Wacker Neuson 2503 User manual

Operator's Manual
Track Excavator
2503, 3503
Machine type E03-04/E03-07
Edition 4.1
Order no 1000255984
Language us
1000255984
This Operator's Manual includeS
The AEM PafETyJanual@B*.--6

Legend
Edition Issued
4.1 01/2016
Copyright © 2015 Wacker Neuson Linz GmbH, Hörsching
Printed in Austria
All rights reserved, in particular the global copyright laws, right of reproduction and right of distribution.
No part of this publication may be reproduced,translated or used in any form or byany means – graphic, electronic or
mechanical including photocopying, recording, taping or information storage or retrieval systems – without prior per-
mission in writing from the manufacturer.
No reproduction or translation of this publication, in whole or part, without the written consent of Wacker Neuson
Linz GmbH.
Any violation of the legal provisions, in particular those relating to copyright protection, will lead to both civil and crimi-
nal prosecution.
Wacker Neuson Linz GmbH keep abreast of the latest technical developments and constantly improve their products.
For this reason, we may from time to time need to make changes to figures and descriptions in this documentation
which do not reflect products that have already been delivered and that will not be attached on these machines.
Technical data, dimensions and weights are only given as an indication. Responsibility for errors or omissions not
accepted. Non-metric weights and measurements are approximate. Translation of original Operators´s Manual.
The cover features the machine with possible optional equipment.
Photographs and graphics are symbolic representations and may differ from the actual products.
Wacker Neuson is authorized to reprint the copyright-protected material contained in this publication,
belonging to Perkins Engines Company Ltd.
The Operator's Manual and any amendments to it must beconstantly available at the place of use
of the vehicle. Possible amendments are included at the end of the Operator’s Manual.
Wacker Neuson Linz GmbH
Flughafenstr. 7
A-4063 Hörsching
Tel.: [phone]
E-mail: [email protected]
www.wackerneuson.com
Document: OM 25-3503 us
Order no.: 1000255984
Edition: 4.1
Documentation
Title Language Order no.
Operator’s Manual us 1000255984
Spare parts catalog 2503 de/en/fr 1000179989
3503 1000189534

OM 25-3503 us - Edition 4.1 * Ba2503_3503us4_0IVZ.fm I-1
Table of contents
Table of contents
Introduction 1
Important information on this Operator’s Manual ..................................................... 1-1
Machine overview .................................................................................................... 1-2
Brief description ....................................................................................................... 1-3
Traveling drive ................................................................................................... 1-3
Operating hydraulics .......................................................................................... 1-3
Cooling system .................................................................................................. 1-3
Cabin ................................................................................................................. 1-3
Fields of application, attachments ........................................................................... 1-4
Use: attachment ................................................................................................ 1-4
........................................................................................................................... 1-7
Regulations .............................................................................................................. 1-8
EC Declaration of Conformity 2503 ......................................................................... 1-9
EC Declaration of Conformity 3503 ....................................................................... 1-10
Type labels and component numbers .................................................................... 1-11
Other signs and symbols (up to AG01597) ............................................................ 1-13
Other signs and symbols (from AG01598) ............................................................ 1-17
Overview of safety labels: ................................................................................ 1-17
Symbols ........................................................................................................... 1-18
Safety labels .................................................................................................... 1-22
Fire extinguisher .................................................................................................... 1-27
Safety instructions 2
Safety Symbols Found In This Manual .................................................................... 2-1
Warranty .................................................................................................................. 2-2
Disposal ................................................................................................................... 2-2
Designated Use ....................................................................................................... 2-2
Preparing To Use The Machine ............................................................................... 2-3
Conditions for use .............................................................................................. 2-3
User training and knowledge ............................................................................. 2-3
Preparing for use ............................................................................................... 2-3
Information on visibility ...................................................................................... 2-4
Modifications and spare parts ............................................................................ 2-4
Operator and Technician Qualifications and Basic Responsibilities ........................ 2-4
User/Owner responsibility .................................................................................. 2-4
Repair person qualifications .............................................................................. 2-4
Safety Instructions Regarding Operation ................................................................. 2-5
Preparing for use ............................................................................................... 2-5
Starting and stopping ......................................................................................... 2-5
Work area awareness ........................................................................................ 2-6
Danger zone awareness .................................................................................... 2-6
Operating the machine ...................................................................................... 2-6
Carrying passengers ......................................................................................... 2-6
Mechanical integrity ........................................................................................... 2-7
Traveling ............................................................................................................ 2-7
Operator Protection System .................................................................................... 2-8
TOPS rollbar (up to serial no. AF01416) ........................................................... 2-8
ROPS rollbar ..................................................................................................... 2-8
Traveling without TOPS rollbar (up to serial no. AF01416) ............................... 2-8
Traveling without ROPS rollbar ......................................................................... 2-8
Shatter protection (Option) ................................................................................ 2-9
Work range and restricted visibility .................................................................... 2-9
Applications with Lifting Gear ................................................................................ 2-10
General information ......................................................................................... 2-10
Operation with lowered TOPS rollbar (up to serial no. AI00966) ..................... 2-10
Table of contents
I

I-2 OM 25-3503 us - Edition 4.1 * * Ba2503_3503us4_0IVZ.fm
Table of contents
Operation with lowered ROPS rollbar .............................................................. 2-10
Attachments ........................................................................................................... 2-10
General information regarding attachments .................................................... 2-10
Installation notes .............................................................................................. 2-11
Trailers ................................................................................................................... 2-11
Hammer operation ................................................................................................. 2-12
Safety instructions ........................................................................................... 2-12
Working with a hammer ................................................................................... 2-12
Transport and Towing ............................................................................................ 2-13
Towing ............................................................................................................. 2-13
Transporting ..................................................................................................... 2-13
Safety Guidelines for Maintenance ........................................................................ 2-13
General maintenance notes ............................................................................. 2-13
Personal safety measures ............................................................................... 2-14
Preparing for maintenance and repair work ..................................................... 2-14
Performing maintenance and repairs ............................................................... 2-15
Special Hazards ..................................................................................................... 2-15
Electrical energy .............................................................................................. 2-15
Underground electric lines ............................................................................... 2-16
Overhead electric lines .................................................................................... 2-16
Gas, dust, steam, smoke ................................................................................. 2-17
Safety instructions regarding internal bombustion engines ............................. 2-17
Hydraulics ........................................................................................................ 2-17
Noise ................................................................................................................ 2-18
MSDS .............................................................................................................. 2-18
Tracks .............................................................................................................. 2-18
Battery ............................................................................................................. 2-19
Safety Guidelines while using Internal Combustion Engines ................................. 2-19
Running the engine .......................................................................................... 2-19
Fueling the engine ........................................................................................... 2-19
Dual Power option ........................................................................................... 2-20
Operation 3
Cabin overview ........................................................................................................ 3-4
Instrument panel overview ....................................................................................... 3-7
Putting into operation ............................................................................................... 3-8
Safety instructions ............................................................................................. 3-8
Putting into operation for the first time ............................................................... 3-8
Running-in period .............................................................................................. 3-8
Check lists ......................................................................................................... 3-9
Start-up checklist ............................................................................................... 3-9
Operation checklist .......................................................................................... 3-10
Parking checklist .............................................................................................. 3-10
Driving the excavator ............................................................................................. 3-11
Preheating start switch .................................................................................... 3-11
Throttle ............................................................................................................. 3-11
Automatic engine speed setting ............................................................................. 3-12
Indicator lights and warning lights Tier III (overview) ............................................. 3-12
Display element 3503 Tier IV ................................................................................. 3-14
Meaning of displays and symbols 3503 Tier IV ............................................... 3-16
Multifunctional display (Tier IV only) ................................................................ 3-19
Menu structure of display setting ..................................................................... 3-19
Before starting the engine ...................................................................................... 3-22
Starting the engine ................................................................................................. 3-22

OM 25-3503 us - Edition 4.1 * Ba2503_3503us4_0IVZ.fm I-3
Table of contents
Procedure ........................................................................................................ 3-22
Starting with the immobilizer (option) ..................................................................... 3-23
Starting with the immobilizer – internal transponder (option) ................................. 3-24
Starting at low temperatures .................................................................................. 3-25
When the engine has started ... ............................................................................. 3-25
Jump-starting the engine (supply battery) ............................................................. 3-25
Special instructions for machine travel on public roads ......................................... 3-27
Starting machine travel .......................................................................................... 3-27
Drive levers ............................................................................................................ 3-27
High speed ............................................................................................................. 3-29
Hydraulic brake ...................................................................................................... 3-30
Mechanical brake ................................................................................................... 3-30
Stabilizer blade as a parking brake ................................................................. 3-30
Machine travel on slopes ....................................................................................... 3-30
Stabilizer blade ...................................................................................................... 3-33
Parking the machine .............................................................................................. 3-34
Parking the machine on slopes ....................................................................... 3-35
Light system ........................................................................................................... 3-36
Working lights .................................................................................................. 3-36
Roof lights (option) .......................................................................................... 3-36
Interior light ...................................................................................................... 3-37
Rotating beacon (option) ................................................................................. 3-37
Travel signal (option) ....................................................................................... 3-37
Socket .............................................................................................................. 3-37
Protective structures .............................................................................................. 3-38
Definition of the term “Protective Structure” .................................................... 3-38
Mechanical integrity ......................................................................................... 3-38
Definition of FOPS/Front Guard levels ............................................................ 3-39
Responsibility for machine equipped with protective structures ...................... 3-39
Protective FOPS structure/small screen – category I (option) ......................... 3-40
Protective FOPS structure/canopy – category I (option) ................................. 3-41
Protective Front Guard structure category I (option) ....................................... 3-43
Shatter protection (option) ............................................................................... 3-45
Emergency exits .................................................................................................... 3-47
Emergency exit for cabin equipped with protective Front Guard structure ...... 3-47
Cabin heating and ventilation ................................................................................ 3-48
Summer/winter operation ....................................................................................... 3-48
Washer system ...................................................................................................... 3-49
Washer system reservoir ................................................................................. 3-49
Seat adjustment ..................................................................................................... 3-50
Weight adjustment ........................................................................................... 3-51
Horizontal adjustment ...................................................................................... 3-51
Backrest adjustment ........................................................................................ 3-51
Seat belt ................................................................................................................. 3-52
Front window ......................................................................................................... 3-54
Door ....................................................................................................................... 3-55
Entry and exit ......................................................................................................... 3-57
Safety instructions regarding entry and exit .................................................... 3-57
Engine cover .......................................................................................................... 3-58
Valve compartment cover ...................................................................................... 3-58
Towing the machine ............................................................................................... 3-59
Important information regarding towing ........................................................... 3-59
Crane lifting the machine ....................................................................................... 3-60

I-4 OM 25-3503 us - Edition 4.1 * * Ba2503_3503us4_0IVZ.fm
Table of contents
Important information regarding loading .......................................................... 3-60
Loading and transporting the machine ................................................................... 3-62
Tying down the machine ........................................................................................ 3-63
Removing the cabin/canopy ................................................................................... 3-63
Installing the cabin/canopy ..................................................................................... 3-66
Machine operation ................................................................................................. 3-68
General safety instructions .............................................................................. 3-68
Wacker Neuson Vario (option) ............................................................................... 3-69
Control levers/ISO controls: overview .................................................................... 3-71
Control lever on the left .................................................................................... 3-72
Auxiliary hydraulics .......................................................................................... 3-72
Boom swivel controls ....................................................................................... 3-73
Hammer operation (option) .............................................................................. 3-73
Control lever on the right ................................................................................. 3-76
Lowering the boom with the engine stopped ................................................... 3-76
Changeover valve for SAE/ISO controls (option) ................................................... 3-77
Control lever on the left .................................................................................... 3-77
Control lever on the right ................................................................................. 3-77
Directional valve position ................................................................................. 3-78
Directional valve .............................................................................................. 3-78
Control lever with proportional controls (option): overview .................................... 3-79
Function ........................................................................................................... 3-79
Measures to be taken in case of malfunctions ................................................. 3-80
Diagnosis display ............................................................................................. 3-80
Control lever on the left .................................................................................... 3-81
Auxiliary hydraulics (proportionally controlled) ................................................ 3-81
Boom swivel controls (proportionally controlled) ............................................. 3-81
Hammer operation (proportionally controlled) ................................................. 3-82
Adjusting control response .............................................................................. 3-82
Characteristic curve status indicator ................................................................ 3-82
Lowering the boom with the engine stopped ................................................... 3-83
Rotating the upper carriage ................................................................................... 3-84
Swivel unit brake .............................................................................................. 3-84
Functional check of swivel unit brake .............................................................. 3-85
Tilting the upper carriage (option 3503) ................................................................. 3-87
Operation (up to serial no. AG02694) .............................................................. 3-87
Operation (from serial no. AG02695) ............................................................... 3-88
Releasing the pressure on the operating hydraulics .............................................. 3-88
Releasing pressure .......................................................................................... 3-88
Pressure release with proportional controls (option) ....................................... 3-88
Re-equipping attachments ..................................................................................... 3-89
Specific safety instructions .............................................................................. 3-89
Removing a bucket .......................................................................................... 3-90
Installing a bucket ............................................................................................ 3-90
Mechanical quickhitch (option) ............................................................................... 3-91
Hydraulic quickhitch (option) .................................................................................. 3-92
Picking up an attachment ................................................................................ 3-93
Setting down an attachment ............................................................................ 3-95
Powertilt (option 3503) ........................................................................................... 3-97
Re-equipping ................................................................................................... 3-98
Installing the Powertilt unit ............................................................................... 3-98
Removing the Powertilt unit ............................................................................. 3-98
Connection ....................................................................................................... 3-99
Operation ....................................................................................................... 3-100
Control lever on the left (Powertilt) ................................................................ 3-100

OM 25-3503 us - Edition 4.1 * Ba2503_3503us4_0IVZ.fm I-5
Table of contents
Control lever on the right (if equipped with auxiliary hydraulics and proportional
controls) ......................................................................................................... 3-100
Connections for auxiliary hydraulics .................................................................... 3-100
Grab operation ..................................................................................................... 3-101
Safe load indicator (option) .................................................................................. 3-102
Safety feature “Hose burst valve” (option) ..................................................... 3-102
Working with the excavator .................................................................................. 3-103
Inadmissible work procedures ....................................................................... 3-103
Excavator work position ................................................................................. 3-105
Bucket position when digging ........................................................................ 3-105
Excavating trenches ...................................................................................... 3-106
Loading .......................................................................................................... 3-106
Grading .......................................................................................................... 3-106
Excavating trenches sideways ...................................................................... 3-106
Working alongside trenches .......................................................................... 3-107
Stabilizer blade at rear ................................................................................... 3-107
Further recommendations for digging ............................................................ 3-108
Loading vehicles ............................................................................................ 3-108
Freeing the machine ...................................................................................... 3-108
Grading ................................................................................................................ 3-109
Grading .......................................................................................................... 3-109
Exhaust gas treatment (Tier IV) ........................................................................... 3-109
Indication of load ........................................................................................... 3-111
Particulate matter catalyst indicator lights ..................................................... 3-111
Regeneration push button ............................................................................. 3-112
Automatic regeneration mode ....................................................................... 3-113
Manual regeneration ...................................................................................... 3-114
Malfunctions 4
Hydraulics .......................................................................................................... 4-2
Malfunctions of the Powertilt unit ............................................................................. 4-3
Engine warning lights (Tier IV only) ......................................................................... 4-4
Engine and engine oil warning lights (Tier IV only) .................................................. 4-4
Malfunctions (display element/multifunctional display – Tier IV only) ...................... 4-5
Engine error messages ..................................................................................... 4-6
Maintenance 5
Introduction .............................................................................................................. 5-1
Safety-relevant parts ................................................................................................ 5-1
Fuel system ............................................................................................................. 5-2
Refueling ........................................................................................................... 5-2
Stationary fuel pumps ........................................................................................ 5-2
Draining fuel ...................................................................................................... 5-3
Diesel fuel specification ..................................................................................... 5-3
Bleeding the fuel system ................................................................................... 5-4
Water separator ................................................................................................. 5-4
Engine lubrication system ........................................................................................ 5-5
Checking the oil level ......................................................................................... 5-5
Adding engine oil ............................................................................................... 5-6
Engine and hydraulics cooling system ..................................................................... 5-7
Specific safety instructions ................................................................................ 5-7
Checking the coolant level/adding coolant .............................................................. 5-8
Checking the coolant level ................................................................................. 5-9
Adding coolant ................................................................................................. 5-10
Draining coolant ............................................................................................... 5-10
Air filter ................................................................................................................... 5-11

I-6 OM 25-3503 us - Edition 4.1 * * Ba2503_3503us4_0IVZ.fm
Table of contents
Replacing the filter ........................................................................................... 5-12
V-belt ...................................................................................................................... 5-14
Hydraulic system .................................................................................................... 5-14
Specific safety instructions .............................................................................. 5-14
Checking the hydraulic oil level ....................................................................... 5-15
Adding hydraulic oil .......................................................................................... 5-16
Important information on the use of biodegradable oil ..................................... 5-17
Checking hydraulic pressure lines ................................................................... 5-18
Tracks .................................................................................................................... 5-19
Checking track tension .................................................................................... 5-19
Setting the tracks ............................................................................................. 5-20
Maintenance of joint rod (lifting eye) and load hook ........................................ 5-21
Traveling drive ....................................................................................................... 5-22
Electrical system .................................................................................................... 5-22
Specific safety instructions .............................................................................. 5-22
Servicing and maintenance at regular intervals ............................................... 5-22
Instructions concerning specific components .................................................. 5-23
Alternator ......................................................................................................... 5-23
Battery ............................................................................................................. 5-24
General maintenance ............................................................................................. 5-25
Cleaning ........................................................................................................... 5-25
General instructions for all areas of the machine ............................................ 5-25
Inside the cabin ................................................................................................ 5-26
Cleaning the seat belt ...................................................................................... 5-26
Exterior of the machine .................................................................................... 5-26
Engine compartment ........................................................................................ 5-26
Threaded fittings and attachments .................................................................. 5-27
Pivots and hinges ............................................................................................ 5-27
Lubrication points ................................................................................................... 5-27
Lubrication points on slewing cylinder/ball bearing race of live ring ................ 5-28
Lubrication points on the stabilizer blade ......................................................... 5-29
Additional lubrication points on slewing stabilizer blade (option 3503) ............ 5-29
Lubricating the teeth of the live ring ................................................................. 5-29
Lubricating the teeth of the live ring VDS ........................................................ 5-30
VDS lubrication points (option) ........................................................................ 5-31
Powertilt (option 3503) ..................................................................................... 5-32
Lubrication points of hydraulic quickhitch (option) ........................................... 5-32
Maintenance when out of service for a longer period of time ................................ 5-33
Preparatory work before taking out of service ................................................. 5-33
Permanently putting out of operation ............................................................... 5-33
Putting into operation again ............................................................................. 5-34
Fluids and lubricants .............................................................................................. 5-35
Additional oil change and filter replacement (hydraulic system) ...................... 5-36
Maintenance plan (overview) ................................................................................. 5-38
Maintenance overview ........................................................................................... 5-43
Maintenance plan (Tier IV) .............................................................................. 5-43
Technical datac 6
Model 2503 .............................................................................................................. 6-1
Engine ................................................................................................................ 6-1
Hydraulic system ............................................................................................... 6-1
Stabilizer blade .................................................................................................. 6-1
Operating hydraulics .......................................................................................... 6-1
Tracks ................................................................................................................ 6-2
Model 3503 .............................................................................................................. 6-2
American Tier III engine ..................................................................................... 6-2
American Tier IV engine .................................................................................... 6-2

OM 25-3503 us - Edition 4.1 * Ba2503_3503us4_0IVZ.fm I-7
Table of contents
Hydraulic system ............................................................................................... 6-3
Stabilizer blade .................................................................................................. 6-3
Operating hydraulics .......................................................................................... 6-3
Tracks ................................................................................................................ 6-3
Model 3503 VDS ...................................................................................................... 6-4
Engine Tier III (option) ....................................................................................... 6-4
Engine Tier IV (option) ....................................................................................... 6-4
Hydraulic system ............................................................................................... 6-4
Stabilizer blade .................................................................................................. 6-5
Operating hydraulics .......................................................................................... 6-5
Tracks ................................................................................................................ 6-5
Operating range (2503/3503/3503 VDS) ........................................................... 6-5
Rotation speed of upper carriage (2503/3503/3503 VDS) ................................ 6-5
Electrical system ...................................................................................................... 6-6
Fuse box in cabin .............................................................................................. 6-6
Noise levels ............................................................................................................. 6-6
Vibration ................................................................................................................... 6-7
Coolant compound table .......................................................................................... 6-9
Powertilt (option 3503) ........................................................................................... 6-10
Weights .................................................................................................................. 6-10
Dimensions model 2503 ........................................................................................ 6-11
Dimensions model 3503 ........................................................................................ 6-12
Dimensions model 3503 VDS ................................................................................ 6-13
Lift capacity table 2503 .......................................................................................... 6-14
Lift capacity table 3503 .......................................................................................... 6-15
Lift capacity table 3503 Vario ................................................................................. 6-16
Lift capacity table 3503 VDS .................................................................................. 6-17
Safety instructions stability tables .................................................................... 6-18

I-8 OM 25-3503 us - Edition 4.1 * * Ba2503_3503us4_0SIX.fm
Index
A
Abbreviations .........................................................................................1-1
Air filter ................................................................................................5-11
Air filter monitoring ...............................................................................3-15
B
Biodegradable oil .................................................................................5-17
C
Charge indicator light ...........................................................................3-15
Check lists .............................................................................................3-9
Crane-lifting the machine .....................................................................3-60
D
Designated use and exemption from liability .........................................2-2
Diesel particulate filter .......................................................................3-109
Automatic regeneration ...............................................................3-113
Indication of load .........................................................................3-111
Indicator lights .............................................................................3-111
Load condition ............................................................................3-110
Manual regeneration ...................................................................3-114
Driving on public roads ........................................................................3-27
Driving the excavator ...........................................................................3-11
E
Engine oil pressure ..............................................................................3-15
Exhaust gas treatment .......................................................................3-109
F
Fire extinguisher ..................................................................................1-27
Fluids and lubricants ............................................................................5-35
H
Heating ................................................................................................3-48
Hose burst valve (option) ...................................................................3-102
Hydraulic oil filter monitoring ...............................................................3-15
Hydraulic quickhitch .............................................................................3-92
I
Important information
On this Operator’s Manual ..............................................................1-1
Indicator lights and warning lights .......................................................3-12
Instrument panel overview .....................................................................3-7
Interior light ..........................................................................................3-37
L
Legal regulations ...................................................................................1-8
Light system ........................................................................................3-36
Lowering the boom with the engine stopped ............................. 3-76, 3-83
M
Machine
Brief description ............................................................................. 1-3
Fields of application ....................................................................... 1-4
Loading and transporting ............................................................. 3-62
Overview ........................................................................................ 1-2
Maintenance
Adding coolant ............................................................................... 5-8
Adding engine oil ............................................................................ 5-6
Adding hydraulic oil ...................................................................... 5-16
Air filter ......................................................................................... 5-12
Biodegradable oil ......................................................................... 5-17
Bleeding the fuel system ................................................................ 5-4
Checking the coolant level ............................................................. 5-8
Checking the engine oil level ......................................................... 5-5
Checking the hydraulic oil level .................................................... 5-15
Cleaning ....................................................................................... 5-25
Electrical system .......................................................................... 5-22
Engine and hydraulics cooling system ........................................... 5-7
Engine lubrication system .............................................................. 5-5
Fluids and lubricants .................................................................... 5-35
Fuel system .................................................................................... 5-2
General maintenance ................................................................... 5-25
Hydraulic pressure lines ............................................................... 5-18
Hydraulic system .......................................................................... 5-14
Instructions concerning specific components ............................... 5-23
Maintenance plan ......................................................................... 5-38
Pivots and hinges ......................................................................... 5-27
Servicing and maintenance at regular intervals ........................... 5-22
Threaded fittings .......................................................................... 5-27
Track maintenance ..............................................................5-19, 5-43
V-belt ............................................................................................ 5-14
Maintenance plan ................................................................................ 5-43
Maintenance when out of service for a longer period of time .............. 5-33
N
Noise levels ................................................................................1-13, 1-18
O
Operation .............................................................................................. 3-1
Before starting the engine ............................................................ 3-22
Cabin overview ............................................................................... 3-4
Hammer operation ....................................................................... 3-82
Instrument panel overview ............................................................. 3-7
Parking the machine .................................................................... 3-34
Seat belt height adjustment .......................................................... 3-52
Starting machine travel ................................................................ 3-27
Starting the engine ....................................................................... 3-22
Vario (option) ................................................................................ 3-69
Operation with lowered ROPS rollbar ................................................. 2-10
Operation with lowered TOPS rollbar (up to serial no. AI00966) ........ 2-10
Index
I

OM 25-3503 us - Edition 4.1 * Ba2503_3503us4_0SIX.fm I-9
Index
P
Particulate matter catalyst .................................................................3-109
Powertilt
Maintenance ..................................................................... 3-99, 3-100
Operation ....................................................................................3-100
Preheating ...........................................................................................3-15
Preheating start switch ........................................................................3-11
Preparing for maintenance and repair work .........................................2-14
Putting into operation .............................................................................3-3
Check lists ......................................................................................3-9
Putting into operation for the first time ............................................3-8
Safety instructions ..........................................................................3-8
R
Refueling ................................................................................................5-2
Rotating beacon ...................................................................................3-37
Running-in period ..................................................................................3-8
S
Safe load indicator .............................................................................3-102
Safety instructions .................................................................................2-1
General conduct .............................................................................2-3
Identification ....................................................................................2-1
Seat adjustment ...................................................................................3-50
Backrest adjustment .....................................................................3-51
Horizontal adjustment ...................................................................3-51
Weight adjustment ........................................................................3-51
Seat belt ...............................................................................................3-52
Seat belt height adjustment .................................................................3-52
Shatter protection ..................................................................................2-9
Signs and symbols ...............................................................................1-13
Starting aid ...........................................................................................3-25
T
Technical data .......................................................................................6-1
Coolant compound table .................................................................6-9
Dimensions ................................................................6-11, 6-12, 6-13
Electrical system .............................................................................6-6
Engine ..............................................................................6-1, 6-2, 6-4
Noise levels ....................................................................................6-6
Operating hydraulics ............................................................... 6-3, 6-5
Vibration ..........................................................................................6-7
Tilting the upper carriage .....................................................................3-87
Track maintenance ..............................................................................5-19
V
Ventilation ............................................................................................3-48
Ventilation, fresh air ......................................................................3-48
W
Warranty ................................................................................................2-2
Washer system ....................................................................................3-49
Reservoir ......................................................................................3-49
Working
Freeing the machine ...................................................................3-108
Recommendations ......................................................................3-108

I-10 OM 25-3503 us - Edition 4.1 * * Ba2503_3503us4_0SIX.fm
Index

OM 25-3503 us – Edition 4.1 * 2503_3503b110.fm 1-1
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 personnel, but it
also serves as a reference for experienced personnel. It helps to avoid hazardous situa-
tions and reduce repair costs and downtimes. Furthermore, the reliability and the service
life of the machine will beincreased by following the instructions inthe 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 familiarize 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
preparedforpossible hazardoussituations,asitwill betoolate foritduring operation.As a
rule, keep the following in mind:
Careful and prudent working is the best way to avoid accidents!
Operationalsafety and readinessof the machinedo notonly depend onyour skill,but also
on maintenance and servicing of the machine. This is why regular maintenance and ser-
vicing is absolutely necessary. Extensive maintenance and repair work must always be
performed by a technician with appropriate training. Insist on using original spare parts
when performing maintenance and repair work. This ensures operational safety and readi-
ness 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
authorization, 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
• Identifies a list
•Subdivision within lists or an activity. Follow the steps in the recommended
order
☞Identifies an activity
➥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.
PMC = particulate matter catalyst

1-2 OM 25-3503 us – Edition 4.1 * * 2503_3503b110.fm
Introduction
1.2 Machine overview
1 Boom light
2 Boom
3Stick
4 Rubber tracks
5 Travel gear
6 Stabilizer blade
7 Cabin
8 Valve cover
9 Handhold
Fig. 1: Machine outside views
6
9
14
13
13
15
8
7
1
14
13 Exhaust pipe
14 Lifting eye/tie-down point
15 Lubrication point for track tension
16 Engine cover
2
3
4
5
5
7
16

OM 25-3503 us – Edition 4.1 * 2503_3503b110.fm 1-3
Introduction
1.3 Brief description
Observe the legal regulations of your country.
Themachinecan beequipped withabackhoe bucket,shovel bucketorgrab forloosening,
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
• Stabilizer 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 cabin (closed version) – option
•FOPS (Falling Object Protective Structure) – option
• Water-cooled diesel engine
• Hydraulic and electrical components
•Boom
Information!
The machine can be equipped with the “Telematic” option (for transmitting
operating data, location, etc. via satellite)!
Traveling drive
Thediesel engine permanentlydrives thetwin axialvariable displacementpump whoseoil
flow is sent to a hydraulic motor.
Operating hydraulics
The diesel engine also drives the joint gear pump for the operating hydraulics. The oil flow
of this pump depends on the diesel engine speed only.
Cooling system
The coolant temperature is monitored with the indicator light on the machine’s instrument
panel.
Cabin
Modifyingorperforming improperrepairworkon thecabinis dangerous.Donot modifythe
cabin. Repair work may only be performed by a Wacker Neuson service center. If the
cabinhasbeen damaged,checkit beforeresumingwork andhaveit repairedifnecessary.
Pleasecontactyour WackerNeusondealerforsupport. Failuretofollow thisprecautionary
measurecanlead toserious orfatal injury.The cabinhasbeen speciallydesigned foryour
protection in case of an accident.
Fasten your seatbelt, otherwise you can be thrown around or even outside the cabin and
crushed. Therefore always fasten your seat belt as you perform machine traveland opera-
tion. Tighten the seatbelt before starting machine operation.

1-4 OM 25-3503 us – Edition 4.1 * * 2503_3503b110.fm
Introduction
1.4 Fields of application, attachments
The attachments will decide in the first place how the excavator is used.
NOTICE
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 attachments other than Caterpillar, or using attachments that are to be used with
other excavator types, can reduce the machine’s output and stability considerably and
cause damage to the machine and injury.
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.
Information!
Please refer to the Operator’s and maintenance manual of the attachment
manufacturer for using and performing maintenance on attachments such as
hammers, grabs, etc.
Use: attachment
2503 without quickhitch
Bucket type Width Capacity Weight
Bucket 260 mm (10 in) 0.036 m3(1.27 ft3)38 kg (84 lbs)
Bucket 300 mm (12 in) 0.043 m3 (1.52 ft3)41 kg (90 lbs)
Bucket 400 mm (16 in) 0.059 m3 (2.08 ft3)48 kg (106 lbs)
Bucket 500 mm (20 in) 0.075 m3 (2.65 ft3)55 kg (121 lbs)
Bucket 600 mm (24 in) 0.091 m3 (3.21 ft3)63 kg (139 lbs)
Bucket 700 mm (28 in) 0.107 m3 (3.78 ft3)71 kg (157 lbs)
Ditch cleaning bucket 850 mm (33 in) 0.069 m3 (2.44 ft3)66 kg (146 lbs)
Ditch cleaning bucket 1000 mm (39 in) 0.082 m3 (2.90 ft3)66 kg (146 lbs)
Ditch cleaning bucket 1200 mm (47 in) 0.098 m3 (3.46 ft3)75 kg (165 lbs)
Offset bucket 850 mm (33 in) 0.073 m3 (2.58 ft3)92 kg (203 lbs)
Offset bucket 1000 mm (39 in) 0.087 m3 (3.07 ft3)94 kg (207 lbs)

OM 25-3503 us – Edition 4.1 * 2503_3503b110.fm 1-5
Introduction
2503 with mechanical Neuson quickhitch
Bucket type Width Capacity Weight
Bucket 260 mm (10 in) 0.036 m3 (1.27 ft3)38 kg (84 lbs)
Bucket 300 mm (12 in) 0.043 m3 (1.52 ft3)44 kg (97 lbs)
Bucket 400 mm (16 in) 0.059 m3 (2.08 ft3)52 kg (115 lbs)
Bucket 500 mm (20 in) 0.075 m3 (2.65 ft3)58 kg (128 lbs)
Bucket 600 mm (24 in) 0.091 m3 (3.21 ft3)67 kg (148 lbs)
Bucket 700 mm (28 in) 0.107 m3 (3.78 ft3)75 kg (165 lbs)
Ditch cleaning bucket 850 mm (33 in) 0.069 m3 (2.44 ft3)65 kg (143 lbs)
Ditch cleaning bucket 1000 mm (39 in) 0.080 m3 (2.83 ft3)74 kg (163 lbs)
Ditch cleaning bucket 1200 mm (47 in) 0.095 m3 (3.35 ft3)88 kg (194 lbs)
Offset bucket 850 mm (33 in) 0.073 m3 (2.58 ft3)110 kg (243 lbs)
Offset bucket 1000 mm (39 in) 0.087 m3 (3.07 ft3)121 kg (267 lbs)
2503 with hydraulic Easy Lock quickhitch
Bucket type Width Capacity Weight
Bucket 300 mm (12 in) 0.042 m3 (1.48 ft3)43 kg (95 lbs)
Bucket 400 mm (16 in) 0.056 m3 (1.98 ft3)50 kg (110 lbs)
Bucket 500 mm (20 in) 0.070 m3 (2.47 ft3)60 kg (132 lbs)
Bucket 600 mm (24 in) 0.084 m3 (2.97 ft3)67 kg (148 lbs)
Ditch cleaning bucket 850 mm (33 in) 0.065 m3 (2.30 ft3)63 kg (139 lbs)
Ditch cleaning bucket 1000 mm (39 in) 0.078 m3 (2.75 ft3)72 kg (159 lbs)
Ditch cleaning bucket 1200 mm (47 in) 0.094 m3 (3.32 ft3)84 kg (185 lbs)
Offset bucket 850 mm (33 in) 0.062 m3 (2.19 ft3)103 kg (227 lbs)
Offset bucket 1000 mm (39 in) 0.073 m3 (2.58 ft3)110 kg (243 lbs)
Offset bucket 1200 mm (47 in) 0.088 m3 (3.11 ft3)121 kg (267 lbs)

1-6 OM 25-3503 us – Edition 4.1 * * 2503_3503b110.fm
Introduction
3503 without quickhitch
Bucket type Width Capacity Weight
Bucket 300 mm (12 in) 0.050 m3 (1.77 ft3)46 kg (101 lbs)
Bucket 400 mm (16 in) 0.069 m3 (2.44 ft3)54 kg (119 lbs)
Bucket 500 mm (20 in) 0.088 m3 (3.11 ft3)62 kg (137 lbs)
Bucket 600 mm (24 in) 0.107 m3 (3.78 ft3)82 kg (181 lbs)
Bucket 700 mm (28 in) 0.127 m3 (4.48 ft3)90 kg (198 lbs)
Ditch cleaning bucket 1000 mm (39 in) 0.117 m3 (4.13 ft3)87 kg (192 lbs)
Ditch cleaning bucket 1400 mm (55 in) 0.166 m3 (5.86 ft3)130 kg (287 lbs)
Offset bucket 1000 mm (39 in) 0.111 m3 (3.92 ft3)107 kg (236 lbs)
Offset bucket 1400 mm (55 in) 0.158 m3 (5.58 ft3)147 kg (324 lbs)
3503 with mechanical Neuson quickhitch
Bucket type Width Capacity Weight
Bucket 300 mm (12 in) 0.050 m3 (1.77 ft3)64 kg (141 lbs)
Bucket 400 mm (16 in) 0.069 m3 (2.44 ft3)72 kg (159 lbs)
Bucket 500 mm (20 in) 0.088 m3 (3.11 ft3)82 kg (181 lbs)
Bucket 600 mm (24 in) 0.107 m3 (3.78 ft3)90 kg (198 lbs)
Bucket 700 mm (28 in) 0.127 m3 (4.48 ft3)99 kg (218 lbs)
Ditch cleaning bucket 1000 mm (39 in) 0.116 m3 (4.10 ft3)102 kg (225 lbs)
Ditch cleaning bucket 1400 mm (55 in) 0.164 m3 (5.79 ft3)130 kg (287 lbs)
Offset bucket 1000 mm (39 in) 0.111 m3 (3.92 ft3)142 kg (313 lbs)
Offset bucket 1400 mm (55 in) 0.158 m3 (5.58 ft3)155 kg (342 lbs)

OM 25-3503 us – Edition 4.1 * 2503_3503b110.fm 1-7
Introduction
3503 with hydraulic Easy Lock quickhitch
Bucket type Width (in) Capacity Weight
Bucket 300 mm (12 in) 0.063 m3 (2.22 ft3)56 kg (123 lbs)
Bucket 400 mm (16 in) 0.083 m3 (2.93 ft3)64 kg (141 lbs)
Bucket 500 mm (20 in) 0.102 m3 (3.60 ft3)75 kg (165 lbs)
Bucket 600 mm (24 in) 0.120 m3 (4.24 ft3)85 kg (187 lbs)
Bucket 700 mm (28 in) 0.141 m3 (4.98 ft3)92 kg (203 lbs)
Bucket 800 mm (31 in) 0.160 m3 (5.65 ft3)103 kg (227 lbs)
Ditch cleaning bucket 1000 mm (39 in) 0.113 m3 (4.00 ft3)92 kg (203 lbs)
Ditch cleaning bucket 1200 mm (47 in) 0.135 m3 (4.77 ft3)106 kg (234 lbs)
Ditch cleaning bucket 1400 mm (55 in) 0.158 m3 (5.58 ft3)121 kg (267 lbs)
Offset bucket 1200 mm (47 in) 0.129 m3 (4.56 ft3)142 kg (313 lbs)
Offset bucket 1400 mm (55 in) 0.150 m3 (5.30 ft3)153 kg (337 lbs)
Equipment
Attachments Machine Weight
Mechanical Neuson quickhitch console 2503 14 kg (31 lbs)
Mechanical Neuson quickhitch console 3503 27 kg (60 lbs)
Hydraulic Easy Lock quickhitch console (HS 02) 2503 19 kg (42 lbs)
Hydraulic Easy Lock quickhitch console (HS 03) 3503 34 kg (75 lbs)
Hammer bracket HS 02/NE 16 2503 14 kg (31 lbs)
Hammer bracket HS 03/NE 16 3503 27 kg (60 lbs)
Hammer bracket HS 03/NE 22 3503 30 kg (66 lbs)
Hammer NE 16 2503/3503 150 kg (331 lbs.)
Hammer NE 22 3503 220 kg (485 lbs)
Easy Lock quickhitch console with Powertilt 3503 104 kg (229 lbs)

1-8 OM 25-3503 us – Edition 4.1 * * 2503_3503b110.fm
Introduction
1.5 Regulations
Requirements to be met by the operator
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 perform work reliably.
They have been appointed by the contractor for driving and servicing the earth moving
machine.
Observe the legal regulations of your country.
Warranty
Warrantyclaims can bemade onlyif the conditionsof warrantyhave beenobserved. 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, Hörsching (Austria). Further-
more, the instructions in this Operator’s Manual must be observed.