503b110.fm


Introduction

Meaning
Do not loosen the securing screws before the extra weight has been secured.
Location
On the rear left and right of the upper carriage.

9705492

Fig. 20: Warning label

Meaning
D ACHTUNG, Hydraulikl-
tank steht unter Druck! Hydraulic oil tank under pressure!
E ATTENTION, hydraulic
reservoir under pressure! Location
ATTENZIONE, serbatoio olio
I
idraulico sotto pressione! On the hydraulic oil tank.
F ATTENTION, le rservoir
d'huile hydraulique est sous

Notice!
pression!
9705024

Fig. 21: Hydraulic oil tank under pressure


Observe the information given on this safety label UNDER ALL CIRCUM-
STANCES!

Meaning
Position in which the ball-type cock must be during hammer/normal operation.
Location
On the hydraulic oil tank.

9705591

Fig. 22: Ball-type cock

Meaning
1. CAUTION, danger of being caught up!
2. Stay clear of the engine compartment with the engine running!
3. Carry out work in the engine compartment at engine standstill only.
Location
In the engine compartment.

Notice!
ALWAYS follow the instructions on the safety label!

Fig. 23: Fan warning label

Meaning
The valve cover is opened with this Bowden cable.
Location
Under the seat.

9705239G
Fig. 24: Opening the valve cover

BA 25-3503 EN Edition 2.3 *2503_3503b110.fm 1-13


Introduction

Meaning
The engine cover is opened with this Bowden cable.
Location
Under the seat.

9705276G
Fig. 25: Open the engine cover

Meaning
Provides information on the directives this cab complies with.
WARNING: The operator protection provided by a ROPS/FOPS/TOPS is reduced if it altered, subjected to an
upset or has structural damage, and it must be replaced. Any alternations or repairs without the written consent of
the manufacturer will void the warranty and certification of the structure.

BAUMASCHINEN GmbH
R
ROLLOVER PROTECTIVE STRUCTURE
At the time of installation, when properly installed in MODEL: LK - 88 8800AR50
Cab no longer complies with these directives if it is modified
accordance with the manufacturer's instructions on a
Location
Haidfeldstrae 37
machine that has not been altered to exceed the FOR USE ON: 2503 - 3003
4060 Linz-Leonding
certification test weight, this structure meets criteria: 3503 - 3703

Inside the cab.


ISO 3449 - ISO 3471 - ISO 12117 TEST WEIGHT (kg): 4020
MADE IN AUSTRIA
9705503

Fig. 26: ROPS/FOPS/TOPS label

Meaning
1. CAUTION, rotating fan!
2. Stop the engine before opening the engine cover!
3. Stay clear of the engine compartment if the fan is still running!

Notice!
ALWAYS follow the instructions on the safety label!

Fig. 27: Fan label


Location
On the engine cover and in the engine compartment
Meaning
1. CAUTION, danger of being caught up!
2. Always use the handles to open and close the front window.
3. Always lock the front window with both locks!
Location
Fig. 28: Front window label On the front window.

Notice!
ALWAYS follow the instructions on the safety label!

Meaning
The Powertilt function is enabled once the excavator is started.

Not assigned.

Not assigned.

The unit is operated with the slide switch on the left-hand side control lever (right-hand
side control lever with auxiliary hydraulics and proportional controls).
Fig. 29: Powertilt Location
On the headliner
see chapter 3.51 Powertilt 3505 (option) on page 3-65

1-14 BA 25-3503 EN Edition 2.3 * *2503_3503b110.fm


Introduction

1.10 Other signs and symbols (from AG01598)


Overview of safety labels:

BA 25-3503 EN Edition 2.3 *2503_3503b110.fm 1-15


Introduction

Symbols
The following symbols are displayed on the machine to provide pictorial information to the
user. The information and explanations are provided to avoid misinterpretation by the user.
The symbols have been chosen to provide important information to those involved with
operating, adjusting, maintaining, and repairing this machine.
Description
Locates the lifting points for hoisting the excavator with lifting devices (slings, chains, or
cables).
Location
On either side of the stabiliser blade, and on either side of the boom.

Fig. 30: Eye hooks

Description
Tie down points.
Points for tying down the machine during transport to prevent movement during transport.
Location
On either side of the stabiliser blade, and on either side of the undercarriage.

Fig. 31: Tie down points

Description
Noise levels produced by the machine.
LWA = sound power level
Location
On the upper carriage next to the swivelling console.

Fig. 32: Noise level indication

Meaning
This label shows the forwards driving direction.
Location
On either side of the undercarriage

Fig. 33: Direction indicator

Meaning
The CE mark means that the machine meets the requirements of the Machine Directive
and that the conformity procedure has been carried out. The machine meets all the health
and safety requirements of the Machine Directive.
Location
On the type label
Fig. 34: CE mark
Meaning

10 Interval at which lubrication point must be lubricated.


Location
50 On upper carriage
9705016G

Fig. 35: Lubrication interval

1-16 BA 25-3503 EN Edition 2.3 * *2503_3503b110.fm


Introduction

Meaning
Position in which the ball-type cock must be during hammer/normal operation.
Location
On the hydraulic oil tank.

9705591

Fig. 36: Ball-type cock

Meaning
The valve cover is opened with this Bowden cable.
Location
Under the seat.

9705239G

Fig. 37: Opening the valve cover

Meaning
The engine cover is opened with this Bowden cable.
Location
Under the seat.

9705276G

Fig. 38: Open the engine cover

Meaning
Fill in diesel fuel only!
Location
Next to the filler inlet.

Fig. 39: Diesel


Meaning
The tank contains hydraulic oil.
see chapter 5.6 Engine and hydraulics cooling system on page 5-7
Location
On the hydraulic oil tank.

Fig. 40: Hydraulic oil


Description
Explains the functions of the joysticks (control pattern A) and of other controls. If the
machine is fitted with a changeover valve, check before starting the machine the control
pattern that has been chosen!
Location
On the headliner.

Fig. 41: Control pattern A

BA 25-3503 EN Edition 2.3 *2503_3503b110.fm 1-17


Introduction

Description
Explains the joystick functions (control pattern B).
Check before starting the machine the control pattern that has been chosen!
Position (option)
On the headliner.

Fig. 42: Control pattern B (option)

Safety labels

Notice!
Always follow the instructions on the safety labels!

Description
The label means the following:
Grease can be ejected under high pressure from the track tension system.
Always read the Operator's Manual before slackening or tightening the tracks to avoid
potential injury from ejected grease.
Location
Fig. 43: Tightening the tracks On the undercarriage near the lubrication system.
Description
Stop the engine before opening or dismounting the safety devices (e.g. engine cover, fan
guard ...)
Location
On the engine cover.

Fig. 44: Stop the engine

Description
This safety label warns of the following dangers:
1: Rotating fan.
Stay clear of the engine compartment if the fan is still running.
2: Stay clear of the engine compartment with the engine running!
3: The radiators are hot and under pressure!
Allow the radiators to cool down!
Carefully and slowly open the cover only after the radiator has cooled down, to allow
the pressure to escape.
Wear safety goggles and gloves when opening the cover.

Location
In the engine compartment.

Fig. 45: Warning label

1-18 BA 25-3503 EN Edition 2.3 * *2503_3503b110.fm


Introduction

Description
Do not touch hot surfaces, wait for parts to cool down.
Location
In the engine compartment.

Fig. 46: Hot surface


Meaning
Do not loosen the securing screws before the extra weight has been secured.
Location
On the rear left and right of the upper carriage.

9705492

Fig. 47: Warning label

Description
The tank is hot and under pressure!
Allow the fluids to cool down!
Carefully and slowly open the cover only after the radiator has cooled down, to allow
the pressure to escape.
Wear safety goggles and gloves when opening the cover.
Location
On the hydraulic oil tank.

Fig. 48: Tank under pressure

Meaning
1. CAUTION, danger of being caught up!
2. Always use the handles to open and close the front window.
3. Always lock the front window with both locks!
Location
On the front window.
Fig. 49: Front window
Notice!
ALWAYS follow the instructions on the safety label!

Description
Read and understand the Operator's Manual before starting, working, adjusting, carrying
out maintenance or repairing the machine.
Location
On the B pillar in the cab.

Fig. 50: Read the Operator's Manual

BA 25-3503 EN Edition 2.3 *2503_3503b110.fm 1-19


Introduction

Description
This label alerts persons standing or working near the machine of an existing danger
within the area of increased danger around the machine. Stay clear of machine!
Location
On either side of the boom.

Fig. 51: Keep distance


Description
Accumulator is under high pressure. Always read the Operator's Manual before carrying
out maintenance or repairs
Location
On the upper carriage next to the accumulator.

Fig. 52: Under pressure

Description
Indicates that persons other than the driver must keep a safe distance from the machine
during operation. Stay clear of machine!
Location
On the valve cover and the upper carriage next to the swivelling console.

Fig. 53: Keep distance

Description
Indicates that persons other than the driver must keep a safe distance from the machine
during operation. Stay clear of machine!
Location
On the rear window.

Fig. 54: Keep distance


Description
1: Before carrying out maintenance or repairs on the machine, stop the engine, remove the
key, and read and understand the Operator's Manual and the service manual.
2: Before leaving the machine lower all equipment to the ground, remove the key and lock
the controls.
Location
On the B pillar in the cab.

Fig. 55: Read the manual before carrying out maintenance


or repairs

1-20 BA 25-3503 EN Edition 2.3 * *2503_3503b110.fm


Introduction

Description
1: Operate only from the seat and fasten the seat belt to prevent falling out of the machine.
2: Operate within the stability limits of machine, do not overload, use only approved attach-
ments and operate only on solid ground. Follow the instructions in the Operator's Manual.
Location
On the B pillar in the cab.

Fig. 56: Fastening the seat belt

Meaning
The Powertilt function is enabled once the excavator is started.

Not assigned.

Not assigned.

The unit is operated with the slide switch on the left-hand side control lever (right-hand
side control lever with auxiliary hydraulics and proportional controls).
Location
On the headliner
Fig. 57: Powertilt
see chapter 3.51 Powertilt 3505 (option) on page 3-65

Meaning
Bear in mind the authorised (pay)load according to the table.
see chapter 6.12 Lift capacity table 2503 on page 6-9
see chapter 6.13 Lift capacity table 3503 on page 6-10
see chapter 6.15 Lift capacity table 3503 VDS on page 6-12
Location
On the headliner

Fig. 58: Lift capacity table 2503

Fig. 58: Lift capacity table 3503

BA 25-3503 EN Edition 2.3 *2503_3503b110.fm 1-21


Introduction

Meaning (option)
This label describes the functions of the hydraulic quickhitch.
Location
On the headliner
see chapter 3.50 Hydraulic quickhitch system (option) on page 3-62

Fig. 59: Hydraulic quickhitch system

1.11 Fire extinguisher


A fire extinguisher can be installed at the rear right or left on the cab frame.

1-22 BA 25-3503 EN Edition 2.3 * *2503_3503b110.fm


Safety instructions

2 Safety instructions
2.1 Identification of warnings and dangers
Important indications regarding the safety of the staff and the machine are identified in this
Operator's Manual with the following terms and symbols:

Danger!
Failure to observe the instructions identified by this symbol can result in
personal injury or death for the operator or other persons.
Measures for avoiding danger

Caution!
Failure to observe the instructions identified by this symbol can result in
damage to the machine.
Measures for avoiding danger for the machine

Notice!
This symbol identifies instructions for a more efficient and economical use of the
machine.

Environment!
Failure to observe the instructions identified by this symbol can result in dam-
age to the environment. The environment is in danger if environmentally haz-
ardous material (e.g. waste oil) is not subject to proper use or disposal.

2.2 Warranty
Warranty claims can be brought forward to your Wacker Neuson dealer only.
Furthermore, the instructions in this Operator's Manual must be observed.

2.3 Disposal
All fluids, lubricants, material, etc., used on the machine are subject to specific regulations
regarding collection and disposal. Dispose of different materials and consumables sepa-
rately and in an environmentally friendly manner!
Disposal may be carried out by a Wacker Neuson dealer only. Also observe the legal reg-
ulations of your country regarding disposal!

Environment!
Avoid damage to the environment! Do not allow the oil and oily wastes to get
into the ground or stretches of water!

If the machine is no longer used according to its designated use, make sure it is decom-
missioned or put out of operation and disposed of according to applicable regulations.

BA 25-3503 EN Edition 2.3 *2503_3503b210.fm 2-1


Safety instructions

Observe all applicable safety regulations during machine disposal!


Machine disposal must be carried in accordance with state-of-the-art standards that apply
at the time of disposal!

2.4 Designated use and exemption from liability


The machine is intended for:
moving earth, gravel, coarse gravel or ballast and rubble as well as for
working with the attachments mentioned in chapter Fields of application
Every other application is regarded as not designated for the use of the machine.
Wacker Neuson will not be liable for damage resulting from use other than mentioned
above. The user alone will bear the risk.
Designated use also includes observing the instructions set forth in the Operator's
Manual and observing the maintenance and service conditions.
The safety of the machine can be negatively affected by carrying out machine modifica-
tions without proper authority and by using spare parts, equipment, attachments and
optional equipment which have not been checked and released by Wacker
Neuson GmbH. Wacker Neuson GmbH will not be liable for damage resulting from this.
Wacker Neuson GmbH shall not be liable for personal injury and/or damage to property
caused by failure to observe the safety instructions and the Operator's Manual, and by
the negligence of the duty to exercise due care when:
handling
operating
servicing and carrying out maintenance work and
repairing the machine. This is also applicable in those cases in which special
attention has not been drawn to the duty to exercise due care, in the safety instruc-
tions, the Operator's Manuals and maintenance manuals (machine/engine).
Read and understand the Operator's Manual before starting up, servicing or repairing
the machine. Observe the safety instructions!
The machine may not be used for transport jobs on public roads
In applications with lifting gear, the machine is used according to its designated use
only if the prescribed devices are installed and functional!
The quickhitch is only used for locking an attachment.
Hammer operation is only allowed in specified areas.

2-2 BA 25-3503 EN Edition 2.3 * *2503_3503b210.fm


Safety instructions

2.5 General conduct and safety instructions


Organisational measures
The machine has been designed and built in accordance with state-of-the-art standards
and the recognised safety regulations. Nevertheless, its use can constitute a risk to life
and limb of the user or of third parties, or cause damage to the machine and to other
material property
The machine must only be used in technically perfect condition in accordance with its
designated use and the instructions set forth in the Operator's Manual, and only by
safety-conscious persons who are fully aware of the risks involved in operating the
machine. Any functional disorders, especially those affecting the safety of the machine,
must therefore be rectified immediately!
Basic rule:
Before starting up the machine, inspect the machine for safety in work and road
operation!
Careful and prudent working is the best way to avoid accidents!
The Operator's Manual must always be at hand at the place of use of the machine, and
must therefore be kept in the storage compartment provided for in the cab.
Immediately complete or replace an incomplete or illegible Operator's Manual.
In addition to the Operator's Manual, observe and instruct the operator in all other
generally applicable legal and other mandatory regulations relevant to accident
prevention and environmental protection.
These compulsory regulations may also deal with handling hazardous substances,
issuing and/or wearing personal protective equipment, or traffic regulations
With regard to specific operational features, e.g. those relevant to job organisation,
work sequences or the persons entrusted with the work, supplement the Operator's
Manual by corresponding instructions, including those relevant to supervising and
reporting duties
Persons entrusted with work on the machine must have read and understood the
Operator's Manual and in particular, chapter Safety Instructions before beginning
work. This applies especially to persons working only occasionally on the machine, e.g.
set-up or maintenance
The user/owner must check at least from time to time whether the persons
entrusted with operation or maintenance of the machine are working in compliance with
the Operator's Manual and are aware of risks and safety factors
The user/owner commits himself to operate and keep the machine in perfect condition,
and, if necessary or required by law, to require the operating or servicing persons to
wear protective clothing etc.
In the event of safety-relevant modifications or changes on the machine or of its
behaviour, stop the machine immediately and report the malfunction to the competent
authority/person.
Safety-relevant damage or malfunctions of the machine must be rectified immediately
Never make any modifications, additions or conversions to the machine and its super-
structures (e.g. cab etc.), as well as to the attachments, which might affect safety
without the approval of Wacker Neuson! This also applies to the installation and the
adjustment of safety devices and valves, as well as to welding work on load-bearing
elements
Spare parts must comply with the technical requirements specified by Wacker
Neuson GmbH. Original spare parts can be relied to do so.
Replace hydraulic hoses within stipulated and appropriate intervals even if no safety-
relevant defects have been detected.

BA 25-3503 EN Edition 2.3 *2503_3503b210.fm 2-3


Safety instructions

Before working on or with the machine, remove jewellery, such as rings, wristwatches,
bracelets etc., and tie back long hair and do not wear loose-fitting garments, such as
unbuttoned or unzipped jackets, ties or scarves.
Injury can result from being caught up in the machinery or from rings catching on
moving parts!
Keep the machine clean. This reduces
Fire hazard, e.g. due to oil-soaked rags lying around
Danger of injury, e.g. due to dirt or debris on the footholds, and
Danger of accidents e.g. due to dirt pile-up on the drive pedals
Observe all safety, warning and information signs and labels on the machine!
Adhere to prescribed intervals or those specified in the Operator's Manual for routine
checks/inspections and maintenance work!
For service, inspection, maintenance or repair work, tools and workshop equipment
adapted to the task on hand are absolutely indispensable

Selection and qualification of staff, basic responsibilities


Any work on or with the machine must be carried out by reliable staff only. Do not let
unauthorised persons drive or work with the machine! Observe statutory minimum age
limits!
Employ only trained or instructed staff on the machine, and clearly and unequivocally
define the individual responsibilities of the staff for operation, set-up, maintenance and
repair!
Define the machine operator's responsibilities also with regard to observing traffic
regulations. Give the operator the authority to refuse instructions by third parties that
are contrary to safety
Do not allow persons to be trained or instructed or persons taking part in a general
training course to work on or with the machine without being permanently supervised
by an experienced person!
Work on the electrical system and equipment, on the undercarriage and the steering
and brake systems may be carried out only by skilled staff which has been specially
trained for such work.
Work on the hydraulic system of the machine must be carried out only by staff with
special knowledge and experience in hydraulic equipment!
Seal off the danger area should it not be possible to keep a safe distance.
Stop work if persons do not leave the danger area in spite of warning! Keep out of the
danger area!
Danger area:
The danger area is the area in which persons are in danger due to the movements of the
machine
work equipment
additional equipment or
material
This also includes the area affected by falling material, equipment or by parts which
are thrown out.
The danger area must be extended by 0.5 m in the immediate vicinity of
buildings
scaffolds or
other elements of construction

2-4 BA 25-3503 EN Edition 2.3 * *2503_3503b210.fm


Safety instructions

2.6 Safety instructions regarding operation

Normal operation
Put the machine into operation only after you have fastened and tightened the seat belt.
Apart from the driver, no other persons are allowed to ride on the machine.
Fold up the control lever base before releasing the seat belt in order to avoid uninten-
tional operation.
Avoid any operational mode that might be prejudicial to safety!
Before beginning work, familiarise yourself with the surroundings and circumstances of
the work site. These are e.g. obstacles in the working and travelling area, the soil
bearing capacity and any necessary barriers separating the work site from public roads
Take the necessary precautions to make sure the machine is used only when in a safe
and reliable state!
Operate the machine only if all protective and safety-oriented devices, e.g. removable
safety-devices, soundproofing elements and exhausters etc., are in place and fully
functional!
Check the machine at least once a day/per work shift for visible damage and defects.
Report any changes (incl. changes in the machine's working behaviour) to the
competent organisation/person immediately! If necessary, stop the machine immedi-
ately and lock it!
In the event of malfunctions, stop the machine immediately and lock it! Have any
defects rectified immediately!
Start and operate the machine from the seat only!
Carry out start-up and shut-down procedures in accordance with the Operator's
Manual, and observe the telltales!
Before putting the machine/attachment into operation (start-up/moving), make sure no-
one is at risk by putting the machine/attachment into operation!
Before driving with the machine, and also after interrupting work, check whether the
drive pedals, the signalling and the light systems are functional!
Before moving the machine always check whether the supplementary equipment and
the attachments have been safely stowed away or attached!
When driving on public roads, ways and places, observe the valid traffic regulations
and, if necessary, make sure beforehand that the machine is in a condition perfectly
compatible with these regulations!
Always switch on the lights in conditions of poor visibility and after dark!
No lifting, lowering or carrying persons in the work equipment/attachments!
Installing a man basket or a working platform is prohibited!
When crossing underpasses, bridges and tunnels, or when passing under overhead
lines always make sure there is enough clearance!
Always keep at a safe distance from the edges of building pits and slopes!
When working in buildings or in enclosed areas, look out for:
Height of the ceiling/clearances
Width of entrances
Maximum load of ceilings and floors
Sufficient room ventilation danger of poisoning!

BA 25-3503 EN Edition 2.3 *2503_3503b210.fm 2-5


Safety instructions

Avoid any operation that might be a risk to machine stability!


During operation on slopes, drive or work uphill or downhill. If driving across a slope
cannot be avoided, bear in mind the tilting limit of the machine!
Always keep the attachments/work equipment close to the ground. This also applies to
driving downhill! When driving or working across a slope, the load must be on the uphill
side of the machine
Install a Front Guard when working in areas with a risk of objects falling from the front
(e.g. demolition work).
On sloping terrain always adapt your drive speed to the prevailing ground conditions!
Never change to lower gear on a slope but always before reaching it!
Before leaving the seat always secure the machine against unintentional movement
and unauthorised use!
Lower the work equipment/attachments to the ground
Before starting work check whether
all safety devices are properly installed and functional
Before moving the machine or before taking up work:
Make sure visibility is sufficient (do not forget rearview mirrors!)
Adjust your correct seat position, never adjust the seat when driving or working!
Fasten your seat belt
Inspect the immediate area (children!)
In the work area the operator is responsible for third parties!
Caution when handling fuel increased danger of fire!
Make sure fuel does not come into contact with hot parts!
Do not smoke during refuelling, and avoid fire and sparks! Stop the engine during
refuelling and do not smoke!
Never get on or off a moving machine! Never jump off the machine!
Should the lights of the machine not be sufficient for carrying out work safely, provide
additional lighting of the work area.
Installed work lights must not be switched on for travel on public roads. They can be
switched on in work operation if users of public roads are not dazzled.
The drive pedals take time getting used to them. Therefore, adjust the drive speed to
your abilities and the circumstances.
Check the windows for damage and cracks
Make sure the windows are clean and in a good condition

2-6 BA 25-3503 EN Edition 2.3 * *2503_3503b210.fm


Safety instructions

Cab and protective structures


The machine's standard equipment includes a ROPS/FOPS safety cab/canopy.
FOPS The optional protective FOPS structure protects the driver against material falling from
above. The optional protective Front Guard structure protects the driver against material
from the front.

Danger!
Equip the machine with correctly mounted protective structures (FOPS, Front
Guard) during applications involving a risk of falling material!

Front Guard

Fig. 60: Protective FOPS and Front Guard structure Caution!

No drilling, cutting or grinding.


Do not mount any brackets.
No welding, straightening or bending.
Always replace the complete cab/canopy, FOPS or Front Guard if it is
deformed, cracked or otherwise damaged.
If you are not sure, always contact a Wacker Neuson dealer.
Repair work may be carried out by a Wacker Neuson dealer only.

Operation without cab/canopy

Danger!
Operation without cab/canopy is prohibited.
However, operation without cab/canopy is temporarily allowed depending on
the situation (e.g. in case of low clearance heights) but only if the following
conditions are fulfilled:
Danger of severe crushing of body and of death!
Obtain the approval of the competent national authority!
Driving and working with the machine is only allowed on absolutely level
ground.
Avoid tipping movements of the machine under all circumstances.
Working in areas involving a risk of falling objects is prohibited.
Hammer operation is prohibited.
Overhead working is not allowed under any circumstances.
Do not use the seat belt.

Checks when reversing the machine


Careful when reversing the machine danger of accidents!
Persons in the blind spot of the machine cannot seen by the driver.
Make sure nobody is within the danger area of the machine when changing the driving
direction!

BA 25-3503 EN Edition 2.3 *2503_3503b210.fm 2-7


Safety instructions

Applications with lifting gear


Lifting gear applications are procedures involving raising, transporting and lowering loads
with the help of lifting gear and slings.
No applications with lifting gear under any circumstances!
Exception: Machines with a maximum authorised lifting capacity of over 1000 kg (2205
lbs.) or an overturning moment of over 40,000 Nm (29,500 lb/ft) may be used for lifting
gear applications if the following conditions are fulfilled:
Acoustic and optical warning device
Sling
see chapter 3.54 Safe load indicator (option) on page 3-70
Hose burst valve see chapter Safety feature Hose burst valve (option) on
page 3-70
Proper equipment for slinging and securing the load must be available (joint rod
enabling loads to be picked up, Powertilt unit with load hook).
The lift capacity table must be observed
see chapter 6 Specifications on page 6-1.
Lifting gear
Get informed on and follow the legal regulations of your country.
(joint rod)
Fig. 61: Lifting gear joint rod
Instructions on fastening loads
The help of an accompanying person is necessary for securing and detaching the load.
Load hook
The load must be secured so as to prevent it from falling or slipping.
Fasten the lifting gear so that it is not possible to unhook the sling unintentionally.
Position the lifting gear ensuring the sling is not deflected by other parts.
Do not use any lifting gear and slings that are damaged or not sufficiently dimen-
sioned.
The lifting gear must be designed to withstand the loads that can arise in the different
positions of the work equipment or parts of the boom. Lateral loads and diagonal
tensile forces must also be taken into account.
Sling
The sling must be checked regularly by a technician, at least once a year. Replace
damaged slings immediately.
Fig. 62: Load hook
Fasten lifting gear and slings avoiding danger (rotating parts, crushing or shearing)
for the person securing the load. Furthermore, neither must the work equipment be
affected by the lifting gear, nor must the functions of the lifting gear be affected by
external influences (e.g. dirt that cannot be removed by simple means).
Do not place slings over sharp edges.
Always wear protective gloves and a hard hat when working with lifting gear and
slings.
The persons attaching or securing loads may approach the boom from the side only,
and only after the machine operator has given his permission. The machine operator
may give his permission only after the machine is at a standstill and the work
attachment no longer moves!
General instructions
Staying under suspended loads, in the danger area or under the machine's
attachment is forbidden.
The machine operator and the person attaching or securing the load must have visual
contact.
Persons guiding the load or securing it must stay in visual contact with the machine
operator! Should this not be possible, ask another person to guide.
The machine operator must guide the load the nearest possible to the ground and
avoid any oscillating or swinging movements!
The machine may be driven with a raised load only if the path of the machine is level!
The machine operator must not raise loads over persons.
The machine operator may not leave his seat as long as the load is raised.

2-8 BA 25-3503 EN Edition 2.3 * *2503_3503b210.fm


Safety instructions

Working with attachments


Prior to driving on public roads remove all attachments which cannot be secured in
compliance with the legal regulations of your country!
Attachments and counterweights affect handling and the machine's steering capability!
Fit the attachments with the specially required devices only!
Before uncoupling or coupling hydraulic lines (hydraulic quick couplers)
Stop the engine
Release the pressure in the hydraulic system. In order to do so, move the control
levers of the hydraulic control units back and forth a couple of times
Coupling attachments requires special care!
Secure the attachments against unintentional movement!
Operate the machine only if all protective facilities have been installed and are
functional, and if all brake, light and hydraulic connections have been connected!
If optional equipment is installed, all light installations, telltales etc. that are required in
addition must be installed and functional
Mount the attachments only if the engine and the drive have been switched off.
Especially when driving or working with machines equipped with a quickhitch for the
attachments, make sure the attachment is securely locked in the quickhitch. The lock
pin must be visible on either side of the bores on the attachment. Check before starting
work!
Fold the control lever base up before mounting attachments on the stick.
Be careful when coupling attachments to the machine: danger of personal injury due to
crushing and shearing. Make sure nobody is between the machine and the attachment!

Transport
The machine must be towed, loaded and transported only in accordance with the
Operator's Manual!
For towing the machine observe the prescribed transport position, admissible speed
and itinerary
Use only suitable means of transport of adequate capacity/payload!
Safely secure the machine on means of transport! Use suitable mounting points and
load-securing devices.
The recommissioning procedure must be strictly in accordance with the Operator's
Manual!
Check the cab fastening screws with a torque wrench before raising the machine.

Working in the area of underground electric lines


Before starting any work, the machine operator must make sure that there are no lines
in the work area.
If you are not sure, contact the person in charge at the network operator.
If there are lines, take the following safety measures:
Mark the position and path of the lines unambiguously
Fasten, support or secure exposed lines
Safely fasten lines if vibration or shocks to these lines must be avoided

BA 25-3503 EN Edition 2.3 *2503_3503b210.fm 2-9


Safety instructions

Working near overhead electric lines

Danger!
Touching overhead electric lines carries a risk of fatal injuries!
Risk of fatal injuries due to electric shock!
When working with the machine, maintain a safe distance from overhead
electric lines!
If work must be carried out close to overhead lines, the equipment/attach-
ments must be kept well away from them.

Safety distance
Rated voltage (volts)
Metres Feet
Up to 1000 V 1m 3.3 ft.
Over 1 kV to 110 kV 3m 9.8 ft.
Over 110 kV to 220 kV 4m 13.1 ft.
Over 220 kV to 380 kV 5m 16.4 ft.
Unknown rated voltage 5m 16.4 ft.
If no sufficient distance can be kept to overhead electric lines, the machine operator
must take other safety measures, for instance switching off the current, in agreement
with the owner or operator of the lines.
If an energised line is touched nevertheless:
Do not leave the machine
Drive the machine out of the danger area
Warn others against approaching and touching the machine
Have the live wire de-energised
The driver must not touch any metallic parts
Do not leave the machine until the line that has been touched or damaged has been
safely de-energised!

2-10 BA 25-3503 EN Edition 2.3 * *2503_3503b210.fm


Safety instructions

2.7 Safety instructions for maintenance


Avoid any operational mode that might be prejudicial to safety!

Observe the adjustment, maintenance and inspection activities and intervals set forth in
the Operator's Manual, including information on the replacement of parts/partial
equipment!
These activities must be carried out by technical staff only

The machine may not be serviced, repaired or test-driven by unauthorised staff

Brief the staff/the driver before beginning special operations and maintenance work!
Appoint a person to supervise the activities!

In any work concerning the operation, conversion or adjustment of the machine and its
safety-oriented devices, or any work related to maintenance, inspection and repair,
observe the start-up and shut-down procedures set forth in the Operator's Manual, and
the information on maintenance work

If required, secure the maintenance area appropriately!

Prior to carrying out service, maintenance and repair work, attach a warning label, such
as Repair work do not start machine!, to the ignition lock or to the control elements.
Remove the ignition key!

Carry out service, maintenance and repair work only if the

machine is positioned on firm and level ground

all hydraulically movable attachments and working equipment have been lowered to
the ground

control lever base is folded up

engine is at a standstill

ignition key is removed and

machine has been secured against unintentional movement

Should maintenance or repair be inevitable with the engine running:

Only work in groups of two

Both persons must be authorised for the operation of the machine

One person must be seated on the seat and maintain visual contact with the other
person

Observe the specific safety instructions in the work manual

Keep a safe distance from all rotating and moving parts, e.g. fan blades, V-belt
drives, PTO shaft drives, fans etc.

Prior to carrying out assembly work on the machine, make sure no movable parts will
roll away or start moving

To avoid the risk of accidents, parts and large assemblies being moved for replacement
purposes must be carefully attached and secured to lifting gear.
Use only suitable lifting gear and suspension systems in a technically perfect state with
adequate load-bearing capacity!
Stay clear of suspended loads!

BA 25-3503 EN Edition 2.3 *2503_3503b210.fm 2-11


Safety instructions

Have loads fastened and crane operators instructed by experienced persons only!
The person giving the instructions to the operator must be within sight or sound of him
Always use specially designed or otherwise safety-oriented ladders and working
platforms to carry out overhead assembly work.
Never use machine parts or attachments/superstructures as a climbing aid!
Wear a safety harness when carrying out maintenance work at greater heights!
Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow
and ice!
Clean the machine, especially connections and threaded unions, of any traces of oil,
fuel or preservatives before carrying out maintenance/repair work!
Do not use aggressive detergents!
Use lint-free cleaning rags!
Before cleaning the machine with water, steam jet (high-pressure cleaner) or deter-
gents, cover or tape up all openings which for safety and functional reasons must
be protected against water, steam or detergent penetration. Special care must be taken
with the electrical system
After cleaning, remove all covers and tapes applied for that purpose!
After cleaning, examine all fuel, lubricant and hydraulic oil lines for leaks, chafe marks
and damage!
Rectify all defects without delay!
Always tighten any screw connections that have been loosened during maintenance
and repair!
Any safety devices removed for set-up, maintenance or repair purposes must be
refitted and checked immediately upon completion of the maintenance and repair work
Make sure all consumables and replaced parts are disposed of safely and with
minimum environmental impact!
Do not use the work equipment as lifting platforms for persons!
Before taking up work on machine parts dangerous for life and limb (bruising, cutting),
always ensure safe blocking/support of these areas
Carry out maintenance and repair work beneath a raised machine, attachments or
additional equipment only if a safe and secure support has been provided for (the sole
use of hydraulic rams, jacks etc. does not sufficiently secure raised machines or
equipment/attachments)
Avoid contact with hot parts, such as the engine block or the exhaust system during the
operation of the machine and for some time afterwards danger of burns!
Retainer pins can fly out or splinter when struck with force danger of personal injury!
Do not use starting fuel! This especially applies to those cases in which a heater plug
(intake-air preheating) is used at the same time danger of explosions!
Apply special care when working on the fuel system increased danger of fire!

2-12 BA 25-3503 EN Edition 2.3 * *2503_3503b210.fm


Safety instructions

2.8 Warning of special hazards


Electrical energy
Use only original fuses with the specified current rating!
Switch off the machine immediately and rectify the malfunction if trouble occurs in the
electrical system!
When working with the machine, maintain a safe distance from overhead electric lines!
If work must be carried out close to overhead lines, the equipment/attachments must be
kept well away from them. Caution, danger! Get informed on the prescribed safety
distances!
If your machine comes into contact with a live wire
Do not leave the machine
Drive the machine out of the danger area
Warn others against approaching and touching the machine
Have the live wire de-energised
Do not leave the machine until the line that has been touched or damaged has been
safely de-energised!
Work on the electrical system may only be carried out by a technician with appropriate
training, in accordance with the applicable electrical engineering rules
Inspect and check the electric equipment of the machine at regular intervals. Defects
such as loose connections or scorched cables must be rectified immediately
Observe the operating voltage of the machine/attachments!
Always remove the earthing strap from the battery when working on the electrical
system or when carrying out welding work!
Starting with a battery jump cable can be dangerous if carried out improperly. Observe
the safety instructions regarding the battery!
Gas, dust, steam, smoke
Operate the machine only on adequately ventilated premises! Before starting internal
combustion engines or operating fuel-operated heating systems on enclosed premises,
make sure there is sufficient ventilation!
Observe the regulations in force at the respective site!
Carry out welding, flame-cutting and grinding work on the machine only if this has been
expressly authorised. There can be a risk of explosion and fire, for example!
Before carrying out welding, flame-cutting and grinding work, clean the machine and its
surroundings from dust and other inflammable substances, and make sure the
premises are adequately ventilated danger of explosions!
Hydraulics
Work on the hydraulic equipment of the machine must be carried out only by persons
having specific technical knowledge and experience in hydraulic systems!
Check all lines, hoses and screw connections regularly for leaks and obvious damage!
Repair any damage and leaks immediately! Splashed oil can cause injury and fire.
In accordance with the Operator's Manual/instructions for the respective assembly,
release the pressure in all system sections and pressure lines (hydraulic system) to be
opened before carrying out any implementing/repair work!
Hydraulic and compressed-air lines must be laid and fitted properly. Make sure no
connections are interchanged. The fittings, lengths and quality of the hoses must
comply with the technical requirements

BA 25-3503 EN Edition 2.3 *2503_3503b210.fm 2-13


Safety instructions

Noise
During operation all sound baffles must be closed
Wear ear protectors if necessary!

Oil, grease and other chemical substances


When handling oil, grease and other chemical substances (e.g. battery electrolyte
sulphuric acid), observe the product-related safety regulations (safety data sheet)!
Be careful when handling hot consumables risk of burning or scalding!

Battery
When handling the battery observe the specific safety instructions and regulations
relevant to accident prevention. Batteries contain sulphuric acid caustic!
Especially when charging batteries, as well as during normal operation of batteries, an
oxyhydrogen mixture is formed in the battery cells danger of explosion!
In case of a frozen battery or of an insufficient electrolyte level, do not try start-up with a
battery jump cable. The battery can burst or explode
Dispose of the battery immediately

Tracks
Repair work on the tracks must be carried out by technical staff or by an authorised
workshop only!
Defective tracks reduce the machine's operational safety. Therefore carry out regular
checks of the tracks for
Cracks, cuts or other damage
Check track tension at regular intervals

2-14 BA 25-3503 EN Edition 2.3 * *2503_3503b210.fm


Safety instructions

2.9 Protective structures

FOPS
Danger!
When working in areas with a risk of objects falling from above or the front,
install a protective FOPS structure or/and a protective Front Guard structure.
Otherwise machine operation is prohibited!
Observe the following safety instructions see chapter Cab and protective
structures on page 2-7!
Front Guard

Fig. 63: Protective FOPS and Front Guard structure

2.10 Hammer operation


Switch over to hammer operation see chapter Hammer operation on page 3-47.
Contact your Wacker Neuson dealer for information on the correct equipment.

Safety instructions
see chapter 2.5 General conduct and safety instructions on page 2-3
If there is a risk of material coming off in fragments and splinters, e.g. when working
with a hydraulic hammer, a suitable protection, e.g. a safety glass, protective screen or
another suitable protective facility must be installed on the machine.
During operation, all persons must stay clear of the work area of the machine.
Do not place the machine directly underneath the workplace during demolition,
otherwise parts can fall onto the machine or the building can collapse.
Do not carry out demolition work below the machine, otherwise it can lose its balance
and tip over.
The machine can lose its balance and tip over if a hammer or other heavy attachment is
used. Proceed as follows to carry out work both on level ground and on slopes:
Never turn, lower or set down the attachment abruptly.
Do not extend or retract the boom abruptly, otherwise the machine can tip over.
Do not use the impact force of the attachment to carry out demolition work. Demolished
parts can cause personal injury or damage to property or the equipment.
Stop work immediately if a hydraulic hose moves back and forth. This could be a cause
for a pressure accumulator defect. Contact your Wacker Neuson dealer and have the
error repaired immediately.
Close the windows and doors.
Use the canopy version only with appropriate protective strutures.
Carrying out work with a hammer is prohibited if the machine is not equipped with a cab
or canopy.

BA 25-3503 EN Edition 2.3 *2503_3503b210.fm 2-15


Safety instructions

Working with a hammer

2 2
Caution!
Bear in mind the following for hammer operation:
Keep the hammer perpendicular to the surface (max. deviation to all sides
is 2).
After you have driven the hammer into the material, do not try to fragment
the material with movements to the sides.
Never move the hammer as you drive it into the material.
Do not hammer in the same spot uninterruptedly for more than 15 seconds.
Fig. 64: Hammer position
If the applied impact force does not break the material, move the hammer
to the edge or start again in another place in order to break the material.
Do not put the hammer into operation if a ram is fully extended or retracted.
Never use the hammer horizontally or upwards.
Do not use the hammer for catching or collecting material.
Press the hammer firmly against the material to avoid hammer operation
without any resistance.
Do not use the hammer to raise loads.
Do not hit the hammer against rocks, concrete, etc..

Caution!
Bear in mind the following when working with the machine:
Do not raise the machine with the boom.
Do not carry out any movements with the machine during hammer opera-
tion.
Do not work if rams and/or the boom are fully extended.

Fig. 65: Inadmissible machine position

2-16 BA 25-3503 EN Edition 2.3 * *2503_3503b210.fm


Operation

3 Operation
This chapter describes the controls, and contains information on the function and handling
of the telltales and controls in the cab.

The pages stated in the table refer to the description of the controls.
A combination of digits, or a combination of digits and letters (e.g. 40/18 or 40/A) used for
identifying the control elements, means:
fig. no. 40/control element no. 18 or position A in fig. no. 40
Figures carry no numbers if they are placed to the left of the text.

The symbols used in the description have the following meanings:


This symbol stands for a list
Subdivision within lists or an activity. Follow the steps in the recommended sequence
This symbol requires you to carry out the activity described
Description of the effects or results of an activity
n. s. = not shown
Opt = option
Stated whenever controls or other components of the machine are installed as an option.

BA 25-3503 EN Edition 2.3 *2503_3503b320.fm 3-1


Operation

28 13 10 24 22 23 25 31 7 18 17 8

20

32

3 27

26

5 19

14
30

21
16

15

11

29

12 9 12

3-2 BA 25-3503 EN Edition 2.3 * *2503_3503b320.fm


Operation

3.1 Cab overview


Pos. Description For more information see page
1 Control lever (left) ..............................................................................................................................................................3-46
2 Control lever (right) ............................................................................................................................................................3-49
3 Control lever base (left)
4 Control lever base (right)
5 Armrest (left)
6 Armrest on the right (not shown)
7 Lever (horizontal seat adjustment) ......................................................................................................................................3-3
8 Air vents...............................................................................................................................................................................3-3
9 Radio (option)
10 Seat (backrest adjustment)..................................................................................................................................................3-3
11 Seat belt (lock).....................................................................................................................................................................3-3
12 Cup holder
13 Document storage (underneath the seat console)
14 Right-hand side switch panel...............................................................................................................................................3-3
15 Left-hand side switch panel .................................................................................................................................................3-3
16 Throttle.................................................................................................................................................................................3-9
17 Stabiliser blade lever ...........................................................................................................................................................3-3
18 Auxiliary hydraulics pedal ....................................................................................................................................................3-3
19 Preheating start switch ........................................................................................................................................................3-9
20 Cigarette lighter
21 Round display element ........................................................................................................................................................3-5
22 Drive pedal (left) ..................................................................................................................................................................3-3
23 Drive pedal (right) ................................................................................................................................................................3-3
24 Drive lever (left) ...................................................................................................................................................................3-3
25 Drive lever (right) .................................................................................................................................................................3-3
26 Drive interlock status indicator (option)..............................................................................................................................3-13
27 Drive interlock emitter/receiver unit ...................................................................................................................................3-13
28 Changeover valve for SAE/ISO controls (option, underneath the base plate)...................................................................3-49
29 Weight adjustment for seat ................................................................................................................................................3-27
30 Proportional controls indicator (option) ..............................................................................................................................3-54
31 Lever for engine and valve cover.......................................................................................................................................3-34
32 Hydraulic quickhitch pedal (option) ...................................................................................................................................3-62

BA 25-3503 EN Edition 2.3 *2503_3503b320.fm 3-3


Operation

34

35
33

36
37

49 38

39

40

Left-hand side control elements Right-hand side control elements

41

45 42 46 47 43

44

48 50

3-4 BA 25-3503 EN Edition 2.3 * *2503_3503b320.fm


Operation

3.2 Instrument panel overview

Pos. Description For more information see page


33 Hydraulic oil filter telltale (red)............................................................................................................................................3-10
34 Alternator charge function telltale (red) ..............................................................................................................................3-10
35 Engine oil pressure telltale (red) ........................................................................................................................................3-10
36 Coolant temperature telltale (red) ......................................................................................................................................3-11
37 Cold starter telltale (yellow)................................................................................................................................................3-11
38 Safe load indicator telltale (red) (option) ............................................................................................................................3-11
39 Fuel level indicator ............................................................................................................................................................3-11
40 Hour meter .........................................................................................................................................................................3-11
41 High speed .........................................................................................................................................................................3-18
42 Ventilation ..........................................................................................................................................................................3-24
43 Safe load indicator (option) ................................................................................................................................................3-70
44 Proportional controls status indicator (option)....................................................................................................................3-54
45 Washer system ..................................................................................................................................................................3-25
46 Working lights.....................................................................................................................................................................3-23
47 Rotating beacon (option)....................................................................................................................................................3-24
48 Automatic engine speed setting (option)............................................................................................................................3-10
49 Indicator for air filter contamination ....................................................................................................................................5-10
50 Hydraulic quickhitch system (option)..................................................................................................................................3-62

BA 25-3503 EN Edition 2.3 *2503_3503b320.fm 3-5


Operation

3.3 Putting into operation


Safety instructions
Only use the steps and handles provided when entering and leaving the cab
Never use the controls or movable lines and cables as handles
Never get on or off a moving machine! Never jump off the machine
Refer to the corresponding load diagrams for the boom

Putting the machine into operation for the first time


Important information
The machine may be put into operation by authorised staff only see chapter
Selection and qualification of staff, basic responsibilities on page 2-4 and see
chapter 2 Safety instructions on page 2-1 of this Operator's Manual.
The staff must have read and understood this Operator's Manual before putting the
machine into operation
The machine may only be used in technically perfect condition in accordance with its
designated use and the instructions set forth in the Operator's Manual, and only by
safety-conscious persons who are fully aware of the risks involved in operating the
machine.
Go through the Start-up checklist in the following chapter

Running-in period
Handle the machine carefully during its first 50 operating hours.
The future performance and service life of the machine are heavily dependent on the
observance of the following recommendations during the running-in period.
Do not change engine speed abruptly
Avoid using the machine under heavy loads and/or at high speeds.
Avoid abrupt acceleration, braking and changing driving direction.
Do not run the engine at high speed for extended periods
Strictly observe the maintenance schedules in the appendix
see chapter 5.18 Maintenance plan (overview) on page 5-35

3-6 BA 25-3503 EN Edition 2.3 * *2503_3503b320.fm


Operation

Check lists
The checklists below are intended to assist you in checking and monitoring the machine
before, during and after operation.
These checklists cannot claim to be exhaustive; they are merely intended as an aid for you
in fulfilling your duties as a conscientious operator.
The checking and monitoring jobs listed below are described in greater detail in the follow-
ing chapters.
If the answer to one of the following questions is NO, first rectify the cause of the fault
before starting or continuing work.

Start-up checklist
Check the following points before putting the machine into operation or starting the engine:

No. Question
1 Enough fuel in the tank? ( 5-2)
2 Coolant level OK? ( 5-8)
3 Water drained from the water separator? ( 5-4)
4 Engine oil level OK? ( 5-5)
5 Oil level in hydraulic tank OK? ( 5-15)
6 Water level in washer tank OK? ( 3-25)
7 V-belt condition and tension checked? ( 5-12)
8 Lubrication points greased? ( 5-31)
9 Tracks checked for cracks, cuts etc. ? ( 5-19)
Lights, signals, indicators, warning lights and telltales OK?
10
( 3-12)
11 Windows, mirrors, lights and steps clean?
12 Control lever base folded down? ( 3-33)
13 Attachment safely locked? ( 3-75)
14 Engine cover safely locked? ( 3-34)
Especially after cleaning, maintenance or repair work:
15
Rags, tools and other loose objects removed?
16 Correct seat position? ( 3-26)
17 Seat belt fastened? ( 3-28)
18 Cab/canopy installed ( 3-38)

BA 25-3503 EN Edition 2.3 *2503_3503b320.fm 3-7


Operation

Operation checklist
After starting the engine and during operation, check and observe the following points:

No. Question
1 Anyone dangerously close to the machine?
Telltales for engine oil pressure and alternator charge function gone out?
2
( 3-10)
3 Temperature indicator for engine coolant in normal range? ( 3-11)
4 Drive pedals working correctly? ( 3-17)

Parking checklist
Check and observe the following points when parking the machine:

No. Question
1 Attachments lowered to the ground? ( 3-48)
2 Control lever base folded up? ( 3-33)
3 Cab locked, especially if the machine cannot be supervised? ( 3-31)
When parking on public roads:
Machine adequately secured?
4 Machine also secured with chocks under the tracks to prevent it from rolling
away?
When parking on slopes:
Machine also secured with chocks under the tracks to prevent it from rolling
5
away?

3-8 BA 25-3503 EN Edition 2.3 * *2503_3503b320.fm


Operation

3.4 Driving the excavator


Preheating start switch

1
0 2 Notice!
3 The engine can only be started if the left-hand side control lever base is folded
down.

Position Function Power consumer


19 0 Insert or remove the ignition key None
Fig. 66: Preheating start switch All functions are operational
1 ON/drive position Telltales come on
Shrill sound
Preheats the engine (10 15
2
seconds)
Starter is actuated
3 Starts the engine
Telltales must go out

Throttle
Throttle 16 controls the engine speed progressively as follows:
Push throttle 16 upwards.
Engine speed is reduced.
Press throttle 16 downwards.
Engine speed is increased.

16

Fig. 67: Engine speed control

BA 25-3503 EN Edition 2.3 *2503_3503b320.fm 3-9


Operation

3.5 Automatic revs setting


From serial number AG00580
Diesel engine speed is automatically reduced to idling after 5 seconds if no hydraulic func-
tions are carried out and if the automatic revs setting (option) is enabled.
As soon as a hydraulic function is carried out with the control levers, diesel engine speed
is automatically increased again to the engine speed adjusted with the throttle.

Automatic engine speed setting (option)


ON Press switch 48 down Telltale in switch 48 comes on
48 OFF Press switch 48 up Telltale in switch 48 goes out

Fig. 68: Automatic engine speed setting from serial


number AG00580

Telltales and warning lights: overview


33 Hydraulic oil filter telltale (red)
Indicates inadmissibly high pressure in the hydraulic reflux line to the tank. In this case:
Have the hydraulic oil reflux filter checked and, if necessary, replaced by an authorised
workshop
The telltale can come on briefly if the hydraulic oil is cold, but goes out again once oper-
ating temperature is reached

34 Alternator charge function telltale (red)

Caution!
The coolant pump no longer runs if the V-belt is faulty. Danger of engine
overheating or breakdown!
If telltale comes on with the engine running:
Stop the engine immediately and
Have the cause repaired by an authorised workshop

The V-belt or the charging circuit of the alternator is faulty if the telltale comes on with the
engine running. The battery is no longer charged.

35 Engine oil pressure telltale (red)


Comes on if the engine oil pressure is too low. In this case:
Stop the machine
Stop the engine immediately and check the oil level
The telltale comes on when the ignition is turned on and goes out as soon as the engine
runs.

3-10 BA 25-3503 EN Edition 2.3 * *2503_3503b320.fm


Operation

36 Coolant temperature telltale (red)

Danger!
Never open the radiator and never drain coolant if the engine is warm since the
cooling system is under high pressure

Danger of burns!
Wait at least 10 minutes after stopping the engine!
Wear protective gloves and clothing
Open the cap to the first notch and release the pressure

37Cold starter telltale (yellow)


Comes on if the key in the preheating start switch is in position 2.
A glow plug preheats the air in the combustion chamber of the engine when the key is in
this position.

39 Fuel level indicator

40Hour meter
Counts the engine service hours with the engine running.

43Safe load indicator telltale (red) (option)


This optical warning device tells the driver whether he has reached the admissible
(pay)load or load moment according to the (pay)load diagram.
Reduce the load until the telltale goes out

BA 25-3503 EN Edition 2.3 *2503_3503b320.fm 3-11


Operation

Operation

3.6 Before starting the engine


Operate the machine only on adequately ventilated premises! Ensure sufficient ventila-
tion on enclosed premises!
Adjust seat position and rearview mirror
see Seat adjustment on page 3-26

Notice!
All controls must be within easy reach. You must be able to move the drive levers
to their limit positions!

Fasten your seat belt see Seat belt on page 3-28


Fold the left-hand side control lever base down
Check whether all levers and pedals are in neutral position
Move the throttle to the centre position (between minimum and maximum) if the engine
is cold

3.7 Starting the engine (general information)


The starter cannot be actuated if the engine is already running (start repeat interlock)
Do not run the starter for more than 10 seconds
Wait about 1 minute so the battery can recover before trying again.
Procedure

Caution!
Actuating the preheating system too long can damage the preheater.
Never preheat the engine more than 20 seconds

After you have completed the starting preparations:


1 Insert the ignition key in preheating start switch 19
0 2 Turn the ignition key to position 1
3 Check whether all telltales come on:
Replace defective telltales immediately
Turn the ignition key to position 3 and hold it in this position until the engine starts
19
If the engine does not start after 10 seconds
Fig. 69: Preheating start switch Interrupt the start procedure and try again after about 1 minute
If the engine still does not start after the second try
Contact a Wacker Neuson workshop for troubleshooting
As soon as the engine runs:
Release the ignition key

Fig. 70: Telltales

3-12 BA 25-3503 EN Edition 2.3 * *2503_3503b330.fm


Operation

3.8 Starting with the drive interlock (option)


After you have completed the starting preparations:
Approach the transponder key to about 2 cm from the emitter/receiver unit 27
The machine can be started as soon as the red telltale 26 goes out
26
Insert the ignition key in the preheating start switch 19 within 30 seconds and
Turn the ignition key at least to position 1
Check whether all telltales come on:
Replace defective telltales immediately
27 Turn the ignition key to position 2 and hold it in this position for about 5 seconds
Fig. 71: Drive interlock
The intake air is preheated
Turn the ignition key to position 3 and hold it in this position until the engine starts
1
0 2 If the engine does not start after 10 seconds
Interrupt the start procedure and try again after about 1 minute
3
If the engine still does not start after the second try
Contact a Wacker Neuson workshop for troubleshooting
19 As soon as the engine runs:
Fig. 71: Preheating start switch Release the ignition key

Fig. 71: Telltales

BA 25-3503 EN Edition 2.3 *2503_3503b330.fm 3-13


Operation

3.9 Starting with the drive interlock internal transponder (option)


A = operator's key (blue key)
A B For starting the machine. Scope of delivery includes 2 keys.
B = master key (red key)

Notice!
2x 1x Store the master key in a safe place. It is only used for coding new keys.
All keys are deleted if the key remains in position 1 for more than 20 seconds.
Fig. 72: Drive interlock key internal transponder

The flashing LED C indicates the active status of the antitheft protection.
1
0 2 The machine can be started without carrying out any further settings.

C
Fig. 73: Starting with drive interlock internal transponder

Coding a new key


Insert master key B in the ignition lock
Turn the ignition key to position 1 for a maximum 5 seconds
Turn the ignition key to position 0 and remove master key B
Now insert the new key or the key requiring coding in the ignition lock and turn it to
position 1 within 15 seconds
This action registers the key
The procedure is automatically cancelled if no key requiring coding is detected within 15
seconds. Several keys requiring coding can be inserted one after another in the ignition
lock. Each key must then remain at least 1 second in position 1. Coding can be carried out
for a maximum 10 keys.

Deleting coded keys


Deleting coded keys is necessary whenever a coded key is lost.
Insert master key B in the ignition lock
Turn the ignition key to position 1 for a minimum 20 seconds
All coded keys are deleted after 20 seconds, and all existing keys can be re-coded.
The master key code is not deleted during deletion.

3-14 BA 25-3503 EN Edition 2.3 * *2503_3503b330.fm


Operation

3.10 Starting at low temperatures


Turn the ignition key to position 2 and hold it in this position for about 5 seconds
Engine is preheated
Turn the ignition key to position 3 and hold it in this position until the engine starts
If the engine does not start after 10 seconds
Interrupt the start procedure and try again after about 1 minute
If the engine still does not start after the second try
Contact a Wacker Neuson workshop for troubleshooting
Release the ignition key
When the engine runs smoothly (increased engine speed):

Notice!
In general, a battery delivers less energy in cold conditions. Therefore make sure
the battery is always well charged.

3.11 When the engine has started ...


Check whether all telltales have gone out:
Let the engine warm up
At cold temperatures:
Increase the engine speed slowly
Do not run the engine at full load until it has reached its operating temperature

Engine warm-up
After the engine has started, allow it to warm up at slightly increased idling speed until it
reaches its operating temperature of 70 C (coolant). Run the engine with no load during
the warm-up phase (fold left-hand side control lever base up). During the warm-up phase,
check for unusual noise, exhaust colour, leaks, malfunctions or damage. In case of mal-
functions, damage or leaks, park and secure the machine, and find out the cause for the
damage and have it repaired.

3.12 Jump-starting the engine (supply battery)


Safety instructions
Never jump-start the engine if the battery of the machine is frozen danger of
explosion!
Dispose of a frozen battery!
The excavator must not touch the jump-starting vehicle when connected with jump
leads risk of sparking!
The external power source must deliver 12 V; higher supply voltages will damage the
electrical system of the vehicles!
Use only authorised jump leads which conform to the safety requirements and which
are in perfect condition!
The jump lead connected to the positive + terminal of the starting battery must never be
brought into connection with electrically conductive vehicle parts
danger of short circuit!
Route the jump leads so they cannot catch on rotating components in the engine
compartment!

BA 25-3503 EN Edition 2.3 *2503_3503b330.fm 3-15


Operation

Procedure
Drive the jump-starting vehicle close enough to the machine so that the jump leads can
reach to connect the two batteries
Let the engine of the jump-starting vehicle run
Flat battery First connect one end of the red jump lead (+) to the + terminal of the flat battery, then
connect the other end to the + terminal of the starting battery
12 V Connect one end of the black jump lead () to the terminal of the starting battery
Connect the other end of the black jump lead () onto a solid metal component fimly
mounted on the engine block or onto the engine block itself. Do not connect it to the
negative terminal of the flat battery, as otherwise explosive gas emerging from the bat-
tery can ignite if sparks are formed!
Start the engine of the machine with the flat battery
Once the engine has started:
12 V
With the engine running, disconnect both jump leads in exactly the reverse order (first
Starting remove the terminal, then the + terminal) this prevents sparking in the vicinity of
battery the battery!

Fig. 74: Starting aid with jump leads


34001b710_05.eps

3-16 BA 25-3503 EN Edition 2.3 * *2503_3503b330.fm


Operation

3.13 Special instructions for driving on public roads


The machine is subject to the:
Applicable legal regulations of your country
Also observe the applicable regulations for accident prevention of your country.

3.14 Moving off

Notice!
The machine will not move off unless the left-hand side control lever is folded
down.

After starting the engine:


The alternator charge telltale goes out
Press the drive pedal slowly
Machine moves off

3.15 Drive levers

Danger!
Rotating through 180 (stabiliser blade now at the rear ) inverts the drive lever
functions.
Danger of accidents!
Bear in mind the stabiliser blade's position
see chapter 3.20 Stabiliser blade operation on page 3-21

The stabiliser blade side is the front side.


1 2 Raise the bucket and the stabiliser blade.
The machine can be moved either with the drive levers or with the pedals. Lock the upper
carriage when travelling over longer distances.

3 4 Position Function
1 Push forwards
Track excavator moves forwards
2 Push forwards
3 Pull backwards
Track excavator moves backwards
Fig. 75: Drive lever/drive pedal 4 Pull backwards
3 Pull backwards
Track excavator turns to the left
2 Push forwards
1 Push forwards
Track excavator turns to the right
4 Pull backwards
Forwards or reverse drive speed depends on the position of the drive levers or drive ped-
als.

Notice!
Make sure both tracks move as you change direction, otherwise the rubber tracks
are subject to increased abrasion.

BA 25-3503 EN Edition 2.3 *2503_3503b330.fm 3-17


Operation

3.16 High speed


High speed 2503
The machine has two speed ranges which can be selected as follows:
Press switch 41 High speed 3-18,
see Instrument panel overview on page 3-5
The machine now moves at higher speed
or
Press and hold switch A on the left-hand side drive lever
A This briefly changes over to high speed when driving the machine

Notice!
Reduced tractive power in high speed can affect machine handling when corner-
ing.

High speed 3503


The machine has two speed ranges which can be selected as follows:
Fig. 76: Drive lever switch
Press switch 41 High speed 3-18,
see Instrument panel overview on page 3-5
The machine now moves at higher speed

The drive gear shifts to second speed after high speed is selected, the machine moves at
higher speed. In case of increased resistance (grading, changing direction, travelling
uphill), the drive gear shifts to the lower speed. The machine automatically shifts back to
second speed is soon as there is no resistance.

3.17 Hydraulic brake


The pedals automatically return to their initial positions as soon as they are released,
which creates sufficient hydraulic braking effect.

When driving downhill, the automatic hydraulic brake valves prevent the machine from
racing. The machine does not run any faster than the admissible drive speed.

Notice!
Use the drive pedals to reduce the drive speed as required.

3.18 Mechanical brake


The stop brake and parking brake is designed as a spring-loaded and hydraulically actu-
ated multidisc brake. This brake is automatically applied with a certain delay after having
released the drive levers or the drive pedals.

3-18 BA 25-3503 EN Edition 2.3 * *2503_3503b330.fm


Operation

3.19 Driving on slopes


Follow these safety instructions carefully when driving on slopes, in order to avoid acci-
dents.

Specific safety instructions


Raise the bucket about 20 30 cm off the ground as you move the machine. Avoid
reversing downhill.
When driving through hollows or crossing obstacles
Keep the attachment close to the ground and drive slowly.
Do not steer or drive across slopes.
Always change your driving direction on level ground. This may take more time but is
decisively safer.
When driving the machine, make sure you can stop safely any time if the machine
starts to skid or if it becomes unstable.
Swivelling or operating the attachment on slopes can cause the machine to lose its
balance and to tip over.
Avoid this under all circumstances.
Rotating the upper carriage when driving downhill with a full bucket is especially
dangerous.
Should this be nevertheless necessary, create a platform of level ground so that the
machine can work in horizontal position.
Do not drive on slopes steeper than 15, otherwise the machine can tip over.
If the sliding blocks slip as you drive uphill and if it is no longer possible to move on with
the force of the tracks alone
Do not apply pressure with the boom to move the machine danger of tipping over!

BA 25-3503 EN Edition 2.3 *2503_3503b330.fm 3-19


Operation

Driving on slopes
Proceed as follows to prevent the machine from tipping over or slipping sideways.

Keep the attachment about 20 30 cm above the ground. In an emergency, lower the
attachment immediately to the ground so you can stop the machine more easily.

20 30
cm

c m
20 30

Fig. 77: Uphill/downhill

Place the cab with the front side upwards as you drive uphill, and downwards as you
drive downhill. Always check the ground's firmness underneath the front part of the
machine as you drive.
When driving downhill, extend the attachment to improve stability, and keep it about 20
20 30 30 cm above the ground. Drive slowly.
c m
Reduce engine speed when driving downhill, keep the drive lever next to neutral posi-
Fig. 78: Uphill, attachment above the ground
tion and drive slowly.
Always drive straight ahead when driving uphill or downhill. Driving diagonally or at an
angle to the slope is very dangerous.
Never change direction on slopes or drive across slopes. Always change position on
level ground before continuing to drive on a slope.
Drive slowly in meadows, on leaves or wet steel plates. The machine can slip even if
the ground is level. If the engine stops as you drive across a slope, immediately put the
control levers to neutral position and start the engine again.

Fig. 79: Driving diagonally or at an angle

3-20 BA 25-3503 EN Edition 2.3 * *2503_3503b330.fm


Operation

3.20 Stabiliser blade operation

Danger!
The stabiliser blade lever is not blocked: in case of unintentional operation
Danger of accidents!
Do not touch the control lever for the stabiliser blade if you do not need to
carry out any work with it.

Caution!
Lowering the stabiliser blade too deeply into the ground can create a
resistance see Grading on page 3-77.
Slightly raise the stabiliser blade

1
Position Function
1 Push forwards Stabiliser blade is lowered
2
2 Pull backwards Stabiliser blade is raised

Notice!
Check the position of the stabiliser blade before driving the machine.

Fig. 80: Stabiliser blade operation

BA 25-3503 EN Edition 2.3 *2503_3503b330.fm 3-21


Operation

3.21 Parking the machine

Danger!
Always park the machine on firm ground
Danger of accidents
Lower the boom and the stabiliser blade to the ground
Park the machine on level ground
Secure the tracks accordingly (e.g. chocks)

Stop the machine


Lower the bucket and the stabiliser blade to the ground
Reduce engine speed completely
Switch off ignition
Fold up the control lever base

Caution!
Never stop the engine under full load, otherwise it can be damaged due to
overheating. Except in case of an emergency, always make sure the engine
can cool down before it is stopped.
Let the engine run at idling speed with no load for at least 5 minutes before
you switch it off.

Notice!
Secure the machine against unauthorised operation.
Remove the ignition key.
Lock the cab

Parking the machine on slopes


Avoid stopping the machine abruptly. Always make sure there is enough space for
stopping the machine.
Park the machine on level ground with sufficient bearing capacity. Never park on
slopes. If you cannot avoid parking the machine on a slope:
Place chocks under the tracks and lower the attachment into the ground to prevent
the machine from moving.
Severe accidents may be caused by unintentionally actuating the control levers, and
hence moving the attachment or the entire machine.
Always fold the control lever base up before leaving the seat.
Place the stabiliser blade downhill and lower it to the ground.

Danger!
Severe accidents can be caused by unintentionally actuating the control
levers, and hence moving the attachment or the entire excavator.
Danger of accidents
Always fold the control lever base up before leaving the seat.
Fig. 81: Parking the machine on slopes

3-22 BA 25-3503 EN Edition 2.3 * *2503_3503b330.fm


Operation

3.22 Light system


Working lights
The switch panel for the light system is located on the instrument panel.

Boom light
ON Press switch 46 down Telltale in switch 46 comes on
Press switch 46 Telltale in switch 46 goes out
OFF
up

46

Fig. 82: Light system switches

Roof lights (option)

Danger!
The working lights can dazzle motorists on public roads
Do not switch on the working lights when driving on public roads. When
operating the machine, only switch the working lights on when no-one can
be dazzled by it!

Roof lights
ON Press switch 46 to the 1st position Telltale in switch comes on
Press switch 46 to the 2nd posi-
tion
OFF Press switch 46 up Telltale in switch goes out

46
1
2

Fig. 83: Roof lights switch

BA 25-3503 EN Edition 2.3 *2503_3503b330.fm 3-23


Operation

Interior light

Interior light
ON Press switch to the left or right
OFF Move switch to centre position

Fig. 84: Switch for interior light

Rotating beacon (option)

Rotating beacon (option)


ON Press switch 47 down Telltale in switch 47 comes on
OFF Press switch 47 up Telltale in switch 47 goes out

Notice!
47
Observe the legal regulations of your country for operating the
rotating beacon.

Fig. 85: Switch for rotating beacon

3.23 Cab heating and ventilation

Notice!
The cab is fitted with three air nozzles. Each nozzle can be closed and directed
separately. In order to achieve best results for defrosting the front window, open
both front right nozzles and the leg room nozzle.
Direct the nozzles to the front window
Open or close the nozzles as required to vent or heat the cab.
Do not place flammable or explosive material or objects near the nozzles.
Air the cab from time to time

Ventilation (fresh air)


1st speed Press switch 42 down one step Low fan speed
42 2nd speed Press switch 42 down two steps High fan speed
OFF Press switch 42 all the way down Fan OFF
1
2

Fig. 86: Air circulation in cab

3-24 BA 25-3503 EN Edition 2.3 * *2503_3503b330.fm


Operation

3.24 Summer/winter operation

Danger!
Always stop the engine for switching over from summer to winter operation
and vice versa
Danger of personal injury!
Stop the engine
Open the engine cover only if the engine is at a standstill

Adjust cab temperature as follows:


H
Position Function
A Summer operation Cools
A
B Winter operation Heating water circuit open
B
Open the engine compartment
Turn ball-type cock H as described, to summer or winter operation
Close the engine compartment see chapter 3.32 Engine cover on page 3-34
Fig. 87: Heating adjustment
Notice!
Summer and winter operation does not depend on the season, adjust according to
your personal requirements.

3.25 Washer system

Front window wiper


Press switch 45 down Front wiper is on
1

ON
Press switch 45 up Front wiper returns to base position
2

OFF

Fig. 88: Front wiper switch 1st Press switch 45 down to the 1st Front wiper is on
speed position
2nd Press switch 45 down to the 2nd Pump sprays washer water on the
speed position window

Notice!
Do not actuate the washer system with the front window folded up. Do not actuate
the washer system if the tank is empty, otherwise this can damage the electric
pump.

BA 25-3503 EN Edition 2.3 *2503_3503b330.fm 3-25


Operation

Tank for washer system


The tank's filler inlet is located in the engine compartment.

Notice!
Fill with clean tap water only!
Add a suitable cleaning agent if required.
In winter: add antifreeze for washer systems to the water.
Refer to the antifreeze instructions for further information on concentrations.
The rubber diaphragm in the non-return valve in the housing conglutinates if
stored in a dry condition over a longer period of time. In order to restore this
Fig. 89: Tank for washer system valve's function, moisten this non-return valve, dip it briefly in water and then blow
air through it.

3.26 Seat adjustment

Danger!
Never change the seat position when driving or working!
see chapter 3.6 Before starting the engine on page 3-12
Danger of accidents!
Adjust the seat before moving the machine

Caution!
Adjusting the backrest can damage the rear window and the removable part of
the front window.
Make sure the backrest does not touch the rear window or the removable
part of the front window as you adjust backrest inclination
Select a seat position which will not damage the window panels when work-
ing with the machine

Fig. 90: Seat adjustment

3-26 BA 25-3503 EN Edition 2.3 * *2503_3503b330.fm


Operation

Weight adjustment

Notice!
Adjust the seat suspension correctly to ensure a high level of ride comfort. Use the
lever to adjust the seat suspension.
Adjust the seat only without load!

Adjust the seat to the driver's weight as follows:


Less spring action:
Press the lever down
More spring action:
29 Press the lever up.

Fig. 91: Weight adjustment

Horizontal adjustment
Sit down on the seat
Pull lever 7 upwards and at the same time
Move the seat forwards or backwards

7
Fig. 92: Horizontal seat adjustment

Backrest adjustment
Sit down on the seat
Pull handle 10 forwards and at the same time
Lean back to push the backrest into the required position
Release handle 10 and allow it to lock into place

10
Fig. 93: Backrest adjustment

BA 25-3503 EN Edition 2.3 *2503_3503b330.fm 3-27


Operation

3.27 Seat belt

Danger!
Do not drive or work with the seat belt unbuckled
Danger of personal injury!
Buckle up before moving or working with the machine!
Seat belt must not be twisted!
Seat belt must run over the hips not over the stomach and must
always be applied tightly!
Do not place the seat belt over hard, edged or fragile items (tools, meter
rule, glasses, pen) carried inside your clothes!
Never buckle up 2 persons (children!) with one seat belt!
Check seat belts regularly. Have damaged parts immediately replaced
by an authorised workshop!
Always keep the seat belt clean, as coarse dirt can impair proper func-
tioning!
Seat belt buckle must not be obstructed by foreign bodies (paper or sim-
ilar); otherwise the buckle latch cannot lock into place!
After an accident the belt strap is stretched and no longer serviceable.
In an accident, the seat belt
Will not provide adequate protection!
Replace the seat belt after an accident
Have fastening points and seat fixture checked for bearing capacity!

Seat belt 11 is for the driver's safety during work on construction sites and during road
travel.
Fastening the seat belt:
Fasten seat belt 11 as follows before moving the machine:
A
Hold belt on buckle latch A and run it slowly and steadily over the hips to buckle B
11 Insert buckle latch A into buckle B with an audible click (pull test)
Tighten the seat belt by pulling at its end
B
The seat belt must always be tightly in place over the hips!

Fig. 94: Fastening the seat belt

3-28 BA 25-3503 EN Edition 2.3 * *2503_3503b330.fm


Operation

Unfastening the seat belt:


Unfasten seat belt 11 as follows:
Hold the seat belt
11 Press red switch C on buckle B
A Latch A is released from buckle B by spring pressure
Slowly return the seat belt to the retractor
C

B
Fig. 95: Unfastening the seat belt

A Longer/shorter lap belt adjustment:


Lengthen the lap belt as follows:
Hold buckle latch A at a right angle to the seat belt and pull the seat belt to the
required length
To shorten the lap belt, just pull the free end D of the belt

D
Fig. 96: Longer/shorter seat belt adjustment

3.28 Emergency exit


You can enter and exit the cab through the front window in an emergency.

Danger!
The machine has neither footholds nor handles at the front for a safe access or
exit
Danger of personal injury!
Enter and exit the cab through the front window in an emergency only!

Opening the front window completely:


see Front window on page 3-30

Emergency exit on machines equipped with protective Front Guard structures (option)
The rear window can be used as an emergency exit if the door is blocked. The rear win-
A dow is broken with emergency hammer A fastened over the rear window.

Danger!
Danger of personal injuries when breaking the rear window!
Danger of personal injury!
Use the rear window as an exit only in an emergency!
Remove all glass splinters before leaving the cab.
Make a sufficiently big opening for the exit.
Fig. 97: Emergency exit if equipped with Front Guard
Remove all glass splinters inside and outside the cab!

BA 25-3503 EN Edition 2.3 *2503_3503b330.fm 3-29


Operation

3.29 Front window

Danger!
F
Careful when opening the front window
Danger of crushing!
Stay clear (extremities, clothing) of the window run.
Take care not to hit the front window with your head as you open it!
A
Always pull the front window upwards with both handles B!
Always let levers A lock into place on either side in locks F or C!
C

Notice!
Fold up the control lever base before opening or closing the front window, in order
B to avoid any unintentional operation or movement of the machine!

Open the front window as follows:


The front window is fitted with handles and small levers on either side
Push levers A upwards on either side
Pull the front window upwards with handles B
The front window must lock into rails C on either side
Lock levers A on either side in C
B
Pull levers A to the rear to do this
Check whether both levers A are actually locked in rails C

Fold down the front window as follows:


Push levers A forwards on either side
Pull the front window downwards with handles B
B Lock the front window again by means of levers A in lock F
Pull levers A upwards to do this
Check whether both levers A are actually locked in rails F

Fig. 98: Front window

3-30 BA 25-3503 EN Edition 2.3 * *2503_3503b330.fm


Operation

3.30 Door

Danger!
Close/secure the door and the side window when driving and working with the
machine

Danger of accidents!
Close the door before moving the machine

Opening the door from the outside:


A Press door lock A
Locking the door:
L Turn the key in door lock A to the left (L)
The door is locked
R Unlocking the door:
Turn the key in door lock A to the right (R)
The door is unlocked

Fig. 99: Outside door opener and lock

Opening the door from the inside:


B
Press the lever on the inside left on door lock B down

Fig. 100: Inside door opener (left/right)

Securing an open door:


C D Press the door against bracket C of arrester D with an audible click

Fig. 101: Door arrester

BA 25-3503 EN Edition 2.3 *2503_3503b330.fm 3-31


Operation

Releasing the door opener:


Turn button E to release the door from the arrester.
E

Fig. 102: Releasing the door arrester

Opening the side window:


F Press button F up
At the same time, move the window to one of the positions marked with seven arrows

Fig. 103: Side window

3-32 BA 25-3503 EN Edition 2.3 * *2503_3503b330.fm


Operation

3.31 Exit through the door

Danger!
When entering or exiting the cab
Danger of accidents!
Bear in mind the following before entering or leaving the cab:
2 1
Stop and secure the machine
see chapter 3.21 Parking the machine on page 3-22
Lower the boom
Stop the engine
Remove the ignition key
Move control levers 2 and 3 repeatedly in all directions
A 4
Raise control lever base 4 with handle A to position B
The gas strut keeps the control lever base in the top position
A
B Caution!
Do not use handle A on the control lever base as a support to ease your
entrance to the cab:
4
Use the entrance handles in the cab!
C
Fold control lever base 4 down to position C once you are in the cab
The gas strut keeps the control lever base in the lower position

D Notice!
The height of the control lever base can be set with stop bolt D!

Notice!
Fig. 104: Control lever base
Enter and leave the cab only through the door as a rule. You can enter and exit the
cab through the front and the right-hand side window in an emergency.

BA 25-3503 EN Edition 2.3 *2503_3503b330.fm 3-33


Operation

3.32 Engine cover


Opening:
Pull out the lower handle A
A Open the engine cover upwards
Closing:
Firmly press down the engine cover until the lock engages with an audible click

Fig. 105: Engine cover lock

Canopy version (option)


Opening:
B
Unlock the lock with ignition key B
Pull out the lower handle A
A Open the engine cover upwards
Closing:
Firmly press down the engine cover until the lock engages with an audible click

Fig. 106: Engine cover lock (on machine equipped with can-
opy)

3.33 Valve compartment cover


Opening:
Pull out handle C
C Open the valve compartment cover upwards
L Closing:
Firmly press down the valve compartment cover until the lock the engages with an
audible click

Fig. 107: Valve compartment cover lock

Canopy version (option)


Opening:
C
Unlock the lock with ignition key B
B Pull out handle C
Open the valve compartment cover upwards
Closing:
Firmly press down the valve compartment cover until the lock the engages with an
audible click
Fig. 108: Valve compartment cover lock (on machine
equipped with canopy)

3-34 BA 25-3503 EN Edition 2.3 * *2503_3503b330.fm


Operation

3.34 Towing the track excavator


Safety instructions:
Make sure the excavator can be towed safely
Use towing bracket A for towing the machine
Use the towing bracket only for towing the machine
Use a shackle pin with a lock pin
Move off slowly!
Make sure no-one is close to the towing equipment (towing bar, cable).

Towing

Danger!
Keep out of the danger area of the machine
Danger of accidents!
Make sure no-one is dangerously close to the excavator.

Caution!
Maximum admissible load on towing bracket:
1.5 x excavator dead weight.

Use towing bracket A


B Secure shackle B with the shackle pin and a lock pin
Mount a towing bar or cable of adequate size to the towing bore
Pull the machine slowly
A
Notice!
Fig. 109: Towing bore Follow the following instructions under all circumstances:
Do not tow away the machine if it is at a standstill or broken down, otherwise the
machine's travelling drive can be damaged
The manufacturer's warranty shall not apply to accidents or damage caused by
towing the excavator.
No towing away other machines with towing bracket A.

BA 25-3503 EN Edition 2.3 *2503_3503b330.fm 3-35


Operation

3.35 Crane handling the machine


Safety instructions
The crane and the lifting gear must have suitable dimensions
Crane handling the machine requires suitable lifting gear
Secure the machine against unintentional movement!
Check the cab for damage.

Danger!
Incorrect crane handling of the machine
Danger of accidents!
Make sure no-one is in the danger area!
Make sure no-one is in the machine!
Have loads fastened and crane operators instructed by experienced per-
sons only! The person giving the instructions to the crane operator must be
within sight or sound of him
Make sure the crane and the lifting gear (cables, chains) have sufficient lift-
ing capacity!
Raise the machine only if the standard bucket is empty
Stay clear of suspended loads!
It is essential that you read the safety instructions at the beginning of this
chapter and follow any other safety instructions relevant in your country!
Make sure the lifting gear has the required lengths L1 and L2

Load the machine as follows:


Fit the standard bucket and lock it safely
Empty the standard bucket
Tilt in the standard bucket and lower it to transport position
L1 Stop the engine
Fold the control lever base up
L2
Remove the ignition key
Do not allow anyone to stay in the cab, and close the doors and the engine cover
Use suitable lifting gear, chains etc.
Mount the lifting gear at the point on the boom provided for lifting the machine
Mount the lifting gear at the points on the stabiliser blade provided for lifting the
machine
Make sure the lifting gear has the required lengths L1 and L2
Fig. 110: Craning operation
Slowly raise the machine
Required lengths L1 and L2 of the lifting gear:
Excavator Length Dimension
2503 L1 2240 mm
2503 L2 3670 mm
3503 L1 2270 mm
3503 L2 4000 mm

Authorised loads Force


Boom lift eye 40 kN
Stabiliser blade lift eye 40 kN

3-36 BA 25-3503 EN Edition 2.3 * *2503_3503b330.fm


Operation

3.36 Loading and transporting the machine


Safety instructions
The transport vehicle must be of adequate size refer to Chapter 6 Specifications for
the machine's dimensions and weights!
Remove any mud, snow or ice from the tracks so that the machine can be safely driven
onto the ramps
Secure the machine against unintentional movement see chapter 3.21 Parking the
machine on page 3-22!

Danger!
The machine must be loaded and transported properly
Danger of accidents!
It is essential that you read the safety instructions at the beginning of this
chapter and follow any other safety instructions relevant in your country!

Load as follows:
Secure the transport vehicle with chocks to prevent it from rolling
Place the access ramps at the smallest possible angle. Make sure the grade does not
exceed 17 (30 %). Use access ramps with an antiskid surface only.
Make sure the loading area is clear and access to it is not obstructed e.g. by super-
structures
Fig. 111: Access ramps Make sure the ramps and the tracks of the excavator are free of oil, grease and ice
Start the engine of the excavator
Raise the bucket sufficiently so that it will not touch the ramps
Carefully drive the excavator onto the middle of the transport vehicle
Lower the bucket to the loading area
Stop the engine
Fold the control lever base up
Remove the ignition key
Do not allow anyone to stay in the cab, and close the doors and the engine cover

Notice!
The manufacturer's warranty shall not apply to accidents or damage caused by
loading or transporting the excavator.

BA 25-3503 EN Edition 2.3 *2503_3503b330.fm 3-37


Operation

3.37 Tying down the machine

Danger!
The machine must be loaded and transported properly
Danger of accidents!
It is essential that you read the safety instructions at the beginning of this
chapter and follow any other safety instructions relevant in your country!

Make sure the authorised maximum height is not exceeded


A Secure the tracks of the excavator at the front, rear and at the sides
Lower the stabiliser blade and the boom
Fig. 112: Tying down the excavator
Firmly tie down the excavator at the eye hooks A onto the platform, with belts or
chains of adequate size
Before transporting the machine through heavy rain:
close the outlet of the exhaust silencer with a simple cap or suitable adhesive tape
Make sure the driver of the transport vehicle knows the overall height, width and
weight of his vehicle (incl. excavator) before departure, as well as the legal transport
regulations of the country or countries where transport is to take place!

3.38 Removing the cab/canopy


Follow the safety instructions for assembly see chapter 3.36 Loading and transport-
ing the machine on page 3-37.
Lower the boom slightly.
Stop the engine.
Remove the ignition key.
Fold up the control levers.
Mount the lifting gear at the points on the cab provided for lifting the machine.
Required lengths L1 of the lifting gear:
Length Dimension

L1 L1 1000 mm (39.4)

L1 Raise the cab until the lifting gear is taut.

Fig. 113: Mounting lifting gear

3-38 BA 25-3503 EN Edition 2.3 * *2503_3503b330.fm


Operation

Remove central plug B (X28) from the cab wiring.


Central plug B is located at the rear right next to the seat in the cab.

Fig. 114: Central plug

Remove the hose of the washer fluid tank from non-return valve C.
C C Non-return valve C is located at the front right under the engine cover.

B
Notice!
Removing non-return valve C is not required if the machine is equipped with a can-
opy. Depending on options, central plug B must also be removed.

Fig. 115: Washer fluid tank hose

Remove both screws E.


E E

Fig. 116: Cab attachment

Raise the floor mat on either side.


F
Remove screws F on either side.

Fig. 117: Left-hand side cab attachment

Fig. 118: Right-hand side cab attachment

BA 25-3503 EN Edition 2.3 *2503_3503b330.fm 3-39


Operation

Raise the machine as follows:


Do not allow anyone to stay in the cab, and close the doors and the engine cover.
Slowly raise the cab.

Caution!
Inspect the cab for damage as you raise it.

Set down the cab safely and make sure it cannot tip over.

Fig. 119: Craning operation

3.39 Installing the cab/canopy


Install the cab carefully

Caution!
Inspect the cab for damage as you install it.

Fig. 120: Craning operation

Connect central plug B (X28) with the cab wiring.

Fig. 121: Central plug

3-40 BA 25-3503 EN Edition 2.3 * *2503_3503b330.fm


Operation

Connect the hose of the washer fluid tank with non-return valve C.
C C
Notice!
B
Installing non-return valve C is not necessary if the machine is equipped with a
canopy.

Fig. 122: Washer fluid tank hose

Tighten both screws E to 87 Nm.


E E

Fig. 123: Cab attachment

Raise the floor mat on either side.


F
Tighten screws F to 87 Nm.
Put the floor mat back in place on either side.

Fig. 124: Left-hand side cab attachment

Fig. 125: Right-hand side cab attachment

BA 25-3503 EN Edition 2.3 *2503_3503b330.fm 3-41


Operation

Operation

3.40 Working with the machine


General safety instructions
Never drive up to the edge of a pit from outside danger of cave-in!
Never undermine the foundations of walls danger of collapse!
Do not dig under projecting ground. Stones or the projecting earth can fall onto the
machine.
Do not excavate deeply under the front side of the machine. The ground under the
machine could collapse and cause it to tip over.
In order to leave the cab more easily under especially difficult circumstances, position
the tracks perpendicularly to the roadside or to the uphill slope with the drive pinion
behind the driver.
When working on roofs or similar structures, check the resistance and the structure
itself before starting work. The building can collapse, causing severe injury and
damage.
In general the machine is more liable to tilt if the attachment is positioned laterally than
if it is positioned at the front or rear of the machine.
Do not raise the bucket over the heads of other workers or over the driver seats of
trucks or of other means of transport. The material can tip over, or the bucket can knock
against the truck and cause severe injury or damage.
Operation of the machine by unauthorised staff is prohibited!
Look out for high-voltage cables, underground cables, gas and water pipes during
excavation work!
The hydraulic system of the machine is still pressurised even when the engine is not
running! Release the pressure in the sections of the system and hydraulic lines which
are to be opened before starting setup or repair work, e.g. fitting/removing an
attachment with hydraulic functions
see Lowering the boom with the engine stopped on page 3-48

3-42 BA 25-3503 EN Edition 2.3 * *2503_3503b340.fm


Operation

3.41 Wacker Neuson Vario (option)

Danger!
Lower the excavator arm to the ground when using the Wacker Neuson Vario
feature, otherwise
Danger of accidents
Support the machine with the excavator arm when using the Vario feature

Using the Wacker Neuson Vario feature


The following steps must be followed under all circumstances when changing the eccentric
position
Excavator arm A must be lowered to the ground.
To unlock the Wacker Neuson Vario feature, press and hold both front switches on the
left-hand side B and right-hand side C joystick.
A Press and hold both buttons B and C about 5 seconds without moving the joysticks to
unlock.
The Wacker Neuson Vario feature has four lock positions at offset positions of 90 each
(0/360, 90, 180, 270).
D Press the left-hand side joystick D to the left or right for a 90 rotation, press and hold
buttons B and C as you do so.
Both buttons B and C can be released once the excavator moves.
B C The Wacker Neuson Vario feature automatically engages after a 90 rotation.
Fig. 126: Using the Neuson Vario feature If repositioning beyond 90 is required with the Wacker Neuson Vario feature, press
buttons B and C beyond the 90 lock position.
As soon as buttons B and C are released, the Wacker Neuson Vario feature
engages in the next possible lock position.

Notice!
Always check whether the lock position is engaged!

Driving across slopes with the Wacker Neuson Vario feature

Danger!
For reasons of safety, only the eccentric position shown in Fig. 127 may be
selected for driving across slopes.

BA 25-3503 EN Edition 2.3 *2503_3503b340.fm 3-43


Operation

For increased stability for driving across slopes, position the excavator with respect to the
slope as shown in Fig. 127.

Fig. 127: Driving across slopes

For improved driving features on slopes, reposition the centre of gravity towards the slope
with the Wacker Neuson Vario feature.

Danger area of the Wacker Neuson Vario feature


Fig. 128: Driving on slopes
Danger!
Bear in the mind the danger area when driving and working with the excavator

Caution, danger!
See Fig. 129

Depending on the position of the Vario feature, stability is higher or lower with respect to a
standard excavator. Observe the lift capacity table and the danger areas shown in Fig.
129.
Danger areas:

A B
Crosswise excavation Lengthwise excavation
Upper carriage not in proper range with respect to Vario
Reduced stability
feature, no modification of stability (hydraulically limited)

Danger area A Danger area B Danger area A


Fig. 129: Danger areas danger of tilting! danger of tilting!

3-44 BA 25-3503 EN Edition 2.3 * *2503_3503b340.fm


Operation

Working with the Wacker Neuson Vario feature


The upper carriage can be rotated to the side with the stabiliser blade for excavating pits.
This ensures increased stability when excavating on the side opposite the stabiliser blade,
with perfect visibility of the pit.

Fig. 130: Work position

Improved reach with the Wacker Neuson Vario feature


Reach can be improved with the Wacker Neuson Vario feature.

Fig. 131: Vario reach

The bucket can be moved up to the stabiliser blade by repositioning the upper carriage to
the side opposite the blade.

Fig. 132: Repositioning with the Vario feature

3.42 Control levers/ISO controls: overview

Notice!
Fast actuation of the control lever for the attachment moves the attachment fast.
Slow actuation of the control lever moves the attachment slowly.

Danger!
Unintentional operation of the control levers when driving on public roads
Danger of accidents!

BA 25-3503 EN Edition 2.3 *2503_3503b340.fm 3-45


Operation

Left-hand side control lever

A 1
Position Lever Function
D B A Forwards Stick is extended
B To the right Upper carriage rotates to the right
C C Backwards Stick is retracted
D To the left Upper carriage rotates to the left

Notice!
Always carry out smooth control movements.
Fig. 133: Left-hand side control lever

Auxiliary hydraulics

Caution!
G Ball-type cock E must be in the correct position to ensure optimal functionality.
Turn the handle of ball-type cock towards F when using the auxiliary
E hydraulics.
F

Fig. 134: Ball-type cock

Actuating the auxiliary hydraulics:


Oil flow in 1st direction:
Press hammer pedal 18 forwards.
18
Oil flow in 2nd direction:
Press hammer pedal 18 backwards.

Fig. 135: Auxiliary hydraulics

3-46 BA 25-3503 EN Edition 2.3 * *2503_3503b340.fm


Operation

Boom swivel controls


Swivel boom to the left:
Press and hold button E on the control lever
Move hammer pedal 18 forwards at the same time
Swivel boom to the right:
E Press and hold button E on the control lever
Move hammer pedal 18 backwards at the same time

18

Fig. 136: Swivelling the boom

Hammer operation

Caution!
In order to ensure optimal functionality and to prevent hte excavator from
G
overheating, take the following measure:
E Turn the handle of ball-type cock E towards G.
F

Fig. 137: Ball-type cock

Switching on hammer operation:


Press hammer pedal 18 forwards.

18

Fig. 138: Hammer operation

BA 25-3503 EN Edition 2.3 *2503_3503b340.fm 3-47


Operation

Right-hand side control lever

E Position Lever Function


H E Forwards Boom is lowered
F
F To the right Dumps out the bucket
G
G Backwards Boom is raised
H To the left Dumps in the bucket

Fig. 139: Right-hand side control lever

Button Function
J
J Horn

Fig. 140: Functions of right-hand side control lever

Lowering the boom with the engine stopped


Lower the boom as follows:
1 2
A E Make sure no-one is dangerously close to the machine
Turn the ignition key to position 1
Press forwards and hold the control lever (A and E)
Until the boom is completely lowered
Return the control lever to neutral

Fig. 141: Lowering the boom with the engine stopped

3-48 BA 25-3503 EN Edition 2.3 * *2503_3503b340.fm


Operation

3.43 Changeover valve for SAE/ISO controls (option)

Danger!
Changing the directional valve over modifies the controls (control levers)
Danger of accidents!
Make sure you know which control mode has been selected before starting
work
Always secure wing nut J on the changeover lever of the directional valve

Left-hand side control lever

A 1 Position Lever Function


D B A Forwards Boom is lowered
C
B To the right Upper carriage rotates to the right
C Backwards Boom is raised
D To the left Upper carriage rotates to the left

Fig. 142: Left-hand side control lever (SAE controls)

Right-hand side control lever

2 Position Lever Function


E
E Forwards Stick is extended
H F
F To the right Dumps out the bucket
G G Backwards Stick is retracted
H To the left Dumps in the bucket

Fig. 143: Right-hand side control lever (SAE controls)

BA 25-3503 EN Edition 2.3 *2503_3503b340.fm 3-49


Operation

Directional valve position


Directional valve 28 is located at the left behind the seat.

28

Fig. 144: Directional valve position

Directional valve
The changeover valve switches from ISO to SAE controls and vice versa.

Position Function
A ISO controls
B SAE controls
Tighten wing nut J after changing control mode.

Caution!
No driving or working with the machine if wing nut J is defective!
Immediately contact a Wacker Neuson workshop to replace a defective
wing nut.

A J B

Fig. 145: Directional valve

3-50 BA 25-3503 EN Edition 2.3 * *2503_3503b340.fm


Operation

3.44 Control lever with proportional controls (option): overview

Notice!
Fast actuation of the control lever for the attachment moves the attachment fast.
Slow actuation of the control lever moves the attachment slowly.

Function
This control mode offers proportional operation of the auxiliary hydraulics circuit depending
on the position of slide switch B on the joystick.
You can also modify the properties of the characterisitic curve. Precision work, for instance
with the offset bucket, does not require the full throughput of the auxiliary hydraulics.
Therefore we recommend setting the controls to the low characteristic curve 1 (slow move-
ments).
The slide switch is not pressed fully in this position and you can move the machine more
smoothly (flat characteristic curve).

Characteristic
Valve current [A]

Joystick voltage [V]

If you require the full throughput then characteristic curve 2 will be the choice to make
(slide switch pressed as far as it will go).

Caution!
Always use button C on the joystick for hammer operation.
Do not use characteristic curve 1 for hammer operation since as described
above, oil throughput is not set to maximum in this case and therefore the
hydraulic output is not fully available for hammer operation.
Pressing button C ensures full throughput irrespective of the characteristic
curve that has been selected!

BA 25-3503 EN Edition 2.3 *2503_3503b340.fm 3-51


Operation

Measures to be taken in case of malfunctions

Caution!
The system still works correctly if only one component breaks down. However,
if more than one component breaks down, the pressure regulating valves
possibly run uncontrollably!

Caution!
System breakdowns can never be excluded, therefore:
Disconnect the electric controls from the power supply before carrying out
repair work or maintenance on the hydraulic system!
Stay clear of areas with danger of crushing!
Stay clear of areas between moving hydraulic components and fixed obsta-
cles! Danger of crushing!
The operator of the machine or hydraulic system must be aware of possible
machine or system errors.

Danger!
Unintentional operation of the control levers when driving on public roads
Danger of accidents!

Left-hand side control lever

A
1 Position Lever Function
D A Forwards Stick is extended
B
B To the right Upper carriage rotates to the right
C C Backwards Stick is retracted
D To the left Upper carriage rotates to the left

Notice!
Always carry out smooth control movements.
Fig. 146: Left-hand side control lever

3-52 BA 25-3503 EN Edition 2.3 * *2503_3503b340.fm


Operation

Auxiliary hydraulics

G Caution!
Ball-type cock E must be in the correct position to ensure optimal functionality.
E
Turn the handle of ball-type cock towards F when using the auxiliary
F
hydraulics.
Fig. 147: Ball-type cock

Actuating the auxiliary hydraulics:


Oil flow in 1st direction:
Move hammer pedal 18 to the left
18
Oil flow in 2nd direction:
Move hammer pedal 18 to the right

Fig. 148: Auxiliary hydraulics

Boom swivel controls


Swivel boom to the left:
Press and hold button E on the control lever
Move hammer pedal 18 forwards at the same time
Swivel boom to the right:
E Press and hold button E on the control lever
Move hammer pedal 18 backwards at the same time

18

Fig. 149: Swivelling the boom

BA 25-3503 EN Edition 2.3 *2503_3503b340.fm 3-53


Operation

Hammer operation

Caution!
G
In order to ensure optimal functionality and to prevent hte excavator from
E overheating, take the following measure:
F Turn the handle of ball-type cock E towards G.

Fig. 150: Ball-type cock

Switching on hammer operation:


Press and hold button C on the control lever
Switching off hammer operation:
Release button C on the control lever
C

Fig. 151: Hammer operation


Notice!
Proportional controls and Powertilt with proportional controls: the auxiliary hydrau-
lics pedal is locked.

Adjusting control response


Characteristic curve 1 (slow movements):
D C Switch off ignition
Then move slide switch B to the left D
Hold slide switch B to the left D and switch on ignition at the same time
B Then release slide switch B
Status indicator 44 acknowledges by flashing once
Characteristic curve 2 (fast movements maximum throughput):
Switch off ignition
Then move slide switch B to the right C
Fig. 152: Adjusting control response Hold slide switch B to the right C and switch on ignition at the same time
Then release slide switch B
Status indicator 44 acknowledges by flashing twice
Characteristic curves status indicator
Displays the characteristic curve that has been selected for the control valve.
Characteristic curve 1 (slow movements):
Telltale 1 in status indicator 44 flashes once after switching on ignition
44 Characteristic curve 2 (fast movements maximum throughput):
Telltale 1 in status indicator 44 flashes twice after switching on ignition

Notice!
1
The characteristic curve that has been set last is active after the machine is started
Fig. 153: Characteristic curves status indicator
again.

3-54 BA 25-3503 EN Edition 2.3 * *2503_3503b340.fm


Operation

Right-hand side control lever

E Position Lever Function


H E Forwards Boom is lowered
F
F To the right Dumps out the bucket
G
G Backwards Boom is raised
H To the left Dumps in the bucket

Fig. 154: Right-hand side control lever

Button Function
H H Horn

Fig. 155: Functions of right-hand side control lever

Lowering the boom with the engine stopped


Lower the boom as follows:
1 2 Make sure no-one is dangerously close to the machine
A E
Turn the ignition key to position 1
Press forwards and hold the control lever (A and E)
Until the boom is completely lowered
Return the control lever to neutral

Fig. 156: Lowering the boom with the engine stopped

BA 25-3503 EN Edition 2.3 *2503_3503b340.fm 3-55


Operation

3.45 Rotating the upper carriage


Rotating the upper carriage is described with standard ISO controls.
Specific safety instructions
The upper carriage can rotate a little bit further if the machine has not yet reached its
operating temperature.
Fast actuation of the control lever rotates the upper carriage fast, slow actuation of the
control lever rotates the upper carriage slowly.
If the upper carriage needs to be rotated on a slope, let the engine run at idling speed
and actuate the control lever very slowly. Proceed with extreme care and avoid abrupt
movements if the bucket is full.

Rotate the upper carriage to the left as follows:


A Push the left-hand side control lever 1 to the left A
The upper carriage rotates to the left

Fig. 157: Rotating the upper carriage to the left

Rotate the upper carriage to the right as follows:


B
Push the left-hand side control lever 1 to the right B
The upper carriage rotates to the right

Fig. 158: Rotating the upper carriage to the


right

Swivel unit brake


Hydraulic swivel unit brake:
The upper carriage's rotation is sufficiently braked by moving control lever 1 back to initial
position. Moving the control lever in the opposite direction (counteraction) brakes the
upper carriage with maximum hydraulic output.

Mechanical stop brake:


A multidisc brake integrated in the rotation drive has an additional mechanical brake effect
with time delay. This negative-effect brake is used as a stop brake and parking brake for
the swivel unit. The upper carriage can be stopped in any position.

Notice!
Do not use the brake as a service brake but only as a stop brake and parking
brake for the swivel unit.

3-56 BA 25-3503 EN Edition 2.3 * *2503_3503b340.fm


Operation

3.46 Tilting the upper carriage (option)


Vertical digging on slopes is possible by tilting the upper carriage hydraulically by 15 with
A the VDS.

Tilting the upper carriage:


Press and hold button A on control lever 2
Press control lever 2 to the right
2
The upper carriage is tilted
If the required tilt angle is reached, return control lever 2 to the neutral position and
release button A.

Lowering the upper carriage:


Fig. 159: Tilting the upper carriage
Press and hold button A on control lever 2
Push control lever 2 to the left
The upper carriage is lowered
If the required tilt angle is reached, return control lever 2 to the neutral position and
release button A.
Bear in mind the following when working with the machine:

Danger!
Tilting the machine in the immediate vicinity of walls or parts of buildings
carries a danger of crushing.
Danger of severe crushing of body!
All persons must stay clear of the hazard zone when tilting the machine.

Caution!

Tilt the machine only on firm ground.


Tilt the machine only if it is at a standstill and if the attachment is empty.
All doors and covers must be closed when tilting the machine.
Never turn, lower or set down the attachment abruptly.
Do not extend or retract the boom abruptly. Otherwise there is danger of
tipping over!
When working in the immediate vicinity of a wall or parts of a building, make
sure the upper carriage does not touch anything when it is tilted.
On a slope, position the machine so that the upper carriage is tilted towards
the slope. Otherwise there is danger of tipping over!

see chapter General safety instructions on page 3-42


see chapter 2.8 Warning of special hazards on page 2-13
see chapter 3.55 Working with the excavator on page 3-71

BA 25-3503 EN Edition 2.3 *2503_3503b340.fm 3-57


Operation

3.47 Releasing the pressure on the work hydraulics

Caution!
Before connecting or removing hydraulic lines from the attachment, make sure
the work hydraulics is not under pressure!

Notice!
The hydraulic system of the machine is still pressurised even when the engine is
not running! The hydraulic quick couplers can be released, however they cannot
be re-attached due to the residual pressure in the lines.
Release the pressure in the sections of the system and hydraulic lines which are
to be opened before starting setup or repair work, e.g. fitting/removing an
attachment!

Releasing pressure
Release the pressure as follows:
Park the machine on firm and level ground.
Lower the attachment completely to the ground.
Stop the engine.
Turn the ignition key to position 1.
Move the control lever or the pedal of the hydraulic circuit in all directions repeatedly.
The pressure in the system sections that have been actuated is released. This can
be seen by the brief movement the hoses make as the pressure is actually released.
Uncouple the attachment immediately after the pressure has been released,
otherwise pressure can be created again!

Pressure release with proportional controls (option)


Release the pressure as follows:
Park the machine on level and horizontal ground
Lower the attachment completely to the ground!
Stop the engine
Turn the ignition key to position 1
Release the load only after you have switched on ignition and waited 2 seconds
(otherwise if actuated too early, the characteristic curve is shifted and the load is not
released)!
Release the pressure on the auxiliary hydraulics by pressing the pedal connected with
the left or right-hand side proportional joystick to the left and right
The pressure in the system sections that have been actuated is released. This can
be seen by the brief movement the hoses make as the pressure is actually released.
Uncouple the attachment immediately after the pressure has been released, otherwise
pressure can be created again!

3-58 BA 25-3503 EN Edition 2.3 * *2503_3503b340.fm


Operation

3.48 Re-equipping attachments


Re-equipping the attachments is described below for a bucket. If you are fitting or remov-
ing attachments with their own hydraulic functions e.g. grab or offset bucket you must
follow the special information given in the Operator's Manual of the attachment.
Also refer to the Operator's Manual of the attachment for the procedure to follow for fitting
an attachment onto a quickhitch.
Specific safety instructions
Driving in pins with a hammer can cause them to splinter, which can cause severe
personal injury.
Always carry protective goggles, helmets, gloves and other protective equipment.
Do not stand behind the bucket when removing pins.
Do not place your foot underneath the bucket.
Pay special attention to your fingers when removing and reinserting pins.
Never insert fingers in the bores of the pins as you align them.

Danger!
Re-equipping attachments
Danger of personal injury!
Avoid accidents and injuries by following the information below:
Stop the engine
Fold the control lever base up
Re-equip attachments only with suitable tools
Do not align components with your fingers or your hands but use suita-
ble tools danger of crushing!
Once you have re-equipped the attachments, or before starting work, make
sure the attachment is safely locked with the stick and the tilt rod, or with
the quickhitch (option).

BA 25-3503 EN Edition 2.3 *2503_3503b340.fm 3-59


Operation

Removing a bucket
Re-equip as follows:
Lower the bucket to the ground with its flat side facing down
C Stop the engine
B Remove linch pin A
First remove pin B, and then pin C. Carefully expel pins that are stuck with a hammer
A
and a brass punch
Fig. 160: Removing a bucket
If pin C is stuck:
Start the engine
Slighty raise and lower the boom to take the load off the pin
Stop the engine

Notice!
Place the bucket only with minimum pressure on the ground as you remove the
pins. The higher the pressure on the ground, the higher the resistance and the
more difficult it is to remove the pins.

Mounting a bucket
H D Proceed as follows:
E Lower the bucket to the ground with its flat side facing down
I
Grease the joints and the pins before inserting them
F
Start the engine
K G
J Straighten the stick so that bores D and E are flush
Fig. 161: Mounting a bucket Insert greased pin F
Tighten lock screw G
Actuate the stick ram until bores H and I are flush
Insert the greased pin J
Lock linch pin K

3-60 BA 25-3503 EN Edition 2.3 * *2503_3503b340.fm


Operation

3.49 Mechanical quickhitch system (option)


M
Danger!
The attachment must always be safely locked onto the quickhitch
Danger of accidents!
Before starting work, make sure the attachment is securely locked onto the
L quickhitch by means of the lock mechanism. You must be able to see the
lock on either side of the mounting bore of the attachment.

Re-equip as follows:
Approach the machine to the attachment
Hitch coupling bar M onto coupling claws L of the quickhitch to pick up the bucket
Engage lock mechanism N in mounting bores O
N Place the bucket on level ground

O
Fig. 162: Bucket with quickhitch

Lock as follows:
Stop the engine
S Insert tube P (included in scope of delivery) in clamping sleeve Q
Press the tube downwards
The lock pins must be in position R

Unlock as follows:
Q Stop the engine
R Insert tube P (included in scope of delivery) in clamping sleeve Q
Press the tube upwards
The lock pins must be in position S

Fig. 163: Bucket with quickhitch

BA 25-3503 EN Edition 2.3 *2503_3503b340.fm 3-61


Operation

3.50 Hydraulic quickhitch system (option)

Caution!
Before putting this feature into operation, specific training must be carried out
by authorised technical staff and must be understood by the operator. For
reasons of safety, the quickhitch must be operated with two control elements!
This avoids opening the quickhitch unintentionally during work operation.

Danger!
Before starting work, make sure the attachment is mounted correctly and that it
is fully functional.
Do not allow anyone to stay in the danger area!
For instance, with a short and rapid succession of stick and bucket
movements as close as possible to the ground.
Do not operate an attachment with a defective lock under no
circumstances!

Danger!
For system-specific reasons, the hydraulic quickhitch opens and closes with
the functions Stabiliser blade, Auxiliary hydraulics, Boom swivel and
Rotate upper carriage.
For reasons of safety, only use the function Raise stabiliser blade
to open or close!

3-62 BA 25-3503 EN Edition 2.3 * *2503_3503b340.fm


Operation

Operation
Picking up an attachment

Danger!
Before working, make sure the attachment is mounted correctly and that it is
fully functional.
A
Do not allow anyone to stay in the danger area!
For instance, with a short and rapid succession of stick and bucket
K movements as close as possible to the ground.
Do not operate an attachment with a defective lock under no circum-
stances!
For system-specific reasons, the hydraulic quickhitch opens and closes with
Z
the functions Stabiliser blade, Auxiliary hydraulics, Boom swivel and
Rotate upper carriage.
D For reasons of safety, only use the function Raise stabiliser blade
to open or close!

K
Caution!
The optical check pin K must be fully retracted.
If it can still be seen, or if you are unsure whether the bucket is mounted on the
machine without any play:
Troubleshoot and rectify immediately!
Proceed as follows:
Actuate switch 50.
50
The buzzer sounds.
The hydraulic quickhitch is enabled and can be operated.
Press and hold the foot-operated tip switch 32.
Operate the stabiliser blade (raise as far as it will go).
The quickhitch opens.
Check pin K (red) indicates that the quickhitch is fully open.
Hitch claws A (on the side of the excavator) into pins Z of the bucket mount.
32 Move the attachment inwards with a turning movement by actuating the bucket ram, so
that the second pin D of the attachment also makes contact with quickhitch.
Check whether the bucket touches the quickhitch with the second pin D.
Release the foot-operated tip switch 32.
Operate the stabiliser blade (raise as far as it will go).
The quickhitch closes.
Switch off switch 50.
The buzzer is mute.
The hydraulic quickhitch is disabled.
Check the bucket and make sure it is firmly installed!

Fig. 164: Quickhitch system

BA 25-3503 EN Edition 2.3 *2503_3503b340.fm 3-63


Operation

Setting down an attachment


Proceed as follows:
Lower the attachment to about 5 10 cm above the ground
Press switch 50
The buzzer sounds
Press and hold the foot-operated tip switch 32.
Operate the stabiliser blade (raise as far as it will go).
The quickhitch opens and unhitches the attachment.
Check pin K (red) indicates that the quickhitch is fully open.
Retract the bucket ram
Set down the bucket
Raise the boom
Release the foot-operated tip switch 32.
Operate the stabiliser blade (raise as far as it will go).
The quickhitch closes.
Switch off switch 50.
The buzzer is mute

Shovel bucket operation


With some restrictions, Wacker Neuson backhoe buckets can also be used for shovel
bucket operation.

Danger!
Do not tilt the bucket fully back in shovel bucket operation (see Fig. 165),
otherwise the bucket base can touch and damage the stick.

Fig. 165: Possible damage

3-64 BA 25-3503 EN Edition 2.3 * *2503_3503b340.fm


Operation

3.51 Powertilt 3505 (option)


Two versions are available (Powertilt is not available for model 2503):
Powertilt with hydraulic quickhitch (option) see chapter 3.50 Hydraulic quickhitch
system (option) on page 3-62
Powertilt welded onto an attachment.

Danger!
Danger of crushing due to the rotating movements of the Powertilt unit.
Danger of severe crushing of body and of death!
Do not allow anyone to stay in the danger area!

Do not put the Powertilt unit into operation unless:


The machine is equipped with an acoustic or optical warning device see
chapter 3.54 Safe load indicator (option) on page 3-70
The machine is equipped with a hose burst valve see chapter Safety fea-
ture Hose burst valve (option) on page 3-70
You read, understand and follow the instructions in the following chapter
see chapter Applications with lifting gear on page 2-8
Fig. 166: Powertilt versions 3505

Notice!
When using the Powertilt unit, the maximum bucket width is limited to 1000 mm.

1 Slewing range 180


2 Load hook (option)
3 Hydraulic connection 1/4
4 Hydraulic connection 1/4
5 Type label

Caution!
1 Welding work may be carried out only by an authorised workshop or customer
service!

3 2

5 4
Fig. 167: Powertilt overview

BA 25-3503 EN Edition 2.3 *2503_3503b340.fm 3-65


Operation

Re-equipping

Danger!
Re-equipping attachments
Danger of personal injury!
Observe the following instructions:
Stop the engine
Fold the control lever base up
Re-equip attachments only with suitable tools
Do not align components with your fingers or your hands but use suita-
ble tools danger of crushing!
Once you have re-equipped the attachments, or before starting work, make
sure the attachment is safely locked with the stick and the tilt rod, or with
the Powertilt unit (option).
Release the pressure see chapter 3.47 Releasing the pressure on the
work hydraulics on page 3-58
Follow the safety instructions see chapter 3.48 Re-equipping attachments
on page 3-59

Mounting the Powertilt unit


Proceed as follows:
I H
Lower the Powertilt unit to the ground with its flat side facing down
Grease the joints and the pins before inserting them
Start the engine
Straighten the stick so that bores D and E are flush
Insert greased pin F
J Mount ring J and tighten the securing elements G
D
E Actuate the stick ram until bores H and I are flush
F Insert greased pin F
Mount ring J and tighten the securing elements G
G

Fig. 168: Fitting the wheels

Removing the Powertilt unit


Re-equip as follows:
A Lower the Powertilt unit to the ground with its flat side facing down
Stop the engine
Fold the control lever base up
Remove the ring and the securing elements
First remove pin A, and then pin B. Carefully expel pins that are stuck with a hammer
and a brass punch
If pin A is stuck:
B
Start the engine
Slighty raise and lower the boom to take the load off the pin
Fig. 169: Removing
Stop the engine
Fold the control lever base up

3-66 BA 25-3503 EN Edition 2.3 * *2503_3503b340.fm


Operation

Notice!
Place the bucket only with minimum pressure on the ground as you remove the
pins. The higher the pressure on the ground, the higher the resistance and the
more difficult it is to remove the pins.

Connection
Remove the covers on ports 1 and 2 on the boom and the Powertilt unit
1
The following connections are possible:
1 3rd control circuit with quick-connect coupling
Two different port sizes each
Connection of line between boom 1 and port 1 on the Powertilt unit

Fig. 170: Left-hand side port

Connection of line between boom 2 and port 2 on the Powertilt unit


2
Route the hydraulic line through the duct and fasten it with a clamp.
2
Notice!
In order to avoid possible damage to the lines, check the Powertilt unit in all posi-
tions before putting it into operation.

Fig. 171: Right-hand side port

BA 25-3503 EN Edition 2.3 *2503_3503b340.fm 3-67


Operation

Operation

Notice!
The Powertilt function is enabled once the machine is started. The auxiliary
hydraulics and boom swivel are disabled.

Danger!
Before any work, make sure the attachment is mounted correctly and that it is
fully functional.
Do not allow anyone to stay in the danger area!
Do not operate an attachment with a defective lock under no circum-
stances!

Left-hand side control lever (Powertilt)


The Powertilt functions are operated with the left-hand side control lever.
A B
Position Lever Function
A To the left Powertilt turns to the left
B To the right Powertilt turns to the right

Fig. 173: Left-hand side control lever

Right-hand side control lever (if equipped with auxiliary hydraulics and proportional controls)
The Powertilt functions are operated with the right-hand side control lever.
A B
Position Lever Function
A To the left Powertilt turns to the left
B To the right Powertilt turns to the right

Notice!
The auxiliary hydraulics pedal is locked. The auxiliary hydraulics is operated via
the left-hand side control lever see chapter Left-hand side control lever on
Fig. 174: Right-hand side control lever page 3-52

3-68 BA 25-3503 EN Edition 2.3 * *2503_3503b340.fm


Operation

3.52 Connections for auxiliary hydraulics

Port Stick (left) Stick (right)


T Pressure line
U Pressure line

Notice!
Follow the instructions in the Operator's Manual of the attachment manufacturer
U
for connecting the auxiliary hydraulics to attachments.
T

Fig. 175: Connections for auxiliary hydraulics

3.53 Grab operation


Bucket operation:
A Set the ball-type cocks to position A
Grab operation:
Set the ball-type cocks to position B
B

Coupling:
Park the machine on level and horizontal ground.
Extend stick ram A halfway through.
Stop the engine.
Set the ball-type cocks to position B
Release the pressure in the hydraulic system see chapter 3.47 Releasing the pres-
A sure on the work hydraulics on page 3-58.
The grab can now be coupled onto couplings C and D.

Uncoupling:
B Park the machine on level and horizontal ground.
Extend stick ram A halfway through.
Stop the engine.
Release the pressure in the hydraulic system see chapter 3.47 Releasing the pres-
sure on the work hydraulics on page 3-58.
The grab can now be uncoupled from couplings C and D.
Fig. 176: Grab ball-type cock
Set the ball-type cocks to position A

C
D

Fig. 177: Grab couplings

BA 25-3503 EN Edition 2.3 *2503_3503b340.fm 3-69


Operation

3.54 Safe load indicator (option)

Danger!
Safe load indicator not switched on or adjusted incorrectly
Danger of accidents!
Always switch on the safe load indicator!
Contact a Wacker Neuson dealer should the safe load indicator not be
adjusted correctly

38 Switch on the safe load indicator as follows:


Press switch 43 on the instrument panel
43 Telltale 38 on the round indicating instrument comes on in case of overload

The safe load indicator's telltale comes on, and an acoustic warning is given, to warn the
driver he has reached the maximum admissible load. Any further increase of the load
moment can cause the machine to overturn in this situation. Therefore the driver must
immediately reduce the load moment as follows:
Fig. 178: Safe load indicator telltale Reduce reach until both the acoustic signal and the telltale in the round display element
go out
Safety feature Hose burst valve (option)

Danger!
The Hose burst valve safety feature is activated as soon as a hose or a pipe
bursts
Danger of accidents!
Have damage to the hydraulic system and to the hose burst valve itself
immediately repaired and checked by technical staff with suitable training!

Notice!
The Hose burst valve safety feature avoids the boom from being lowered or dumped
out without being braked, in the event of a bursting hose or pipe.

In the event of damage, proceed as follows:


Immediately stop the machine
Move the boom to transport position
Fold up the left-hand side control lever base
Stop the engine
Remove the ignition key and lock the cab
Fig. 179: Transport position Lock the machine and the attachment

Environment!
Collect the drained hydraulic oil in a suitable container.
Dispose of drained hydraulic oil by an ecologically safe method
Always contact the relevant authorities or commercial establishments in charge of oil
disposal before disposing of biodegradable oil.

3-70 BA 25-3503 EN Edition 2.3 * *2503_3503b340.fm


Operation

3.55 Working with the excavator


Working with the standard bucket
The following section describes work operations with the machine equipped with the
standard bucket.
The standard bucket is mainly used for digging earth, and for loosening, picking up, dig-
ging and loading loose or solid material.

Inadmissible work procedures


Working with the swivel force
Do not use the swivel force of the upper carriage to compact the ground or tear down
piles or walls.
Do not allow the bucket teeth to penetrate into the ground as you rotate the upper car-
riage.
Working this way damages the attachments.

Fig. 180: Working with the swivel force

Working with the drive force


Do not allow the bucket to penetrate into the ground and do not excavate by using the
drive force of the machine.
Working this way can damage the machine or the attachments.

Fig. 181: Working with the drive force

Working with the falling force by lowering the bucket


Do not use the machine's falling force for excavating, and do not use the bucket's falling
force as a hoe, hammer or pile-driver.
Working this way can greatly reduce the machine's service life.

Fig. 182: Working with the falling force by lowering the


bucket

BA 25-3503 EN Edition 2.3 *2503_3503b340.fm 3-71


Operation

Working with the falling force by lowering the machine


Do not use the machine's falling force for excavating.

Fig. 183: Working with the machine's falling force


Retracting attachments
Make sure the bucket does not hit the stabiliser blade as you retract attachments for
driving or transport.

Fig. 184: Retracting attachments

Fully lowering the stabiliser blade


Fully lower the stabiliser blade when using it on the side opposite the excavation side.
No thrusting the stabiliser blade
Do not thrust the stabiliser blade against rocks or blocks to avoid damage to the rams
and the blade itself.

Fig. 185: Fully lowering the stabiliser blade

3-72 BA 25-3503 EN Edition 2.3 * *2503_3503b340.fm


Operation

Excavator work position


Proceed as follows:
Place stabiliser blade A on the side you want to dig

A
Fig. 186: Excavator work position

Bucket position when digging


Move the bucket as shown in A
Move the flat side of the bucket parallel to the ground
B
A C
Notice!
Position B causes the bucket to penetrate into the ground. Work slows down, and
the engine and the hydraulic pump are subject to overload if this position is used
over a longer period of time!
Fig. 187: Bucket position
Position C causes the bucket to be forced upwards and not to be filled completely.
This slows down work, too.

Dig as follows:
Penetrate into the ground with the bucket E
Lower the stick and at the same time align bucket E until
E
Reaching the required digging depth and
The flat side of the bucket is parallel to the ground (see bucket position)

Fig. 188: Penetrating into the ground with the bucket and
aligning it

Pull bucket E parallel to the ground towards the excavator. At the same time, if possi-
ble:
F Move stick F towards the excavator
Lower the boom

E With a sufficiently full bucket E:


Keep on moving the stick towards the excavator and at the same time
Tilt in stick F

Fig. 189: Filling the bucket

BA 25-3503 EN Edition 2.3 *2503_3503b340.fm 3-73


Operation

Excavating trenches
Excavating trenches is more efficient
by using a suitable bucket for this work and positioning the tracks parallel to the limit
line of the trench.
In case of large trenches, first excavate the side sections and then the centre section.

Fig. 190: Excavating trenches

Loading
Loading in confined areas with a limited angle of rotation is more efficient
by positioning the truck so as to ensure maximum visibility for the driver of the exca-
vator.
Loading material on trucks is easier and faster
if the hydraulic excavator is placed at the rear end of the truck and not at the sides.

Fig. 191: Loading

Grading
Use the stabiliser blade to fill in trenches and to grade surfaces.

Notice!
Work on level ground. Grade with the stabiliser blade first in case of sloping
ground

Fig. 192: Grading

Excavating trenches sideways


The machine can be used for excavating trenches sideways in confined areas
by rotating the upper carriage and swivelling the main boom (combined position and
movement of both).

Fig. 193: Excavating trenches sideways

3-74 BA 25-3503 EN Edition 2.3 * *2503_3503b340.fm


Operation

Working alongside trenches

Caution!
Danger of damaging piston rod A of the boom ram when working alongside
trenches, slopes etc. and operating the stabiliser blade and the boom incor-
B rectly.
Always use stabiliser blade B for stabilisation during excavation work
Make sure stabiliser blade B never touches piston rod A
(Fig. 194).
If you carry out deep excavations with stabiliser blade B at the front, make
A sure piston rod A does not touch or rest on stabiliser blade B (Fig. 194).

Fig. 194: Working alongside trenches

Stabiliser blade at rear

Danger!
Improper or careless operation of machine when working alongside trenches,
slopes, etc., with the stabiliser blade B at the rear
Danger of falling!
Use this work position only in an extreme emergency since the machine
can tilt forwards into the trench.
We recommend using the first work position (Fig. 194) described above
and to make sure piston rod A does not touch stabiliser blade B under any
circumstances.

Fig. 195: Deep excavation

BA 25-3503 EN Edition 2.3 *2503_3503b340.fm 3-75


Operation

Further practical hints for digging


When planning and carrying out digging work, we recommend that you observe the follow-
ing points:
Exits from pits must be outside the digging line and as level as possible
Dig by removing adjacent strips if possible
Make sure you can drive forwards when driving out of the digging area with a fully
loaded bucket
Whenever possible, drive in reverse when transporting a full bucket down a steep slope

Loading vehicles
When loading vehicles, we recommend taking the following into account:
If possible, the vehicle and the working direction of the bucket should form an angle of
45
Raise the full bucket to dump height only as you rotate towards the vehicle
If possible dump with the wind behind you to keep the dust away from your eyes, air
filters and fans!

Loading vehicles

Freeing the machine


If your machine gets stuck in the ground:
Dump out the bucket until the blade is vertical above the ground
Lower the boom all the way
Slowly dump out the bucket
The machine is pushed backwards
Reverse slowly
Repeat this procedure until the tracks reach firm ground
Reverse the machine away

3-76 BA 25-3503 EN Edition 2.3 * *2503_3503b340.fm


Operation

3.56 Grading

Danger!
Careful when grading
Danger of accidents!
Make sure no-one is in the danger area when working with the stabiliser
blade

Grading
Lower the stabiliser blade to the ground
see chapter 3.20 Stabiliser blade operation on page 3-21
Set the depth of the layer you want to remove with the stabiliser blade lever
No raising the machine by lowering the stabiliser blade
The clearance between the stabiliser blade and the ground should be about 1 cm

BA 25-3503 EN Edition 2.3 *2503_3503b340.fm 3-77


Operation

3-78 BA 25-3503 EN Edition 2.3 * *2503_3503b340.fm


Troubleshooting

4 Troubleshooting
The information given in this chapter is provided for maintenance staff, for fast and reliable
detection of malfunctions and their appropriate repair.
Repairs must be carried out by authorised staff.

BA 25-3503 EN Edition 2.3 *2503_3503b410.fm 4-1


Troubleshooting

4.1 Engine trouble


Problem Possible causes See
Wrong SAE grade of engine lubrication oil 5-31
Fuel grade does not comply with specifications 5-31
Defective or flat battery 5-24
Loose or oxidised cable connections in starter circuit
Engine does not start or is not easy to start Defective starter, or pinion does not engage
Wrong valve lash
Defective fuel injector
Defective cutoff solenoid
Defective fuse
Fuel grade does not comply with specifications 5-31
Dirty fuel filter
Engine starts, but does not run smoothly or faultless Wrong valve lash
Injection line leaks
Defective fuel injector
Oil level too low 5-5
Oil level too high 5-5
Dirty air filter 5-10
Dirty cooler fins
Engine overheats. Temperature warning system
Coolant level too low
responds
Cooling system leaks
Defective fan, torn or loose V-belt 5-12
Resistance in cooling system too high, flow capacity too low
Defective fuel injector
Oil level too high 5-5
Fuel grade does not comply with specifications 5-31
Dirty fuel filter
Insufficient engine output Dirty air filter 5-10
Wrong valve lash
Injection line leaks
Defective fuel injector
Defective fuel injection pump
Engine does not run on all cylinders Injection line leaks
Defective fuel injector
Oil level too low 5-5
Insufficient or no engine oil pressure Machine inclination too high
Wrong SAE grade of engine lubrication oil 5-31
Oil level too high/wrong oil 5-5
Engine oil consumption too high Worn oil scraper ring
Machine inclination too high

4-2 BA 25-3503 EN Edition 2.3 * *2503_3503b410.fm


Troubleshooting

Problem Possible causes See


Oil level too high/wrong oil 5-5
Blue
Machine inclination too high
Engine starting temperature too low
Fuel grade does not comply with specifications 5-31
White Wrong valve lash
Engine smoke
Defective fuel injector
Defective cylinder-head gasket
Dirty air filter 5-10
Black Wrong valve lash
Defective fuel injector

4.2 Hydraulics
Problem Possible causes See

Jerky movements of work hydraulics. Check pilot control filter for dirt 5-35

4.3 Malfunctions of the Powertilt unit


Problem Possible causes See

If the excavator applies too much pressure against an obstacle, this


can build up pressure in the Powertilt swivel device that activates
the internal decompression valve.
Powertilt does not maintain its position. Oil escapes from the control valve.

Defective decompression valve.

Oil escapes from the seals.

Defective internal decompression valve.


Powertilt turns only in one direction. Both lines are connected to either the P1 or P2 ports of the Powertilt
swivel device.

Air in Powertilt swivel device or hydraulic system.


Inexact lateral Powertilt movements.
Hose/pipe diameter/length is larger/longer than recommended.

Reverse and forwards movement of shaft in housing


Worn or missing pressure discs.
(axial play of shaft).

Lateral bucket movement. A little play due to necessary spacing between teeth is normal.

Defective grease decompression valve of lubrication system, or


Grease cannot be applied to Powertilt grease nipples. grease decompression valve has been replaced by a grease nipple
or plug.

BA 25-3503 EN Edition 2.3 *2503_3503b410.fm 4-3


Troubleshooting

4-4 BA 25-3503 EN Edition 2.3 * *2503_3503b410.fm


Maintenance

5 Maintenance
5.1 Introduction
Operational readiness and the service life of machines are heavily dependent on mainte-
nance.
It is therefore in the interest of the machine owner to carry out the prescribed maintenance
work.
Before carrying out service and maintenance work, always read, understand and follow
the instructions given in:
Chapter 2 SAFETY INSTRUCTIONS of this Operator's Manual
The Operator's Manuals of the attachments.
Carry out the prescribed inspections and rectify any disorders before putting the machine
into operation.
Secure open (engine) covers appropriately. Do not open (engine) covers on slopes or in
strong wind.
Dirt can be blown away and cause severe injuries when using compressed air. Always
wear protective goggles, masks and clothing.
Daily service and maintenance work, and maintenance according to maintenance plan
A must be carried out by a specifically trained driver. All other maintenance work must
be carried out by trained and qualified staff only.
The maintenance plans indicate when the maintenance work mentioned below must be
carried out see Maintenance plan (overview) on page 5-35.

5.2 Safety-relevant parts


Service and maintenance work must be carried out by a specifically trained driver.
All other maintenance work that is not indicated in this Operator's Manual must be carried
out only by the trained and qualified staff of a Wacker Neuson workshop.
The following maintenance plans indicate the maintenance work to be carried out see
Maintenance plan (overview) on page 5-35.
This is necessary to ensure their optimal functioning.

5.3 Fuel system

Danger!
All work involving fuel carries an increased
Danger of fire and poisoning!
Before refuelling, stop the engine and remove the ignition key!
Never carry out work on the fuel system in the vicinity of naked flames or
sparks
Do not refuel in closed rooms
No smoking, no fire!
Do not smoke when working on the fuel system or when refuelling!
Wipe away fuel spills immediately!
Keep the machine clean to reduce the risk of fire!

BA 25-3503 EN Edition 2.3 *2503_3503b510.fm 5-1


Maintenance

5.4 Fuel system


Refuelling
Filler inlet A for the fuel tank is located behind the cab, on the right in driving direction.
A
Environment!
Use a suitable container to collect the fuel as it drains and dispose of it in an
environmentally friendly manner!

Notice!
Fig. 196: Fuel filler inlet
Do not run the fuel tank completely dry. Otherwise, air is drawn into the fuel sys-
tem. This requires bleeding the fuel system see Bleeding the fuel system on
page 5-3.

Notice!
Fill up the tank with the correct fuel type at the end of each working day. This pre-
vents condensation water from forming in the fuel tank over night. Do not fill the
tank completely but leave some space for the fuel to expand.

Stationary fuel pumps

General
Only refuel from stationary fuel pumps. Fuel from barrels or cans is usually dirty.
Even the smallest particles of dirt can cause
Increased engine wear
Malfunctions in the fuel system and
Reduced effectiveness of the fuel filters

Refuelling from barrels


If refuelling from barrels cannot be avoided, note the following points (see fig. 197):
wrong Barrels must neither be rolled nor tilted before refuelling
Protect the suction pipe opening of the barrel pump with a fine-mesh screen
Immerse it down to a max. 15 cm above the floor of the barrel
Only fill the tank using refuelling aids (funnels or filler pipes) with integral microfilter
Keep all refuelling containers clean at all times
right

Fig. 197: Refuelling from a barrel

5-2 BA 25-3503 EN Edition 2.3 * *2503_3503b510.fm


Maintenance

Draining the fuel

A
Danger!
All work involving fuel carries an increased
Danger of fire and poisoning!
Do not work in closed rooms
Never carry out work on the fuel system in the vicinity of naked flames or
sparks
Fig. 198: Fuel tank No smoking, no fire!

Environment!
Use a suitable container to collect the fuel as it drains and dispose of it in an
environmentally friendly manner!

Filler inlet A for the fuel tank is located in the valve compartment, on the left in driving
direction.
Proceed as follows:
Open filler inlet A
Pump out the fuel with a suitable pump
Collect the fuel in a suitable container
Diesel fuel specification
Use only high-grade fuels

Grade Use
2-D ASTM D975 94
USA
1-D ASTM D975 94
EN 590 : 96 EU
ISO 8217 DMX International
BS 2869 A1
England
BS 2869 A2
Sulphur content below 0.05 %
Cetane number over 45
Bleeding the fuel system

Danger!
If the fuel, as it drains, comes into contact with hot engine parts or the exhaust
system, there is an increased
Danger of burns!
Never bleed the fuel system if the engine is hot!

Bleed the fuel system in the following cases:


After removing and fitting the fuel filter, prefilter or the fuel lines back on again
After running the fuel tank empty
After running the engine again, after it has been out of service for a longer period of
time

BA 25-3503 EN Edition 2.3 *2503_3503b510.fm 5-3


Maintenance

Bleed the fuel system as follows:


Fill the fuel tank
Turn the ignition key to the first position
Wait about 5 minutes while the fuel system bleeds itself automatically
Start the engine
If the engine runs smoothly for a while and then stops, or if it does not run smoothly:
Stop the engine
Bleed the fuel system again as described above
Have this checked by authorised staff if necessary
Water separator
Interrupt fuel supply as follows:
Stop the engine.
Turn ball-type cock B to the OFF mark
Off Fuel supply is interrupted
B Turn ball-type cock B to the ON mark
Fuel supply is open again
On
Check the water separator as follows:
C
If the red indicator ring has risen to position C:
Stop the engine.
A Interrupt fuel supply.
Unscrew thread A
Fig. 199: Water separator The fuel/water mixture drains
Wait until the indicator ring returns to the bottom of the water separator
Screw thread A back on again

Environment!
Thread A is fitted with a hose. Collect the fuel/water mixture as it drains with a
suitable container and dispose of it in an environmentally friendly manner.

2503 from AG00790:


3503 from AG00593:
The fuel/water mixture must be drained directly on the fuel filter in addition.
Carry this out at regular intervals according to the maintenance plan see chapter 5.18
Maintenance plan (overview) on page 5-35.
In this case proceed as follows:
Stop the engine.
A
Place a suitable container underneath the filter.
Fig. 200: Fuel filter (from AG00580)
Unscrew screw A.
The fuel/water mixture drains from the filter housing.
Drain about 10 ml of the fuel/water mixture.

Environment!
Collect the fuel/water mixture as it drains with a suitable container and dispose
of it in an environmentally friendly manner.

5-4 BA 25-3503 EN Edition 2.3 * *2503_3503b510.fm


Maintenance

5.5 Engine lubrication system

Caution!
If the engine oil level is too low or if an oil change is overdue, this can cause
Engine damage or loss of output!
Have the oil changed by an authorised workshop
see chapter 5.18 Maintenance plan (overview) on page 5-35

Checking the oil level

Notice!
Check the oil level once a day.
We recommend checking it before starting the engine. After stopping a warm
engine, wait at least 5 minutes before checking.

Proceed as follows:
max
Park the machine on level ground
min
Stop the engine!
Fold the control lever base up
Let the engine cool down
Open the engine cover
Clean the area around the oil dipstick with a lint-free cloth
Oil dipstick A:
Pull it out
A
Wipe it with a lint-free cloth
Fig. 201: Checking the oil level
Push it back in as far as possible
Withdraw it and read off the oil level
However if necessary, fill up oil at the latest when the oil reaches the MIN mark on the
oil dipstick A

BA 25-3503 EN Edition 2.3 *2503_3503b510.fm 5-5


Maintenance

Filling up engine oil

Caution!
Too much or incorrect engine oil can result in engine damage! For this reason:
Do not add engine oil above the MAX mark of oil dipstick 202/A
Use only the specified engine oil

Environment!
Use a suitable container to collect the engine oil as it drains and dispose of it in
an environmentally friendly manner!

Caution!
Filling in the engine oil too fast via filler inlet B in the valve cover can cause
engine damage.
Fill in the engine oil slowly so it can go down without entering the intake
system.

Proceed as follows:
Clean the area around oil filler cap B with a lint-free cloth
Open filler cap B
Raise oil dipstick A slightly to allow any trapped air to escape
B
OIL
Fill in engine oil
Wait about 3 minutes until all the oil has run into the oil sump
A Check the oil level see Checking the oil level on page 5-5
Fill up if necessary and check the oil level again
Close filler cap B
Push oil dipstick A back in as far as possible
Fig. 202: Oil dipstick and oil filler cap Completely remove all oil spills from the engine

5-6 BA 25-3503 EN Edition 2.3 * *2503_3503b510.fm


Maintenance

5.6 Engine and hydraulics cooling system


The oil/water cooler is located in the engine compartment, on the right side of the engine. It
cools the diesel engine, and the hydraulic oil of the drive and work hydraulics.
The expansion tank for the coolant is also located in the engine compartment, in front of
the oil cooler.

Specific safety instructions


Dirt on the radiator fins reduces the cooler's heat dissipation capacity! To avoid this:
Clean the outside of the radiator at regular intervals. Use oil-free compressed air (2
bar max.) to clean. Maintain a certain distance from the radiator to avoid damage to
the radiator fins. Refer to the maintenance plans in the appendix for the cleaning
intervals
In dusty or dirty work conditions, clean more frequently than indicated in the mainte-
nance plans
An insufficient coolant level reduces the heat dissipation capacity as well and can lead
to engine damage! Therefore:
Check the coolant level at regular intervals. Refer to the maintenance plans in the
appendix for the intervals
If coolant must be added frequently, check the cooling system for leaks and/or con-
tact your dealer!
Never fill in cold water/coolant if the engine is warm!
After filling the expansion tank, make a test run with the engine and check the coolant
level again after stopping the engine
The use of the wrong coolant can destroy the engine and the cooler. Therefore:
Add enough antifreeze compound to the coolant but never more than 50 %. If pos-
sible use brand-name antifreeze compounds with anticorrosion additives
Observe the coolant compound table see chapter 6.7 Coolant compound table on
page 6-5
Do not use cooler cleaning compounds if an antifreeze compound has been added to
the coolant otherwise this causes sludge to form, which can damage the engine
Once you have filled the expansion tank:
Test run the engine
Stop the engine
Let the engine cool down
Check the coolant level again

Environment!
Use a suitable container to collect the coolant as it drains and dispose of it in
an environmentally friendly manner!

BA 25-3503 EN Edition 2.3 *2503_3503b510.fm 5-7


Maintenance

5.7 Checking/filling up coolant

Danger!
Never open the coolant tank and never drain coolant if the engine is warm
since the cooling system is under high pressure

Danger of burns!
Wait at least 15 minutes after stopping the engine!
Wear protective gloves and clothing
Open filler cap B to the first notch and release the pressure
Make sure the coolant temperature is sufficiently low so you can touch the
radiator plug with your hands

Danger!
Antifreeze is flammable and poisonous
Danger of accidents!
Keep away from flames
Avoid eye contact with antifreeze
If antifreeze comes into contact with the eyes
Immediately rinse with clean water and seek medical assistance

Checking the coolant level


Proceed as follows:
Park the machine on level ground
A Stop the engine!
Fold the control lever base up
Remove the key and carry it with you
Let the engine and the coolant cool down
Open the engine cover
Check the coolant level on the transparent coolant tank A and on the radiator B
If the coolant level is below the LOW seam or if there is no coolant at the radiator's
filler inlet:
FULL Fill up coolant
LOW
Notice!
Check the coolant level once a day.
Fig. 203: Expansion tank for coolant We recommend checking it before starting the engine.

Caution!
Do not mix the coolant with other coolants.
Only use the coolant recommended by Wacker Neuson see chapter 6.7
Coolant compound table on page 6-5.

5-8 BA 25-3503 EN Edition 2.3 * *2503_3503b510.fm


Maintenance

Filling up coolant
After the engine has cooled down:
Release overpressure in the radiator
Carefully open the cap to the first notch and fully release the pressure
Open filler cap B
Fill in coolant up to the lower edge of the filler inlet (radiator)
Close filler cap B
Start the engine and let it warm up for about 5 10 minutes
B Stop the engine
Remove the key and carry it with you
Let the engine cool down
Fig. 204: Radiator
Check the coolant level again
The coolant level must be between the LOW and FULL tank seams
If necessary, fill up coolant and repeat the procedure until the coolant level remains
constant

Notice!
Check the antifreeze every year before the cold season sets in

Draining coolant

Danger!

A Hot coolant
Danger of burns!
Always use appropriate protective equipment, e.g. protective gloves!
No smoking, no fire!

Fig. 205: Pumping out coolant


Environment!
Use a suitable container to collect the coolant as it drains and dispose of it in
an environmentally friendly manner!

Proceed as follows:
Stop the engine
Let the coolant cool down
Open filler inlet A
Pump out the coolant with a suitable pump
Collect the coolant in a suitable container

BA 25-3503 EN Edition 2.3 *2503_3503b510.fm 5-9


Maintenance

Maintenance

5.8 Air filter

Caution!
The filter cartridge will be damaged if it is washed or brushed out!
Bear in mind the following to avoid premature engine wear!
Do not clean the filter cartridge
Replace the filter cartridge according to the maintenance plan
Never reuse a damaged filter cartridge
Ensure cleanliness when replacing the filter cartridge!

Replace the air filter as indicated in the maintenance plan or if fouling indicator 49 comes
on!
Replace the air filter as indicated in the maintenance plan!

Notice!
The air filter is fitted with an extra inside filter C to protect the engine in case the
outside filter is damaged. In order to avoid engine damage, do not clean inside fil-
ter C, but replace it as indicated in the maintenance plan.

49 Caution!
Filter cartridges degrade prematurely when in service in acidic air for longer
Fig. 206: Indicator for air filter contamination
periods of time. This risk is present for example in acid production facilities,
steel and aluminium mills, chemical plants and other nonferrous-metal plants.
Replace the air filter after 50 service hours at the latest!

General instructions for air filter maintenance:


Store filters in their original packaging and in a dry place
Do not knock the filter against other objects as you install it
Check air filter attachments, air intake hoses and air filters for damage, and immedi-
ately repair or replace if necessary
Check the screws at the induction manifold and the clamps for tightness
Check the function of the dust valve, replace if necessary

5-10 BA 25-3503 EN Edition 2.3 * *2503_3503b520.fm


Maintenance

Replacing the filter


Replace outside filter B as follows:
Stop the engine
Remove the key and carry it with you
Let the engine cool down
E Open the engine cover
Remove dirt and dust from the air filter and the area around the air filter
Turn the lower housing section E to the left
G
Remove lower housing section E
Carefully remove outside filter B with slightly turning movements
Fig. 207: Removing the lower housing section
Make sure all dirt (dust) inside the upper and lower housing sections (F and E), includ-
ing dust valve G, has been removed
Clean the parts with a clean lint-free cloth, do not use compressed air
Check the air filter cartridges for damage, only install intact filters
Carefully insert new the outside filter B in the upper housing section F
Position lower housing section E (make sure it is properly seated)
Turn the lower housing section E to the right
B
Fig. 208: Removing the filter element

Replace inside filter C as follows:


F
Stop the engine
Remove the key and carry it with you
Let the engine cool down
Open the engine cover
Remove dirt and dust from the air filter and the area around the air filter
C
Turn the lower housing section E to the left
Remove lower housing section E
Carefully remove outside filter B with slightly turning movements
Carefully remove inside filter C
Fig. 207: Replacing the inside filter
Cover the air supply at the end of the filter with a clean lint-free cloth to prevent dust
from entering the engine
Make sure all dirt (dust) inside the upper and lower housing sections (F and E), includ-
ing dust valve G, has been removed
Clean the parts with a clean lint-free cloth, do not use compressed air
Remove the cloth from the air supply
Check the air filter cartridges for damage, only install intact filters
Carefully insert the new inside filter C in the inside housing section F
Carefully insert the outside filter B in the upper housing section F
Position lower housing section E (make sure it is properly seated)
Turn the lower housing section E to the right

Notice!
Make sure dust valve G shows downwards once it is installed!

BA 25-3503 EN Edition 2.3 *2503_3503b520.fm 5-11


Maintenance

5.9 V-belt

Danger!
Only check or retighten/replace the V-belt when the engine is stopped
Danger of personal injury!
Stop the engine before carrying out inspection work in the engine compart-
ment!
Disconnect the battery or the battery master switch
Let the engine cool down

Caution!
Cracked and stretched V-belts cause engine damage
Have the V-belt replaced by an authorised workshop

Check the V-belt once a day or every 10 service hours, and retighten if necessary!
Retighten new V-belts after about 15 minutes of running time.

Checking V-belt tension


Check as follows:
Stop the engine
1 Fold the control lever base up
Remove the key and carry it with you
Disconnect the battery or the battery master switch
2 Let the engine cool down
Open the engine cover
About 8 mm Carefully check V-belt 1 for damage, cracks or cuts
Replace the V-belt if it touches the base of the V-belt groove or if the pulleys are dam-
aged.
If the V-belt is damaged:
Fig. 208: Checking V-belt tension Have the V-belt replaced by authorised staff
Press with your thumb about 100 N to check the deflection of the V-belt between the
crankshaft disc and the fan wheel. A new V-belt should have a deflection of 6 to 8
mm, a used V-belt (after about 5 minutes running time) should have a deflection of 7
to 9 mm 2
Retighten the V-belt if necessary

5-12 BA 25-3503 EN Edition 2.3 * *2503_3503b520.fm


Maintenance

Retightening the V-belt

Caution!
Overtightening the V-belt can damage the V-belt, the V-belt guide, the alter-
nator bearing and the water pump bearing. Avoid contact of oil, grease or
similar substances with the V-belt.
Check V-belt tension see Checking V-belt tension on page 5-12

Retighten as follows:
3
Stop the engine
A Fold the control lever base up
Remove the key and carry it with you
Disconnect the battery or the battery master switch
Let the engine cool down
Open the engine cover
5 Slacken fastening screws 3 and 4 (below) of alternator 5
4 Use a suitable tool to push alternator 5 in the direction of arrow A until reaching the
correct V-belt tension (fig. 209)
Fig. 209: Retightening the V-belt
Keep alternator 5 in this position, and at the same time retighten fastening screws 3
and 4 (below)
Check V-belt tension again and adjust it if necessary
Connect the battery or the battery master switch
Close the engine cover

BA 25-3503 EN Edition 2.3 *2503_3503b520.fm 5-13


Maintenance

5.10 Hydraulic system


Specific safety instructions
Release the pressure in all lines carrying hydraulic oil prior to any maintenance and
repair work. To do this:
Lower all hydraulically controlled attachments to the ground
Move all control levers of the hydraulic control valves several times
Fold the control lever base up
Hydraulic oil escaping under high pressure can penetrate the skin and cause serious
injuries. Always consult a doctor immediately even if the wound seems insignificant
otherwise serious infections could set in!
If the hydraulic oil in the sight glass is cloudy, this indicates that water or air has
penetrated the hydraulic system. This can cause damage to the hydraulic pump!
Oil or fuel flowing out of high pressure lines can cause fire or malfunctions, and severe
injuries or damage to property. Interrupt work immediately if slack nuts or damaged
hoses and lines are detected.
Contact your Wacker Neuson dealer immediately
Replace the hose or line if one of the problems mentioned below is detected.
Damaged or leaky hydraulic seals.
Worn or torn shells or uncovered reinforcement branches.
Expanded shells in several positions.
Entangled or crushed movable parts.
Foreign bodies jammed or stuck in protective layers.

Caution!
Dirty hydraulic oil, lack of oil or wrong hydraulic oil
Danger of severe damage to the hydraulic system!
Take care to avoid contamination when working!
Always fill in hydraulic oil using the filling screen!
Only use authorised oils of the same type
see chapter 5.17 Fluids and lubricants on page 5-31
Always fill up hydraulic oil before the level gets too low
see Filling up hydraulic oil on page 5-16
If the hydraulic system is filled with biodegradable oil, then only use biode-
gradable oil of the same type for filling up observe the sticker on the
hydraulic oil tank!
Contact customer service if the hydraulic system filter is contaminated with
metal chippings. Otherwise, follow-on damage can result!

Environment!
Collect drained hydraulic oil and biodegradable oil in a suitable container!
Dispose of drained oil and used filters by an ecologically safe method.
Always contact the relevant authorities or commercial establishments in
charge of oil disposal before disposing of biodegradable oil.

5-14 BA 25-3503 EN Edition 2.3 * *2503_3503b520.fm


Maintenance

Checking the hydraulic oil level

Caution!
Do not fill up oil if the oil level is above the MAX mark, otherwise the hydraulic
system can be damaged and escaping oil can cause serious injuries.
Check the hydraulic oil level each time the machine is put into operation or
once a day

Proceed as follows:
Park the machine on level ground
Retract the bucket and boom rams, lower the boom and the bucket teeth to the
ground
Lower the stabiliser blade to the ground
Fig. 210: Parking the excavator Set the boom straight (offset ram)
B Stop the engine
Fold the control lever base up
Sight glass B is located in the rear left corner of the machine in the trim.
Check the oil level on sight glass B
The oil level must be about 1 cm over the centre, between positions MIN and MAX,
as shown by the arrows in fig. 210.
MAX The MIN level is marked by the lower joint
The MAX level is marked by the upper joint
MIN If the oil level is lower
Fig. 210: Oil level indicator on the hydraulic oil tank Fill up hydraulic oil

The oil level varies according to the machine's operating temperature:

Machine condition Temperature Oil level


Before putting into operation Between 10 and 30 C LOW mark
Normal operation Between 50 and 90 C FULL mark

Notice!
Measure the oil level of the hydraulic system only after the machine reaches its
operating temperature.
1

BA 25-3503 EN Edition 2.3 *2503_3503b520.fm 5-15


Maintenance

Filling up hydraulic oil

Danger!
Removing the filler plug can cause oil to escape
Danger of accidents!
Carefully unscrew the plug to slowly reduce the pressure inside the tank.

Do not fill up the hydraulic oil unless the engine is stopped. Otherwise, hydraulic oil will
overflow at the filler opening on the hydraulic tank.
Fill up as follows:
Park the machine on level ground
Retract the bucket and boom rams, lower the boom and the bucket teeth to the
ground
Lower the stabiliser blade to the ground
Fig. 211: Parking the excavator Set the boom straight (offset ram)
Stop the engine
C Fold the control lever base up
Let the engine cool down
Slowly open cap C of the hydraulic tank
With the filter insert in place:
Fill up hydraulic oil
Check the hydraulic oil level on sight glass B
Fill up if necessary and check again
Close cap C of the hydraulic tank hand tight again
Fig. 211: Hydraulic oil tank

5-16 BA 25-3503 EN Edition 2.3 * *2503_3503b520.fm


Maintenance

Important information for the use of biodegradable oil


Use only the biodegradable hydraulic fluids which have been tested and approved by
Wacker Neuson GmbH. Always contact Wacker Neuson GmbH for the use of other
products which have not been recommended. In addition, ask the oil supplier for a
written declaration of guarantee. This guarantee is applicable to damage occurring on
the hydraulic components, which can be proved to be due to the hydraulic fluid.
Use only biodegradable oil of the same type for filling up. In order to avoid misunder-
standings, a label providing clear information is located on the hydraulic oil tank (next to
the filler inlet) regarding the type of oil currently used!
The joint use of two different biodegradable oils can affect the quality of one of the oil
types. Therefore, make sure the remaining amount of initial hydraulic fluid in the
hydraulic system does not exceed
8 % when changing biodegradable oil (manufacturer indications).
Do not fill up with mineral oil the content of mineral oil should not exceed 2 % in order
to avoid foaming problems and to ensure biological degradability.
When running the machine with biodegradable oil, the same oil and filter replacement
intervals are valid as for mineral oil see chapter 5.18 Maintenance plan (overview) on
page 5-35
Always have the condensation water in the hydraulic oil tank drained by an authorised
workshop before the cold season. The water content may not exceed 0.1 % by weight.
The instructions in this Operator's Manual concerning environmental protection are also
valid for the use of biodegradable oil.
If additional hydraulic attachments are mounted or operated, use the same type of
biodegradable oil for these attachments to avoid mixtures in the hydraulic system.
Subsequent change from mineral oil to biodegradable oil must be carried out by an author-
ised workshop or by your Wacker Neuson partner.

BA 25-3503 EN Edition 2.3 *2503_3503b520.fm 5-17


Maintenance

Checking hydraulic pressure lines


Specific safety instructions

Danger!
Caution when checking hydraulic lines, especially when searching for leaks.
Hydraulic oil escaping under high pressure can penetrate the skin and cause
serious injuries.
Danger of personal injury!
Always consult a doctor immediately, even if the wound seems insignificant
otherwise serious infections could set in!
Always observe the following instructions:
Retighten leaking screwed fittings and hose connections only when the
system is not under pressure; i.e. release the pressure before working
on pressurised lines!
Never weld or solder damaged or leaking pressure lines and screw con-
nections. Replace damaged parts with new ones!
Never search for leaks with your bare hands, but wear protective gloves!
Use paper or wood to check for minor leaks. Never use an unprotected
light or naked flame!
Have damaged flexible lines replaced by authorised workshops only!

Leaks and damaged pressure lines must be immediately repaired or replaced by an


authorised workshop or after-sales staff.
This not only increases the operating safety of your machine but also helps to protect
the environment
Replace hydraulic hoses every 6 years from the date of manufacture, even if they do
not seem to be damaged
In this respect, we recommend that you observe all the relevant safety regulations for
hydraulic lines, as well as the safety regulations regarding accident prevention and occu-
pational health and safety in your country. Also observe DIN 20066, part 5.
The article number is marked on the clamping section, and the date of manufacture is indi-
cated on the hose of each hose connection.

5-18 BA 25-3503 EN Edition 2.3 * *2503_3503b520.fm


Maintenance

Maintenance

5.11 Tracks
Track wear can vary according to work and ground conditions.
We recommend checking track wear and tension once a day.

Checking track tension

Danger!
Working under the machine with the tracks off the ground and only supported
by the attachment is extremely dangerous.
Caution, danger!
Do not allow anyone to stay in the danger area!
Stop the machine on firm, level and horizontal ground.
Support the machine only at the steel parts of the travel gear. Do not dam-
age any parts of the machine as you support it.

Check track tension as follows:


The rubber track has a mark B as shown in Fig. 212
Place the excavator so that mark B of the rubber track is between the drive pinion C
and the track tension roller D
B

D B C

Fig. 212: Rubber track mark

Stop the machine on firm, level and horizontal ground


Raise the machine by means of the boom, stick and stabiliser blade
Slowly and carefully actuate the control levers
Stop the engine
Remove the key and carry it with you
Fold the control lever base up
Use suitable auxiliary means to support the machine

Fig. 213: Raising the excavator

Standard play between the sliding block's shoulder and the contact area of the second
support roller of the drive pinion is 20 25 mm.
Set the tension as follows if it is not in accordance with the rated value.
20 25 mm

Fig. 214: Measuring distance

BA 25-3503 EN Edition 2.3 *2503_3503b530.fm 5-19


Maintenance

Setting the tracks

Danger!
The lubricating valve can be squeezed out due to the high grease pressure in
the hydraulic ram.
Danger of personal injury!
Do not slacken and unscrew the lubricating valve by more than one turn.
Slacken no other component except the lubricating valve.
Keep your face away from the lubricating valve connection.
Contact your Wacker Neuson dealer if this does not reduce the tension
of the rubber sliding block.

Caution!
Excessive tension of the tracks causes severe damage to the ram and the
track.
Tighten the tracks only up to the prescribed measuring distance

Tightening the tracks


Inject grease with the pump through lubricating valve A
Check the tension is correct by starting the engine, letting it run at idling speed and
slowly moving the machine forwards and reverse and switching it off again
Check the tension of the tracks again
If it is not correct:
Adjust again
Should the track still be slack after injecting more grease, replace the track or the seal
A in the ram. Contact a Wacker Neuson dealer in this case
Fig. 215: Tightening the tracks
Reducing tension
Draining grease in a way different from the one described below is very dangerous.
Also bear in mind the safety instructions on this page
Slowly open the lubricating valve A by 1 turn to allow the grease to flow out.
Place a suitable container underneath to collect the grease
The grease flows out of the groove of the lubricating valve
Retighten the lubricating valve A
A Check the tension is correct by starting the engine, letting it run at idling speed and
slowly moving the machine forwards and reverse and switching it off again

Fig. 216: Draining grease


Check the tension of the tracks again
If it is not correct:
Adjust again

Environment!
Use a suitable container to collect the grease as it flows out and dispose of it in
an environmentally friendly manner.

5-20 BA 25-3503 EN Edition 2.3 * *2503_3503b530.fm


Maintenance

5.12 Travelling drive

Danger!
Immediately after stopping the engine, the engine's components and the oil
are very hot. This can cause burns.
If the inside of the drive gear is under pressure, the oil or the plug can be
squeezed out.
Danger of injury and scalding!
Wait until the engine has cooled down before taking up work.
Slowly open the plug to reduce the pressure inside.

Checking the oil level and filling up oil


Park the machine on level and horizontal ground
A Place the machine so that filler plug A is at the top
Stop the engine
Let the engine cool down
B Fold the control lever base up
Unscrew screws A and B with a suitable tool
A small quantity of oil must flow out of opening B
Fig. 217: Checking the oil level If the oil does not flow out of opening B, fill up oil:
Fill in oil through opening A,
until a small quantity of oil flows out of opening B
Screw screws A and B back in again
Move the machine a few metres
Check the oil level again
If the oil level is not correct:
Repeat the procedure
Draining oil
Park the machine on level and horizontal ground
A
Place the machine so that filler plug B is at the bottom
Stop the engine
Let the engine cool down
Fold the control lever base up
B
Unscrew screws A and B with a suitable tool
The oil now flows out of opening B
Fig. 218: Draining oil Use a suitable container to collect the oil as it drains

Environment!
Collect the oil with a suitable container and dispose of it in an environmentally
friendly manner.

Maintenance of attachments

Notice!
Correct maintenance and service is absolutely necessary for smooth and continu-
ous operation, and for an increased service life of the attachments. Please
observe the lubrication and maintenance instructions in the Operator's Manuals of
the attachments.

BA 25-3503 EN Edition 2.3 *2503_3503b530.fm 5-21


Maintenance

5.13 Electrical system


Specific safety instructions
The battery contains sulphuric acid! This acid must not be allowed to come into contact
with the skin, the eyes, clothing or the machine.
Therefore when recharging or working near the battery:
Always wear goggles and protective clothing with long sleeves
If acid is spilt:
Thoroughly rinse all affected surfaces immediately with plenty of water
Thoroughly wash any part of the body touched by the acid immediately with plenty of
water and seek medical attention at once!
Especially when charging batteries, as well as during normal operation of batteries, an
oxyhydrogen mixture is formed in the battery cells danger of explosion!
Do not attempt to jump-start the machine if the battery is frozen or if the acid level is
low. The battery can rupture or explode!
Replace the battery immediately
Avoid naked flames and sparks and do not smoke in the vicinity of open battery cells
otherwise the gas produced during normal battery operation can ignite!
Use only 12 V power sources. Higher voltages will damage the electric components
When connecting the battery leads, make sure the poles +/ are not inverted, otherwise
sensitive electric components will be damaged
Do not interrupt voltage-carrying circuits at the battery terminals because of the danger
of sparking!
Never place tools or other conductive articles on the battery danger of short circuit!
Disconnect the negative () battery terminal from the battery before starting repair work
on the electrical system
Dispose of used batteries properly

Service and maintenance work at regular intervals


Before driving the machine
Check every time before driving the machine:
Is the light system OK?
Is the signalling and warning system OK?

Every week
Check once a week:
Electric fuses see chapter Fuse box in cab on page 6-4
Cable and earth connections
Battery charge condition see Battery on page 5-24
Condition of battery terminals

5-22 BA 25-3503 EN Edition 2.3 * *2503_3503b530.fm


Maintenance

Instructions concerning specific components


Cables, bulbs and fuses
Always observe the following instructions:
Defective components of the electrical system must always be replaced by an
authorised expert. Bulbs and fuses may be changed by unqualified persons
When carrying out maintenance work on the electrical system, pay particular attention
to ensuring good contact in leads and fuses
Blown fuses indicate overloading or short circuits. The electrical system must therefore
be checked before installing the new fuse
Only use fuses with the specified load capacity (amperage) see chapter Fuse box in
cab on page 6-4

Alternator
Always observe the following instructions:
Only test run the engine with the battery connected
When connecting the battery, make sure the poles (+/) are not inverted
Always disconnect the battery before carrying out welding work or connecting a quick
battery charger
Replace defective charge telltales immediately
see chapter 34 Alternator charge function telltale (red) 3-10 on page 3-5

BA 25-3503 EN Edition 2.3 *2503_3503b530.fm 5-23


Maintenance

Battery

Danger!
Battery acid is highly caustic!
Danger of caustic injury!
Therefore when recharging and/or working near the battery:
Always wear goggles and protective clothing with long sleeves
If acid is spilt:
Thoroughly rinse all affected surfaces immediately with plenty of water
Thoroughly wash any part of the body touched by the acid immediately with
plenty of water and seek medical attention at once!
Especially when charging batteries, as well as during normal operation of
batteries, an oxyhydrogen mixture is formed in the battery cells
Danger of explosion!
Avoid naked lights and sparks in the vicinity of the battery and do not
smoke!
Do not attempt to jump-start the machine if the battery is frozen or if the
acid level is low. The battery can rupture or explode!
Replace the battery immediately
Always disconnect the negative terminal () from the battery before starting
repair work on the electrical system!

Battery A is located under the cab, in front of the fuel tank. The battery is maintenance-
A free. However have the battery checked at regular intervals to make sure the electrolyte
level is between the MIN and MAX marks.
Checking the battery requires it to be removed and must be carried out by an authorised
-
workshop.
Always follow the specific battery safety instructions!

+
Notice!
Fig. 219: Battery Do not disconnect the battery while the engine is running.

5-24 BA 25-3503 EN Edition 2.3 * *2503_3503b530.fm


Maintenance

5.14 General maintenance work


Cleaning
Cleaning the machine is divided into 3 separate areas:
Inside the cab
Exterior of the machine
Engine compartment
The wrong choice of cleaning equipment and agents can impair the operating safety of the
machine on the one hand, and on the other undermine the health of the persons in charge
of cleaning the machine. It is therefore essential to observe the following instructions.

General instructions for all areas of the machine

Cleaning with washing solvents


Ensure adequate room ventilation
Wear suitable protective clothing
Do not use flammable liquids, such as petrol or diesel

Cleaning with compressed air


Work carefully
Wear goggles and protective clothing
Do not aim the compressed air at the skin or at other people
Do not use compressed air for cleaning your clothing

Cleaning with a high-pressure cleaner or steam jet


Electric components and damping material must be covered and not directly exposed
to the jet
Cover the vent filter on the hydraulic oil tank and the filler caps for fuel, hydraulic oil etc.
Protect the following components from moisture:
Engine
Electric components such as the alternator etc.
Control devices and seals
Air intake filters etc.

Cleaning with volatile and easily flammable anticorrosion agents


and sprays:
Ensure adequate room ventilation
Do not use unprotected lights or naked flames
Do not smoke!

BA 25-3503 EN Edition 2.3 *2503_3503b530.fm 5-25


Maintenance

Inside the cab

Caution!
Never use high-pressure cleaners, steam jets or high-pressure water to clean
inside the cab. Water under high pressure can
penetrate into the electrical system and cause short circuits and
damage seals and disable the controls!

We recommend using the following aids to clean the cab:


Broom
Vacuum cleaner
Damp cloth
Bristle brush
Water with mild soap solution

Cleaning the seat belt


Clean the seat belt (which remains fitted in the machine) only with a mild soap solution;
do not use chemical agents as they can destroy the fabric!

Exterior of the machine


The following articles are generally suitable:
High-pressure cleaner
Steam jet

Engine compartment

Danger!
Clean the engine at engine standstill only
Danger of personal injury!
Stop the engine before cleaning

Caution!
When cleaning the engine with a water or steam jet
The engine must be cold
and do not point the jet directly at electric sensors such as the oil pressure
switch.
The humidity penetrating any such sensors causes them to fail and leads to
engine damage!

5-26 BA 25-3503 EN Edition 2.3 * *2503_3503b530.fm


Maintenance

Screw connections and attachments


All screw connections must be checked regularly for tightness, even if they are not listed in
the maintenance schedules.
Engine fastening screws
Fastening screws on the hydraulic system
Line, bucket teeth and pin fastenings on the attachment
Retighten loose connections immediately. Contact an authorised workshop if necessary.

Pivots and hinges


All mechanical pivot points on the machine (e.g. door hinges, joints) and fittings (e.g. door
arresters) must be lubricated regularly, even if they are not listed in the lubrication plan.

5.15 Lubrication points


Lubricate the lubrication points with the green caps once a week.
Lubricate the lubrication points with the blue caps daily.

Lubrication unit: Stabiliser blade:

BA 25-3503 EN Edition 2.3 *2503_3503b530.fm 5-27


Maintenance

VDS lubrication points (option)


Apply grease to lubrication points D and E once a week.
see Tilting the upper carriage (option) on page 3-57

D E

Fig. 220: VDS lubrication points

Powertilt (option)
Carry out maintenance on the Powertilt unit once a day with the other maintenance work
for the machine.
Carry out visual checks for possible defects, damage or cracks.
Remove all dirt on and around moving parts.
S Apply grease via grease nipples S.

Fig. 221: Lubricate

5-28 BA 25-3503 EN Edition 2.3 * *2503_3503b530.fm


Maintenance

Lubrication points of hydraulic quickhitch (option)

Notice!
S
Before picking up an attachment, the driver must make sure it can be hitched cor-
rectly by removing all dirt on either claw of the quickhitch.
Carry out maintenance on the quickhitch system once a day with the other mainte-
nance work for the machine.

Carry out visual checks for possible defects, damage or cracks.


Remove all dirt on and around moving parts.
The claws must be clean and slightly greased.
Apply grease to the pins via grease nipples S.
S Apply grease to the friction surfaces of the lock mechanism via 2 further grease nipples N
on either side of the quickhitch (see Fig. 222).
Before starting work, check the acoustic signal which must be audible when pressing
switch 50.

Fig. 222: Lubrication

BA 25-3503 EN Edition 2.3 *2503_3503b530.fm 5-29


Maintenance

5.16 Maintenance if the machine is out of service for a longer period of time

Caution!
If the machine is out of operation, run it once a month without load. Remove
the grease from the piston rods first!

Preparatory work before taking the machine out of service


Carefully clean and dry the entire machine.
Apply grease to all lubrication points
Change the engine oil
Apply grease to the piston rods of the hydraulic rams
Check and if necessary, fill up all oil levels such as in the gearbox and other units.
Check and if necessary, fill up the hydraulic oil
Fill up the fuel tank completely to avoid corrosion on the walls
Check the antifreeze in the coolant, change as required
Check the tyre pressure for the prescribed value and protect the tyres from direct sun-
light
Remove the earthing strap from the battery, or remove the battery and store it in a safe
place. Load the battery and carry out battery maintenance at regular intervals.
Close the exhaust pipe and the air intake opening of the air filter system

Notice!
Store the machine indoors if possible. If storing the machine outdoors cannot be
avoided, place it on wooden boards and cover it with a tarpaulin.

Putting the machine into operation again


Remove the grease from the piston rods.
Install or connect the battery.
Remove the seals from the exhaust pipe and the air filter intake.
Check the condition of the air filter cartridges and replace them if necessary.
If the machine was out of service for over 6 months, change the oil in the gearbox,
engine and other units.
Also replace hydraulic oil filters (reflux and breather filters) if the machine has been out
of service for over 6 months.
Lubricate the machine according to the lubrication plan.
Fill up a little engine oil.
Check the levels.
Remove the cutoff solenoid from the engine.
Let the engine run 10 seconds.
Wait 1 minute.
Let the engine run 10 seconds again.
Fit the cutoff solenoid back on again.
Start the engine and let it run without any load.

5-30 BA 25-3503 EN Edition 2.3 * *2503_3503b530.fm


Maintenance

5.17 Fluids and lubricants


Season/tempera-
Component/ application Engine/machine fluid Specification Capacities1
ture
API: CF, CF-4, CI-4
-20 C
Diesel engine Engine oil SAE 10W-40 ACEA: E3, E4, E5 About 3.4 l
+40 C
JASO: DH-1
Gearbox oil SAE 80W-
Travelling drive API: GL-4, GL-5 Year-round About 0.6 l each
90
HVLP462
Hydraulic oil
HV 464
2503: 27 l
Hydraulic oil tank PANOLIN HLP Synth 46 Year-round3
3503: 50 l
Biodegradable oil5 FINA BIOHYDRAN SE 46
BP BIOHYD SE-46
Roller and friction bear-
KF2K-256
ings
Grease Live ring: ball bearings KF2K-257 Year-round As required
8
Live ring gears KP2N-20
Grease nipples KF2K-259
Battery terminals Acid-proof grease10 FINA Marson L2 Year-round As required
2-D ASTM D975 94 (USA)
1-D ASTM D975 94 (USA)
EN 590 : 96 (EU)
Diesel fuel11 ISO 8217 DMX (International) 2503: 41 l
Fuel tank
BS 2869 A1 (GB) Depending on 3503: 52 l
outside tempera-
tures
BS 2869 A2 (GB) Summer or winter
diesel fuel
Soft water + antifreeze ASTM D4985
Radiator Coolant Distilled water + antifreeze ASTM Year-round About 4.5 l
D4985
Washer system Cleaning agent Water + antifreeze Year-round 1.2 l
1. The capacities indicated are approximative values; the oil level check alone is relevant for the correct oil level
Capacities indicated are no system fills
2. According to DIN 51524 section 3
3. Depending on local conditions see Hydraulics oil grade on page 5-33
4. According to ISO 6743/4
5. Biodegradable hydraulic oil based on saturated synthetic esters with an iodine value of < 10 g/mg, according to DIN 51524, section 3, HVLP, HEES
6. KF2K-25 according to DIN 51502 multipurpose lithium grease with MoS additive
7. KF2K-25 according to DIN 51502 multipurpose lithium grease with MoS additive
8. KP2N-20 according to DIN 51502 EP multipurpose calcium sulphonate complex grease
9. KF2K-25 according to DIN 51502 multipurpose lithium grease with MoS additive
10. Standard acid-proof grease
11. Sulphur content below 0.05 %, cetane number over 45

BA 25-3503 EN Edition 2.3 *2503_3503b530.fm 5-31


Maintenance

Oil grades for the diesel engine, depending on temperature


Engine oil grade Ambient temperature (C)
C -20 -15 -10 -5 0 5 10 15 20 25 30 35 40

SAE 10W

SAE 20W

SAE 10W-30

SAE 10W-40

API CD, CF, CF-4,


CI-4 SAE 15W-40
ACEA E3, E4, E5

SAE 20

SAE 30

SAE 40

F -4 5 14 23 32 41 50 59 68 77 86 95 104

Additional oil change and filter replacement (hydraulics)

Caution!
An additional oil change and filter replacement can be required depending on
how the machine is used. Failure to observe these replacement intervals can
cause damage to hydraulic components.
Observe the following intervals

Application Hydraulic oil Hydraulic oil filter insert


Normal work (excavation work) Every 1000 s/h Replace the first time after 50 s/h, then every 500 s/h
20 % Every 800 s/h
300 s/h
40 % Every 400 s/h
Percentage of hammer work
60 % Every 300 s/h
100 s/h
Over 80 % Every 200 s/h

Notice!
Please refer to the maintenance plan on page 5-35 for additional maintenance
work.

5-32 BA 25-3503 EN Edition 2.3 * *2503_3503b530.fm


Maintenance

Oil grades for the hydraulic system, depending on temperature

Hydrau-
lics oil Ambient temperature
grade
C -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 50

ISO VG32

HVLP1 ISO VG46

ISO VG68

F -4 5 14 23 32 41 50 59 68 77 86 95 104 122
1. According to DIN 51524 section 3

BA 25-3503 EN Edition 2.3 *2503_3503b530.fm 5-33


Maintenance

5-34 BA 25-3503 EN Edition 2.3 * *2503_3503b530.fm


Maintenance

Maintenance plan/service hours (s/h)


5.18 Maintenance plan (overview)
Work description
For service and maintenance work on the attachment, please refer to the operation and maintenance manual
Customer
workshop

of the attachment manufacturer as well.


Authorised

once a year

(once a day)
Every 250 s/h
Every 500 s/h

50 s/h service
Every 1000 s/h
Every 2000 s/h

Maintenance work
Fluid and filter changes ( ):
Carry out the following oil and filter changes (check oil levels after test run):

BA 25-3503 EN Edition 2.3 * *2503_3503b540.fm


Engine oil1
Engine oil filter2
Fuel filter3
Air filter element (as indicated by the telltale)
Coolant
Hydraulic oil filter insert 4
5
Hydraulic oil
Hydraulic oil tank breather
Gearbox oil6
Inspection work ( ):
Check the following material. Refill if necessary:
Engine oil
Engine coolant
Fuel
Hydraulic oil
Gearbox oil
Clean water ducts 7
Check radiator for engine and hydraulic oil for dirt. Clean if necessary
Check cooling systems, heating and hoses for leaks (visual check)
Air filter (visual check for damage)
Check the pilot control filter for dirt, clean it if necessary

5-35
Maintenance
Maintenance plan/service hours (s/h)

5-36
5.18 Maintenance plan (overview)
Work description
For service and maintenance work on the attachment, please refer to the operation and maintenance manual
Maintenance

Customer
workshop
of the attachment manufacturer as well.
Authorised

once a year

(once a day)
Every 250 s/h
Every 500 s/h

50 s/h service
Every 1000 s/h
Every 2000 s/h

Maintenance work
Prefilter with water separator: drain water
Clean
Fuel filter: from AG00580: drain 10 ml of fuel/water mixture
Check V-belt condition and tension
Check exhaust system for damage and condition
Check valve lash. Adjust if necessary
Clean and adjust the fuel injection pump 8
Check and adjust the injection pressure of the injection nozzles, clean the injection needles/nozzles
Check and adjust injection time 9
Empty diesel fuel tank
Check battery electrolyte. Fill up with distilled water if necessary
Check alternator, starter and electric connections, bearing play and function
Check preheating system and electric connections
Check correct function of air filter contamination gauge
Pressure check of primary pressure limiting valves
Check tracks for cracks and cuts
Check track tension. Retighten if necessary
Check bearing play of tread rollers, track carrier rollers, front idlers
Check piston rods for damage
Check screws for tightness
Check pin lock
Check line fixtures
Check telltales for correct function

BA 25-3503 EN Edition 2.3 * *2503_3503b540.fm


Maintenance plan/service hours (s/h)
5.18 Maintenance plan (overview)
Work description
For service and maintenance work on the attachment, please refer to the operation and maintenance manual
Customer
workshop
of the attachment manufacturer as well.
Authorised

once a year

(once a day)
Every 250 s/h
Every 500 s/h

50 s/h service
Every 1000 s/h
Every 2000 s/h

Maintenance work
Couplings, dirt pile-up on hydraulic system dust caps
Check insulating mats in the engine compartment for damage/condition

BA 25-3503 EN Edition 2.3 * *2503_3503b540.fm


Ensure grease supply of central lubrication system (option)
Check labels and Operator's Manual for completeness and condition
Check function of engine cover gas strut
Check hydraulic quickhitch system for damage
Check Powertilt for damage
Check Powertilt for axial play (must not be over 0.38 mm.)
Actuate Powertilt swivel device in final position for 1 minute10
Lubrication service ( ):
Lubricate the following assemblies/components:
Stabiliser blade
Swivelling console
Boom
Stick
Attachments
Hydraulic quickhitch system (option) see Hydraulic quickhitch system (option) on page 3-62
Powertilt
Tilting the upper carriage (VDS)
Grease strip on chassis
Functional check ( ):
Check the function of the following assemblies/components. Rectify if necessary:
Lights, signalling system, acoustic warning system

5-37
Maintenance
Maintenance plan/service hours (s/h)

5-38
5.18 Maintenance plan (overview)
Work description
For service and maintenance work on the attachment, please refer to the operation and maintenance manual
Maintenance

Customer
workshop
of the attachment manufacturer as well.
Authorised

once a year

(once a day)
Every 250 s/h
Every 500 s/h

50 s/h service
Every 1000 s/h
Every 2000 s/h

Maintenance work
Hydraulic quickhitch system (lock)
Check the Powertilt
Leakage check ( ):
Check for tightness, leaks and chafing: pipes, flexible lines and screw connections of the following assemblies and components. Rectify if necessary:
Visual check
Engine and hydraulic system
Cooling and heating circuit
Travelling drive
Hydraulic quickhitch system (hoses, valve)

1. Drain engine oil the first time after 50 s/h, then every 500 s/h
2. Replace the engine oil filter the first time after 50 s/h, then every 500 s/h
3. Replace the fuel filter the first time after 50 s/h, then every 500 s/h
4. Replace the hydraulic oil filter insert the first time after 50 s/h, then every 500 s/h
5. Replace the hydraulic oil the first time after 50 s/h, then every 1000 s/h
6. Drain the gearbox oil the first time after 50 s/h, then every 1000 s/h
7. Clean the water ducts every other 1000 s/h servicing
8. Clean and adjust the fuel injection pump every other 1000 s/h servicing
9. Check and adjust injection time every other 1000 s/h servicing
10. Rinse the system to remove dirt. Repeat the procedure in the opposite flow direction.

BA 25-3503 EN Edition 2.3 * *2503_3503b540.fm


Specifications

6 Specifications
6.1 Model 2503
Engine
Engine Model 2503
Product Yanmar diesel engine
Type Yanmar 3TNV 88-BSNS
Design Water-cooled diesel engine
No. of cylinders 3 cylinders
Displacement 1642 cm
Nominal bore and stroke 88 x 90 mm
Output 19.4 kW (26.0 hp)
Max. torque 107 Nm at 1200 rpm
Max. engine speed without load 2400
Idling speed 1100
Fuel injection system Direct fuel injection
Starting aid Sheathed-element heater plugs
Max. inclined position (engine no longer supplied with oil): 30
Exhaust values according to 97/68/EC, EPA

Hydraulic system
Hydraulics Model 2503
Pump Double variable displacement + gear pump
Flow rate 28.8 + 28.8 + 19.2 l/min
Operating pressure for work and drive
240 bar
hydraulics
Swivel unit operating pressure 200 bar
Hydraulic oil cooler Standard
Hydraulic tank capacity (system fill) 27.2 l

Stabiliser blade
Stabiliser blade Model 2503
Width 1370 mm
Height 340 mm
Max. lift over subgrade 390 mm
Scraping depth 415 mm

Work hydraulics
Work hydraulics Model 2503
Max. operating pressure 240 bar
Main pressure restriction for boom/bucket/stick 240 bar
Main pressure restriction for stabiliser blade 210 bar
Main pressure restriction for pilot control pressure 35 bar
Main pressure restriction for swivel drive (hydraulic motor pressure restriction) 200 bar
Filter Reflux filter
Hydraulic tank capacity 27.2 l

BA 25-3503 EN Edition 2.3 *2503_3503b610.fm 6-1


Specifications

6.2 Model 3503


Engine
Engine Model 3503
Product Yanmar diesel engine
Type Yanmar 4TNV 88-BWNS
Design Water-cooled diesel engine
No. of cylinders 4 cylinders
Displacement 2190 cm
Nominal bore and stroke 88 x 90 mm
Output 23.7 kW (32.2 hp)
Max. torque (intermittent) 143/1200
Max. engine speed without load 2025 rpm
Idling speed 1100
Fuel injection system Direct fuel injection
Starting aid Sheathed-element heater plugs
Max. inclined position (engine no longer supplied with oil): 30
Exhaust values according to 97/68/EC/EPA

Hydraulic system
Hydraulics Model 3503
Double variable displacement
Pump
pump + gear pump
Flow rate 44.5 + 44.5 + 25.0 l/min
Operating pressure for work and drive hydraulics 240 bar
Swivel unit operating pressure 200 bar
Hydraulic oil cooler Standard
Hydraulic tank capacity (system fill) 50 l

Stabiliser blade

Stabiliser blade Model 3503


Width 1620 mm
Height 370 mm
Max. lift over subgrade 410 mm
Scraping depth 480 mm

Work hydraulics
Work hydraulics Model 3503
Max. operating pressure 240 bar
Main pressure restriction for boom/bucket/stick 240 bar
Main pressure restriction for stabiliser blade 210 bar
Main pressure restriction for pilot control pressure 35 bar
Main pressure restriction for swivel drive (hydraulic motor pres-
200 bar
sure restriction)
Filter Reflux filter
Hydraulic tank capacity 50 l

6-2 BA 25-3503 EN Edition 2.3 * *2503_3503b610.fm


Specifications

6.3 Model 3503 VDS


Engine
Engine Model 3503 VDS
Type Yanmar 4TNV 88-BWNS
Design Water-cooled diesel engine
No. of cylinders 4 cylinders
Displacement 2190 cm
Nominal bore and stroke 88 x 90 mm
Output 23.7 kW (32.2 hp)
Max. torque (intermittent) 143/1200
Max. engine speed without load 2025 rpm
Idling speed 1100
Fuel injection system Direct fuel injection
Starting aid Sheathed-element heater plugs
Max. inclined position (engine no longer supplied with oil): 30
Exhaust values according to 97/68/EC/EPA
Type Yanmar 4TNV 88-BWNS

Hydraulic system
Hydraulics Model 3503 VDS
Double variable displacement
Pump
pump + gear pump
Flow rate 44.5 + 44.5 + 25.0 l/min
Operating pressure for work and drive hydraulics 240 bar
Swivel unit operating pressure 200 bar
Operating pressure for auxiliary hydraulics 240/210 bar
Hydraulic oil cooler Standard
Hydraulic tank capacity (system fill) 50 l

Stabiliser blade
Stabiliser blade Model 3503 VDS
Width 1620 mm
Height 370 mm
Max. lift over subgrade 410 mm
Scraping depth 480 mm

Work hydraulics
Work hydraulics Model 3503 VDS
Max. operating pressure 240 bar
Main pressure restriction for boom/bucket/stick 240 bar
Main pressure restriction for stabiliser blade 210 bar
Main pressure restriction for pilot control pressure 35 bar
Main pressure restriction for swivel drive (hydraulic motor pres-
200 bar
sure restriction)
Filter Reflux filter
Hydraulic tank capacity 50 l

BA 25-3503 EN Edition 2.3 *2503_3503b610.fm 6-3


Specifications

6.4 Electrical system


Fuse box in cab

1 2 3 4 Rated cur-
Fuse no. Protected circuit
rent (A)

Switch assignment, telltales and indicators, engine


9 11 1 10
relays

2 15 Lights, boom, roof lights


10
3 10 12V/15 cab

5 6 7 4 15 Heating, horn
8
5 10 Valves
Fig. 223: Fuse box
6 10 Window wiper, cab

7 10 Alternator excitation

8 15 Spare

Rotating beacon, radio, cigarette lighter, antitheft pro-


9 10
tection

10 15 Socket

11 10 Spare

6.5 Noise levels

Sound power level 2503 3503


1
Sound power level (LWA) 94 dB (A) 95 dB (A)
Sound pressure level (LPA ) at the driver's ear2 75dB (A) 76 dB (A)
3
Uncertainty (KPA) 0.8 dB (A) 0.8 dB (A)
1. According to ISO 6395
2. According to ISO 6396
3. According to EN ISO 4871

Notice!
Measurement of sound power level according to EC Directive 2000/14/EC and
2005/88/EC.
Noise level at the driver's ear measured according to EC Directives 84/532/EEC,
89/514/EEC and 95/27/EEC.
Measurements carried out on asphalted surface.

6-4 BA 25-3503 EN Edition 2.3 * *2503_3503b610.fm


Specifications

6.6 Vibration
Vibration
< Trigger value
Effective acceleration value for the upper extremities of the body1 m
< 2.5 -----
2
-
s

m
< 0.5 ------
Effective acceleration value for the body 1 s2

1. Measurements as per 2002/44/EC, EN ISO 20643 and ISO/TR 25398 (excavating, driving and hammering with a Wacker
Neuson hammer). Machine and attachment operation and maintenance as per Operator's Manual.

Uncertainty of measurement: measurements as per EN 12096:1997

6.7 Coolant compound table


Outside tempera- Eurolub SF D12 coolant (based on ethylene glycol)
ture Water Anticorrosion agent Antifreeze agent
% by cm/l
Up to C (F) % by volume % by volume
volume (cu. in./gal)
-37 (-34.6) 50 10 (2.6) 1 50
Use the 1:1 concentration for warm outside temperatures, too:
Protection against corrosion, cavitation and deposits
Do not mix the coolant with other coolants.
Coolant with specified features is filled in the machine at the factory.
6.8 Powertilt
Powertilt Models 2503, 3503
Model size 6
Piston stroke 525 cm (32 cu. in.)
Required oil flow 3 6 l/min (0.8 1.6 gal/min)
Connections 1/4
Slewing range 180
Weight 65 kg (143.3 lbs.)
Drive torque at 210 bar (3045 psi) 2990 Nm (2205 lb/ft)
Holding torque at 225 bar (3263 psi) 7270 Nm (5362 lb/ft)
Minimum hose/pipe size 10 mm (0.4)
Connecting hose size 6 mm (0.23)

BA 25-3503 EN Edition 2.3 *2503_3503b610.fm 6-5


Specifications

6.9 Dimensions model 2503

Fig. 224: Machine dimensions (model 2503)

Main data Model 2503


Service weight with cab/canopy 2620/2525 kg
Height 2370 mm
Width 1370 mm
Transport length 4410 mm
Max. digging depth 2620 mm
Stick length (standard) 1150 mm
Stick length (long version) 1350 mm
Max. digging depth for long stick (+ 300 mm) 2825 mm
Max. vertical digging depth 1810 mm
Max. vertical digging depth (long stick) 2000 mm
Max. digging height 4125 mm
Max. digging height (long stick) 4250 mm
Max. dump height 2925 mm
Max. dump height (long stick) 3080 mm
Max. digging radius 4515 mm
Max. digging radius (long stick) 4693 mm
Max. reach at ground level 4410 mm
Max. reach at ground level (long stick) 4602 mm
Max. breakout force at bucket tooth 20 kN
Max. tearout force (standard stick) 13 kN
Max. tearout force (long stick) kN
Min. tail end slewing radius 1240 mm
Max. tail end lateral projection (90 rotation of upper carriage) mm
Max. boom displacement to bucket centre (right-hand side) 653 mm
Max. boom displacement to bucket centre (left-hand side) 393 mm

6-6 BA 25-3503 EN Edition 2.3 * *2503_3503b610.fm


Specifications

6.10 Dimensions model 3503

Fig. 225: Machine dimensions (model 3503)

Main data Model 3503 Vario 3503


Service weight with cab/canopy 3500/3405 kg 3775/3680 kg
Height 2405 mm 2508 mm
Width 1620 mm 1620 mm
Transport length 5170 mm 5170 mm
Max. digging depth 3230 mm 3127 mm
Stick length (standard) 1335 mm 1335 mm
Stick length (long version) 1635 mm 1635 mm
Max. digging depth for long stick (+ 300 mm) 35030 mm 3427 mm
Max. vertical digging depth 2220 mm 2117 mm
Max. vertical digging depth (long stick) 2500 mm 2396 mm
Max. digging height 4910 mm 5013 mm
Max. digging height (long stick) 5100 mm 5211 mm
Max. dump height 3620 mm 3723 mm
Max. dump height (long stick) 3810 mm 3923 mm
Max. digging radius 5270 mm 5100/5440**
Max. digging radius (long stick) 5546 mm 5296/5796**
Max. reach at ground level 5175 mm 5005/5345 mm
Max. reach at ground level (long stick) 5456 mm 5206/5706**
Max. breakout force at bucket tooth 30.3 kN 30.3 kN
Max. tearout force (standard stick) 20.6 kN 20.6
Max. tearout force (long stick) 16.8 kN 16.8 kN
Min. tail end slewing radius 1400 mm 1400 mm
Max. tail end lateral projection (90 rotation of upper carriage) 590 mm 420/760** mm
Max. boom displacement to bucket centre (right-hand side) 685 mm 855** mm
Max. boom displacement to bucket centre (left-hand side) 415 mm 585** mm

BA 25-3503 EN Edition 2.3 *2503_3503b610.fm 6-7


Specifications

6.11 Dimensions model 3503 VDS

Fig. 226: Machine dimensions (model 3503 VDS)

Main data Model 3503 VDS


Service weight with cab/canopy 3734/3639 kg
Height 2520 mm
Width 1620 mm
Transport length 5170 mm
Max. digging depth 3120 mm
Stick length (standard) 1335 mm
Stick length (long version) 1635 mm
Max. digging depth for long stick (+ 300 mm) 3417 mm
Max. vertical digging depth 2105 mm
Max. vertical digging depth (long stick) 2385 mm
Max. digging height 5020 mm
Max. digging height (long stick) 5220 mm
Max. dump height 3735 mm
Max. dump height (long stick) 3935 mm
Max. digging radius 5270 mm
Max. digging radius (long stick) 5546 mm
Max. reach at ground level 5150 mm
Max. reach at ground level (long stick) 5432 mm
Max. breakout force at bucket tooth 30.4 kN
Max. tearout force (standard stick) 20.6 kN
Max. tearout force (long stick) 16.8 kN
Min. tail end slewing radius 1400 mm
Max. tail end lateral projection (90 rotation of upper carriage) 590 mm
Max. boom displacement to bucket centre (right-hand side) 686 mm
Max. boom displacement to bucket centre (left-hand side) 416 mm
Max. tilt angle for VDS 15

6-8 BA 25-3503 EN Edition 2.3 * *2503_3503b610.fm


Specifications

6.12 Lift capacity table 2503


All table indications in kg and horizontal position on firm ground without bucket.

3.5 m 3.0 m 2.5 m 2.0 m


A
(115) (98) (82) (66)

3.0 m 415* 415* 400* 400*


(98) (915*) (915) (882*) (882*)
2.0 m 410* 350 410* 380 420* 420* 460* 460*
(66) (904*) (772) (904*) (838) (926*) (926*) (1014*) (1014*)
1.0 m 425* 310 460* 365 540* 460 670* 595 1000* 815
(33) (937*) (683) (1014*) (805) (1190*) (1014) (1477*) (1312) (2205*) (1797)
0.0 m 450* 315 505* 355 635* 440 835* 560 1210* 770
(00) (992*) (694) (1113*) (783) (1400*) (970) (1841*) (1235) (2668*) (1698)
-1.0 m 475* 380 580* 435 790* 560 1030* 775
(33) (1047*) (838) (1279*) (959) (1742*) (1235) (2271*) (1709)
-2.0 m 445* 445* 435* 435*
(66) (981*) (981*) (959*) (959*)

max Admissible load on extended stick


A Reach from live ring centre
B Load hook height
* Lift capacity limited by hydraulics

With the stabiliser blade in driving direction

Without the stabiliser blade, 90 to driving direction

Fig. 227: Lift capacity table (model 2503)


If equipped with a bucket or other attachments, lift capacity or tilt load is reduced by bucket
or attachment dead weight.

Calculation basis: according to ISO 10567


The compact excavator's lift capacity is restricted by the settings of the pressure limiting
valves and the hydraulic system's stabilising features.
Neither 75 % of the static tilt load nor 87 % of the hydraulic lift capacity is exceeded.

BA 25-3503 EN Edition 2.3 *2503_3503b610.fm 6-9


Specifications

6.13 Lift capacity table 3503


All table indications in kg and horizontal position on firm ground without bucket.

4.5 m 3.5 m 2.5 m 1.5 m


A
(148) (115) (82) (49)

3.0 m 800* 545 745* 685


(98) (1764*) (1202) (1642*) (1510)
2.0 m 840* 480 870* 660 1110* 1105
(66) (1852*) (1058) (1918*) (1455) (2447*) (2436)
1.0 m 890* 415 900* 1100* 620 1795* 1000
(33) (1962*) (915) (1984*) (2425*) (1367) (3957*) (2205)
0.0 m 955* 420 955* 1300* 595 2130* 930
(00) (2105*) (926) (2105*) (2866*) (1312) (4696*) (2050)
-1.0 m 1045* 475 1310* 590 2100* 950 4200* 2295
(33) (2304*) (1047) (2888*) (1301) (4630*) (2094) (9259*) (5060)
-2.0 m 1150* 675 1700* 975 3300* 2345
(66) (2533*) (1488) (3748*) (2150) (7275*) (5170)

max Admissible load on extended stick


A Reach from live ring centre
B Load hook height
* Lift capacity limited by hydraulics

With the stabiliser blade in driving direction

Without the stabiliser blade, 90 to driving direction

Fig. 228: Lift capacity table (model 3503)


If equipped with a bucket or other attachments, lift capacity or tilt load is reduced by bucket
or attachment dead weight.

Calculation basis: according to ISO 10567


The compact excavator's lift capacity is restricted by the settings of the pressure limiting
valves and the hydraulic system's stabilising features.
Neither 75 % of the static tilt load nor 87 % of the hydraulic lift capacity is exceeded.

6-10 BA 25-3503 EN Edition 2.3 * *2503_3503b610.fm


Specifications

6.14 Lift capacity table 3503 Vario


All table indications in kg and horizontal position on firm ground without bucket.

4.5 m 3.5 m 2.5 m 1.5 m


A
(148) (115) (82) (49)

3.0 m 800* 760 435 745* 745* 545


(98) (1764*) (1676) (959) (1642*) (1642*) (1202)
2.0 m 840* 670 385 870* 870* 530 1110* 1110* 885
(66) (1852*) (1477) (849) (1918*) (1918*) (1168) (2447*) (2447*) (1951)
1.0 m 890* 580 335 900* 600 345 1100* 870 500 1795* 1395 800
(33) (1962*) (1279) (739) (1984*) (1323) (761) (2425*) (1918) (1102) (3957*) (3075) (1764)
0.0 m 955* 590 335 955* 590 335 1300* 835 475 2130* 1330 760
(00) (2105*) (1301) (739) (2105*) (1301) (739) (2866*) (1841) (1047) (4696*) (2932) (1675)
-1.0 m 1045* 670 380 1310* 825 470 2100* 1330 520 4200* 3215 1835
(33) (2304*) (1477) (838) (2888*) (1819) (1036) (4630*) (2932) (1146) (9259*) (7088) (4045)
-2.0 m 1150* 940 540 1700* 1365 780 3300* 3280 1875
(66) (2533*) (2072) (1190) (3748*) (3009) (1720) (7275*) (7231) (4134)

max Admissible load on extended stick


A Reach from live ring centre
B Load hook height
* Lift capacity limited by hydraulics

With the stabiliser blade in driving direction

C Without the stabiliser blade 90 in driving direction


Upper carriage shifted to the rear with Vario option
D Characteristic curve C
Without the stabiliser blade 90 in driving direction
Fig. 229: Lift capacity table (model 3503 Vario) Upper carriage shifted to the front with Vario option
Characteristic curve D
If equipped with a bucket or other attachments, lift capacity or tilt load is reduced by bucket
or attachment dead weight.

Calculation basis: according to ISO 10567


The compact excavator's lift capacity is restricted by the settings of the pressure limiting
valves and the hydraulic system's stabilising features.
Neither 75 % of the static tilt load nor 87 % of the hydraulic lift capacity is exceeded.

BA 25-3503 EN Edition 2.3 *2503_3503b610.fm 6-11


Specifications

6.15 Lift capacity table 3503 VDS


All table indications in kg and horizontal position on firm ground without bucket.

4.5 m 3.5 m 2.5 m 1.5 m


A
(148) (115) (82) (49)

3.0 m 800* 650 750* 550*


(98) (1764*) (1433) (1653*) (1213*)
2.0 m 845* 350 900* 530 1210* 890
(66) (1863*) (772) (1984*) (1168) (2668*) (1962)
1.0 m 900* 340 900* 340 1125* 500 1850* 800
(33) (1984*) (750) (1984*) (750) (2480*) (1102) (4079*) (1764)
0.0 m 955* 340 955* 340 1300* 460 2150* 750
(00) (2105*) (750) (2105*) (750) (2866*) (1014) (4740*) (1653)
-1.0 m 1050* 395 1300* 450 2080* 750 4200* 1855
(33) (2315*) (871) (2866*) (992) (4586*) (1653) (9259*) (4090)
-2.0 m 1150* 575 1650* 790 3150* 1910
(66) (2536*) (1268) (3638*) (1742) (6945*) (4211)

max Admissible load on extended stick


A Reach from live ring centre
B Load hook height
* Lift capacity limited by hydraulics

With the stabiliser blade in driving direction

Without the stabiliser blade, 90 to driving direction

Fig. 230: Lift capacity table (model 3503 VDS)


If equipped with a bucket or other attachments, lift capacity or tilt load is reduced by bucket
or attachment dead weight.

Calculation basis: according to ISO 10567


The compact excavator's lift capacity is restricted by the settings of the pressure limiting
valves and the hydraulic system's stabilising features.
Neither 75 % of the static tilt load nor 87 % of the hydraulic lift capacity is exceeded.

6-12 BA 25-3503 EN Edition 2.3 * *2503_3503b610.fm


Wacker Neuson Linz GmbH keep abreast of the latest technical developments and con-
stantly improve their products. For this reason, we may from time to time need to make
changes to diagrams and descriptions in this documentation which do not reflect products
which have already been delivered and which will not be implemented on these machines.
Technical data, dimensions and weights are given as an indication only. Responsibility for
errors or omissions not accepted.
No reproduction or translation of this publication, in whole or part, without the written con-
sent of Wacker Neuson Linz GmbH.
All rights under the provision of the Copyright Act are reserved.
Wacker Neuson Linz GmbH
Haidfeldstr. 37
A-4060 Linz-Leonding
Austria
Wacker Neuson Linz GmbH
Haidfeldstr. 37
A-4060 Linz-Leonding
Austria
Tel.: +43 (0) 732 90 5 90-0
Fax: +43 (0) 732 90 5 90-200
E-mail: verkauf@wackerneuson.com
www.wackerneuson.com

Order no. 1000188382


Language EN