Wacker Neuson 9503 Manuel utilisateur

Operator’s Manual

Mobile Excavator

Notice d’Emploi

Pelle sur pneumatiques

5200009046 30 1012

EN / FR

5200009046

1000270930

1000172100

30

21

0811

2012

Mobile Excavator

9503

OPERATOR'S MANUAL

1000270930 3.0

0811

www.wackerneuson.com

1000270930

Documentation

Description Order no.

Operator's Manual 1000270930

Spare parts catalogue DE/EN/FR

DE/IT/ES

1000172540

1000172541

Legend

Edition Issued

3.0 08 / 2011

Copyright – 2011 Wacker Neuson Linz GmbH, Linz-Leonding

Printed in Michigan U.S.A

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.

Translation of original Operators Manual.

Non-metric weights and measurements are approximate.

The cover features the machine with possible optional equipment.

Wacker Neuson Linz GmbH

Haidfeldstr. 37

A-4060 Linz-Leonding

Document: BA 9503 US

Order no.: 1000270930

Edition: 3.0

BA 9503 US - Edition 3.0 *Ba9503en2_1IVZ.fm I-1

Table of contents

Introduction

Important Operator Information .................................................................................. 1-1

Abbreviations/symbols ......................................................................................... 1-2

Machine Overview ...................................................................................................... 1-3

Brief description ......................................................................................................... 1-4

Travelling drive ..................................................................................................... 1-5

Operating hydraulics ............................................................................................ 1-5

Cooling system .................................................................................................... 1-5

Cab (ROPS and FOPS) ....................................................................................... 1-5

Fields Of Application of Attachments ......................................................................... 1-5

Use: Attachment .................................................................................................. 1-6

Regulations ................................................................................................................ 1-7

Declaration of conformity version 9503-2 ................................................................... 1-8

Type labels and component numbers ........................................................................ 1-9

Overview of adhesive labels .............................................................................. 1-12

Symbols ................................................................................................................... 1-13

Overview of safety labels ................................................................................... 1-17

Safety Labels ........................................................................................................... 1-18

Mark on front stabilizer blade (option) ...................................................................... 1-22

Fire extinguisher ....................................................................................................... 1-23

Safety Information

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 ......................................................................................... 2-3

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 ................................................................... 2-4

Preparing for use ................................................................................................. 2-4

Starting and stopping ........................................................................................... 2-5

Work area awareness .......................................................................................... 2-5

Danger area awareness ....................................................................................... 2-5

Operating the machine ......................................................................................... 2-5

Carrying passengers ............................................................................................ 2-6

Mechanical integrity ............................................................................................. 2-6

Traveling .............................................................................................................. 2-6

Special Instructions for Traveling on Public Roads .................................................... 2-7

Operator Protection System ....................................................................................... 2-7

Applications with Lifting Gear ..................................................................................... 2-8

General information ............................................................................................. 2-8

Conditions for safe operation ............................................................................... 2-8

Attachments ............................................................................................................... 2-9

General information regarding attachments ......................................................... 2-9

Installation notes .................................................................................................. 2-9

Trailers ..................................................................................................................... 2-10

Hammer operation ................................................................................................... 2-10

Safety instructions .............................................................................................. 2-10

Table of contents

I-2 BA 9503 US - Edition 3.0 * *Ba9503en2_1IVZ.fm

Table of contents

Working with a hammer ..................................................................................... 2-10

Transport and Towing .............................................................................................. 2-11

Towing ................................................................................................................ 2-11

Transporting ....................................................................................................... 2-11

Safety Guidelines for Maintenance .......................................................................... 2-12

General maintenance notes ............................................................................... 2-12

Personal safety measures .................................................................................. 2-12

Preparing for maintenance and repair work ....................................................... 2-12

Performing maintenance and repairs ................................................................. 2-13

Special Hazards ....................................................................................................... 2-14

Electrical energy ................................................................................................. 2-14

Underground electric lines ................................................................................. 2-14

Overhead electric lines ....................................................................................... 2-15

Gas, dust, steam, smoke ................................................................................... 2-15

Hydraulics .......................................................................................................... 2-15

Noise .................................................................................................................. 2-16

MSDS ................................................................................................................. 2-16

Using the quickhitches in water .......................................................................... 2-16

Battery ................................................................................................................ 2-16

Battery (from serial number AH01647 up to AH02436) ..................................... 2-16

Tires ................................................................................................................... 2-17

Safety Guidelines while using Internal Combustion Engines ................................... 2-18

Running the engine ............................................................................................ 2-18

Fueling the engine .............................................................................................. 2-18

Operation

Cab overview (up to serial no. AH 02757) .................................................................. 3-2

Cab overview (from serial no. AJ 02775) ................................................................... 3-4

Instrument panel overview (up to serial no. AH 02757) .............................................. 3-6

Instrument panel overview (from serial no. AJ 02775) ............................................... 3-8

Operating the Excavator ........................................................................................... 3-11

Safety instructions .............................................................................................. 3-11

Putting the machine into operation for the first time ........................................... 3-11

Running-in period ............................................................................................... 3-11

Checklists ........................................................................................................... 3-12

Starting checklist ................................................................................................ 3-12

Operation checklist ............................................................................................. 3-13

Parking checklist ................................................................................................ 3-13

Indicator lights and warning lights Overview ........................................................... 3-14

Before starting the engine ........................................................................................ 3-17

Starting the engine (general information) ................................................................. 3-17

Throttle ............................................................................................................... 3-18

Starting with the drive interlock (option) (up to serial no. AH 02757) ....................... 3-19

Starting with the drive interlock – internal transponder (option) (from serial no. AJ 02775)

3-20

Starting at low temperatures .................................................................................... 3-21

When the engine has started ................................................................................... 3-21

Engine warm-up ....................................................................................................... 3-21

Jump-starting the engine (supply battery) ................................................................ 3-22

Hydraulic brake ........................................................................................................ 3-23

Hydraulic brake effect when moving in work position (with hydraulic operation) 3-23

Hydraulic brake effect when traveling on roads (with accelerator pedal) ........... 3-23

Service brake ........................................................................................................... 3-23

Lock the service brake ....................................................................................... 3-23

BA 9503 US - Edition 3.0 *Ba9503en2_1IVZ.fm I-3

Table of contents

Release lever ........................................................................................................... 3-24

Parking brake ........................................................................................................... 3-25

Safety-critical function: work position/road travel ..................................................... 3-25

4 wheel steering ................................................................................................. 3-25

Steering direction ............................................................................................... 3-25

Oscillating axle interlock .................................................................................... 3-26

1st/2nd speed switch ......................................................................................... 3-26

Service brake ..................................................................................................... 3-26

Stabilizer legs ..................................................................................................... 3-26

Front stabilizer blade (option) ............................................................................ 3-26

Work position/road travel switch ........................................................................ 3-26

Operating hydraulically in work position ................................................................... 3-26

Drive lever .......................................................................................................... 3-27

Travel pedal ....................................................................................................... 3-27

Preparing for Changing Over to Road Travel ........................................................... 3-28

Operating on Roads ................................................................................................. 3-29

Travel lever ........................................................................................................ 3-29

Accelerator pedal ............................................................................................... 3-30

Travel direction Changeover (option) ....................................................................... 3-30

Steering modes ........................................................................................................ 3-31

Changing the steering mode (option) ....................................................................... 3-32

Front wheel steering .......................................................................................... 3-32

Crab steering (option) ........................................................................................ 3-33

Four wheel steering (option) .............................................................................. 3-33

Steering direction changeover ................................................................................. 3-33

Adjusting the steering column .................................................................................. 3-34

2nd speed ................................................................................................................ 3-35

Locking the oscillating axle ...................................................................................... 3-36

Automatic engine speed setting ............................................................................... 3-36

Operating on Slopes ................................................................................................ 3-37

Specific safety instructions ................................................................................. 3-37

Operating on slopes ........................................................................................... 3-38

Front stabilizer legs (option) ..................................................................................... 3-39

Rear stabilizer legs ................................................................................................... 3-41

Stabilizer blade (option) ........................................................................................... 3-43

Front stabilizer blade (option) ............................................................................ 3-44

Parking the machine ................................................................................................ 3-45

Parking the machine on slopes .......................................................................... 3-46

Control elements ...................................................................................................... 3-46

Working light ...................................................................................................... 3-46

Roof lights (option) ............................................................................................. 3-47

Light system ....................................................................................................... 3-48

Multifunctional lever ........................................................................................... 3-48

Hazard warning system ..................................................................................... 3-49

Interior light ........................................................................................................ 3-49

Rotating beacon (option) .................................................................................... 3-49

Cab heating and ventilation ............................................................................... 3-50

Heating adjustment ............................................................................................ 3-51

Air conditioning (option) ..................................................................................... 3-51

Recirculated air mode ........................................................................................ 3-51

Washer system .................................................................................................. 3-52

Seat (standard) ........................................................................................................ 3-52

Weight adjustment ............................................................................................. 3-53

Horizontal adjustment ........................................................................................ 3-53

Seat depth adjustment ....................................................................................... 3-53

Backrest adjustment .......................................................................................... 3-54

Head rests .......................................................................................................... 3-54

I-4 BA 9503 US - Edition 3.0 * *Ba9503en2_1IVZ.fm

Table of contents

Height adjustment .............................................................................................. 3-54

Seat (air suspension option) ..................................................................................... 3-55

Weight adjustment ............................................................................................. 3-56

Height adjustment .............................................................................................. 3-56

Horizontal adjustment ........................................................................................ 3-56

Seat depth adjustment ....................................................................................... 3-56

Backrest adjustment ........................................................................................... 3-57

Head rests .......................................................................................................... 3-57

Horizontal suspension ........................................................................................ 3-57

Seat belt ................................................................................................................... 3-58

Fastening the seat belt ....................................................................................... 3-58

Unfastening the seat belt ................................................................................... 3-59

Longer/shorter lap belt adjustment ..................................................................... 3-59

Mirrors ...................................................................................................................... 3-59

Safety instructions .............................................................................................. 3-59

Road travel position ........................................................................................... 3-60

Adjusting the mirrors .......................................................................................... 3-60

Emergency exit ......................................................................................................... 3-62

Emergency exit on machines equipped with protective Front Guard structures

(option) ............................................................................................................... 3-62

Front window (up to serial no. AH02483) ................................................................. 3-63

Front window (from serial no. AH02496) .................................................................. 3-64

Opening/closing the front window ...................................................................... 3-64

Opening the front window .................................................................................. 3-64

Closing the front window .................................................................................... 3-65

Opening/closing the lower front window ............................................................. 3-65

Opening the lower front window ......................................................................... 3-66

Closing the lower front window .......................................................................... 3-66

Opening/closing the whole front window ............................................................ 3-66

Opening the whole front window ........................................................................ 3-67

Closing the whole front window .......................................................................... 3-67

Opening the front window to a gap .................................................................... 3-68

Door .......................................................................................................................... 3-69

Opening the door from the inside ....................................................................... 3-69

Securing an open door ....................................................................................... 3-69

Releasing the door opener ................................................................................. 3-70

Exit through the door (up to serial no. AH02757) ..................................................... 3-70

Exit through the door (from serial no. AJ02775) ....................................................... 3-71

Armrest adjustment (up to serial no. AH02757) ....................................................... 3-71

Armrest adjustment (from serial no. AJ02775) ......................................................... 3-72

Opening the side window ......................................................................................... 3-72

Engine cover ............................................................................................................ 3-72

Battery master switch ............................................................................................... 3-73

Tilting the cab ........................................................................................................... 3-74

Interlocks .................................................................................................................. 3-77

Bucket position for road travel .................................................................................. 3-79

Stick light for road travel ........................................................................................... 3-79

Wheel chocks ........................................................................................................... 3-79

Towing the mobile excavator .................................................................................... 3-80

Safety instructions .............................................................................................. 3-80

Towing ................................................................................................................ 3-81

Opening the “Travel” hydraulic circuit ................................................................ 3-82

Unlocking the parking brake in an emergency ................................................... 3-83

Adjusting the parking brake after it has been unlocked in an emergency .......... 3-83

Lifting the Excavator ................................................................................................. 3-84

Safety instructions .............................................................................................. 3-84

BA 9503 US - Edition 3.0 *Ba9503en2_1IVZ.fm I-5

Table of contents

Loading and transporting the machine ..................................................................... 3-86

Tying down the machine .......................................................................................... 3-87

Installing and removing the Front Guard .................................................................. 3-87

Operating the machine ............................................................................................. 3-88

General safety instructions ................................................................................ 3-88

Control levers/control pattern ’’A’’: overview ............................................................ 3-89

Left-hand control lever ....................................................................................... 3-89

Boom swivel controls/auxiliary hydraulics/triple articulation boom (option) ........ 3-89

Lowering the boom with the engine stopped ..................................................... 3-90

Rotating the upper carriage ............................................................................... 3-90

Rotating upper carriage brake ........................................................................... 3-91

Changeover valve for control pattern ’’B’’ (option) ................................................... 3-92

Left-hand control lever ....................................................................................... 3-92

Right-hand control lever ..................................................................................... 3-92

Directional valve position ................................................................................... 3-93

Directional valve ................................................................................................. 3-93

Control lever with proportional controls (option): overview ....................................... 3-94

Diagnosis display ............................................................................................... 3-94

Operating the boom/auxiliary hydraulics ............................................................ 3-95

Hammer operation ............................................................................................. 3-95

Adjusting control response ................................................................................. 3-96

Characteristic curves – status indicator ............................................................. 3-96

Control lever if equipped with 3rd control circuit (option): overview ......................... 3-97

Right-hand control lever ..................................................................................... 3-97

Releasing the pressure on the Operating Hydraulics ............................................... 3-98

Releasing pressure ............................................................................................ 3-98

Pressure release with proportional controls (option) .......................................... 3-98

Attaching attachments .............................................................................................. 3-99

Specific safety instructions ................................................................................. 3-99

Removing a bucket .......................................................................................... 3-100

Attaching a bucket ........................................................................................... 3-100

Quickhitch (option) ................................................................................................. 3-101

Hydraulic quickhitch (option) .................................................................................. 3-102

Picking up an attachment ................................................................................. 3-102

Powertilt (option) .................................................................................................... 3-104

Operation ......................................................................................................... 3-105

Right-hand control lever (Powertilt) .................................................................. 3-105

Enabling the 3rd control circuit ......................................................................... 3-106

Auxiliary hydraulics connections ............................................................................ 3-107

Quick-connect couplings .................................................................................. 3-107

Attachments ..................................................................................................... 3-107

Load holding control device safety feature (option) ............................................... 3-108

Worksite Evaluation and Preparation ..................................................................... 3-109

Examining the site ............................................................................................ 3-109

Preparing the ground ....................................................................................... 3-109

Working with the excavator .................................................................................... 3-110

Preparing the excavator ................................................................................... 3-110

Working with the standard bucket .................................................................... 3-110

Prohibited work procedures ............................................................................. 3-110

Excavator operating position ............................................................................ 3-112

Bucket position when digging .......................................................................... 3-112

Excavating trenches ......................................................................................... 3-113

Loading ............................................................................................................ 3-113

Grading ............................................................................................................ 3-113

Excavating trenches sideways ......................................................................... 3-113

Working alongside trenches ............................................................................. 3-114

Loading vehicles .............................................................................................. 3-114

I-6 BA 9503 US - Edition 3.0 * *Ba9503en2_1IVZ.fm

Table of contents

Grading ................................................................................................................... 3-115

Grading ............................................................................................................ 3-115

Load indicator (option) ............................................................................................ 3-116

Applications with lifting gear ................................................................................... 3-117

Lifting gear applications ................................................................................... 3-117

Fastening loads ................................................................................................ 3-118

Troubleshooting

Troubleshooting .......................................................................................................... 4-2

Troubleshooting the hydraulics .................................................................................. 4-5

Malfunctions of the Powertilt unit ................................................................................ 4-5

Central lubrication system .......................................................................................... 4-5

Maintenance

Introduction ................................................................................................................. 5-1

Specific Safety Instructions ........................................................................................ 5-1

Maintenance of attachments ................................................................................ 5-2

Fuel system ................................................................................................................ 5-3

Refuelling ............................................................................................................. 5-4

Fuel-filling pump (option) up to serial no. AH01415 ............................................. 5-4

Fuel-filling pump (option) from serial no. AH01416 .............................................. 5-5

Stationary fuel pumps .......................................................................................... 5-6

Diesel fuel specification ........................................................................................ 5-6

Bleeding the fuel system ...................................................................................... 5-7

Fuel prefilter with water separator ........................................................................ 5-8

Engine lubrication system .......................................................................................... 5-9

Checking the oil level ........................................................................................... 5-9

Adding engine oil ................................................................................................ 5-10

Engine and hydraulics cooling system ..................................................................... 5-11

Specific safety instructions ................................................................................. 5-11

Checking/adding coolant .................................................................................... 5-12

Checking the coolant level ................................................................................. 5-12

Tank for washer system ..................................................................................... 5-13

Air filter ..................................................................................................................... 5-14

Replacing the filter ............................................................................................. 5-15

V-belts ...................................................................................................................... 5-16

Checking the V-belt tension of the coolant and fuel pump ................................. 5-16

Check the V-belt tension of the alternator .......................................................... 5-16

Checking the V-belt of the air conditioning system (option) ............................... 5-17

Retightening V-belts ........................................................................................... 5-18

Alternator ............................................................................................................ 5-18

Coolant and fuel pump ....................................................................................... 5-18

Tightening the V-belt of the air conditioning system (option) ............................. 5-19

Hydraulic system ...................................................................................................... 5-20

Specific safety instructions ................................................................................. 5-20

Checking the hydraulic oil level .......................................................................... 5-21

Adding hydraulic oil ............................................................................................ 5-22

Important information for the use of biodegradable oil ....................................... 5-23

Replacing the return filter ................................................................................... 5-24

Replacing the boost pressure filter ..................................................................... 5-24

Checking hydraulic pressure lines ..................................................................... 5-25

Overview of lubrication points .................................................................................. 5-26

Standard boom ................................................................................................... 5-26

Triple articulation boom (option) ......................................................................... 5-27

Steering housing ................................................................................................ 5-29

Cardan shaft ....................................................................................................... 5-29

Bulkhead – oscillating axle ................................................................................. 5-30

Lubricating the ball bearing race of the swing bearing ....................................... 5-30

BA 9503 US - Edition 3.0 *Ba9503en2_1IVZ.fm I-7

Table of contents

Lubricating the teeth of the swing bearing ......................................................... 5-31

Offset bucket (option) ......................................................................................... 5-31

Offset bucket quickhitch (option) ........................................................................ 5-32

Powertilt (option) ................................................................................................ 5-32

Lubrication points on control lever base (from serial no. AJ 02775) .................. 5-32

IHydraulic quickhitch system .............................................................................. 5-33

Axle mounting .......................................................................................................... 5-34

Front axle ........................................................................................................... 5-34

Rear axle ............................................................................................................ 5-34

Stop plate fastening of the oscillating axle ............................................................... 5-34

Tires ......................................................................................................................... 5-35

Inspection work .................................................................................................. 5-35

Changing wheels ............................................................................................... 5-36

Axle Final Drive ........................................................................................................ 5-38

Checking the oil level and adding oil .................................................................. 5-38

Draining oil ......................................................................................................... 5-38

Cardan shaft ............................................................................................................. 5-39

Daily checks ....................................................................................................... 5-39

Lubrication work ................................................................................................. 5-39

Central lubrication system (option) ........................................................................... 5-40

Function ............................................................................................................. 5-40

Adjusting cycle interval and lubrication times .................................................... 5-41

Repair in case of clogging .................................................................................. 5-41

Electrical system ...................................................................................................... 5-42

Service and maintenance work at regular intervals ........................................... 5-42

Instructions concerning specific components .................................................... 5-42

Alternator ........................................................................................................... 5-42

Battery ...................................................................................................................... 5-43

Dry cell Battery (from serial number AH01647 to AH02436) .................................... 5-44

General maintenance work ...................................................................................... 5-45

Cleaning ............................................................................................................. 5-45

General instructions for all areas of the machine ............................................... 5-45

Inside the cab ..................................................................................................... 5-45

Cleaning the seat belt ........................................................................................ 5-46

Exterior of the machine ...................................................................................... 5-46

Engine compartment .......................................................................................... 5-46

Screw connections and attachments ................................................................. 5-46

Pivots and hinges ............................................................................................... 5-46

Maintenance if the machine is out of service for a longer period of time ................. 5-47

Preparatory work before taking the machine out of service ............................... 5-47

Putting the machine into operation again ........................................................... 5-47

Fluids and lubricants ............................................................................................... 5-48

Additional oil change and filter replacement (hydraulics) ................................... 5-49

Maintenance plan (overview) ................................................................................... 5-52

Maintenance label .................................................................................................... 5-57

Explanation of symbols on the maintenance label ............................................. 5-57

Specifications

Chassis ...................................................................................................................... 6-1

Engine ........................................................................................................................ 6-1

Undercarriage ............................................................................................................ 6-1

Brakes ........................................................................................................................ 6-2

Swing bearing ............................................................................................................ 6-2

Steering system ......................................................................................................... 6-3

Hydraulics .................................................................................................................. 6-4

Electrical system ........................................................................................................ 6-5

Fuse box on right-hand cab wall .......................................................................... 6-5

Main fuse box with relays on partition wall ........................................................... 6-6

I-8 BA 9503 US - Edition 3.0 * *Ba9503en2_1IVZ.fm

Table of contents

Relays .................................................................................................................. 6-6

Noise levels ............................................................................................................... 6-7

Stabilizer legs or stabilizer blade (option) ................................................................... 6-7

Tires ........................................................................................................................... 6-8

Vibration ..................................................................................................................... 6-8

Coolant compound table ............................................................................................ 6-8

Powertilt ...................................................................................................................... 6-8

Dimensions model 9503 WD ...................................................................................... 6-9

Dimensions model 9503 WD with triple articulation boom (option) .......................... 6-11

Lift capacity table 1 (up to serial no. AH01458): rear stabilizer blade, one steering axle,

one-piece boom, twin tires ....................................................................................... 6-13

Lift capacity table 2 (up to serial no. AH01458): rear stabilizer blade, one steering axle,

one-piece boom, wide tires ...................................................................................... 6-14

Lift capacity table 3 (up to serial no. AH01458): rear stabilizer blade, front stabilizer legs,

one steering axle, one-piece boom, twin tires .......................................................... 6-15

Lift capacity table 4 (up to serial no. AH01458): rear stabilizer blade, front stabilizer legs,

one steering axle, one-piece boom, wide tires ......................................................... 6-16

Lift capacity table 5 (up to serial no. AH01458): rear stabilizer legs, one steering axle,

one-piece boom, twin tires ....................................................................................... 6-17

Lift capacity table 6 (up to serial no. AH01458): rear stabilizer legs, one steering axle,

one-piece boom, wide tires ...................................................................................... 6-18

Lift capacity table 7 (up to serial no. AH01458): rear stabilizer blade, one steering axle,

triple articulation boom, twin tires ............................................................................. 6-19

Lift capacity table 8 (up to serial no. AH01458): rear stabilizer blade, one steering axle,

triple articulation boom, wide tires ............................................................................ 6-20

Lift capacity table 9 (up to serial no. AH01458): rear stabilizer blade, front stabilizer legs,

one steering axle, triple articulation boom, twin tires ................................................ 6-21

Lift capacity table 10 (up to serial no. AH01458): rear stabilizer blade, front stabilizer legs,

one steering axle, triple articulation boom, wide tires ............................................... 6-22

Lift capacity table 11 (up to serial no. AH01458): rear stabilizer legs, one steering axle,

triple articulation boom, twin tires ............................................................................. 6-23

Lift capacity table 12 (up to serial no. AH01458): rear stabilizer legs, one steering axle,

triple articulation boom, wide tires ............................................................................ 6-24

Lift capacity table 1 (from serial no. AH01465): rear stabilizer blade, one steering axle,

one-piece boom, twin tires ....................................................................................... 6-25

Lift capacity table 2 (from serial no. AH01465): rear stabilizer blade, one steering axle,

one-piece boom, wide tires ...................................................................................... 6-26

Lift capacity table 3 (from serial no. AH01465): rear stabilizer blade, front stabilizer legs,

one steering axle, one-piece boom, twin tires .......................................................... 6-27

Lift capacity table 4 (from serial no. AH01465): rear stabilizer blade, front stabilizer legs,

one steering axle, one-piece boom, wide tires ......................................................... 6-28

Lift capacity table 5 (from serial no. AH01465): rear stabilizer legs, one steering axle, one-

piece boom, twin tires ............................................................................................... 6-29

Lift capacity table 6 (from serial no. AH01465): rear stabilizer legs, one steering axle, one-

piece boom, wide tires .............................................................................................. 6-30

Lift capacity table 7 (from serial no. AH01465): rear stabilizer blade, one steering axle,

triple articulation boom, twin tires ............................................................................. 6-31

Lift capacity table 8 (from serial no. AH01465): rear stabilizer blade, one steering axle,

triple articulation boom, wide tires ............................................................................ 6-32

Lift capacity table 9 (from serial no. AH01465): rear stabilizer blade, front stabilizer legs,

one steering axle, triple articulation boom, twin tires ................................................ 6-33

Lift capacity table 10 (from serial no. AH01465): rear stabilizer blade, front stabilizer legs,

one steering axle, triple articulation boom, wide tires ............................................... 6-34

Lift capacity table 11 (from serial no. AH01465): rear stabilizer legs, one steering axle,

triple articulation boom, twin tires ............................................................................. 6-35

Lift capacity table 12 (from serial no. AH01465): rear stabilizer legs, one steering axle,

triple articulation boom, wide tires ............................................................................ 6-36

BA 9503 US - Edition 3.0 *Ba9503en2_1SIX.fm I-9

Index

A

Abbreviations .........................................................................................1-2

Adjusting the mirrors ............................................................................3-60

Air filter .................................................................................................5-14

Applications with lifting gear ..................................................................2-8

Attachments ...........................................................................................2-9

Automatic engine speed setting ...........................................................3-36

B

Battery master switch ..........................................................................3-73

Before starting the engine ....................................................................3-17

Brief description .....................................................................................1-4

C

Check lists ...........................................................................................3-12

Component numbers .............................................................................1-9

D

Designated use and exemption from liability .........................................2-2

Drive interlock (option) .........................................................................3-19

E

Emergency exit ....................................................................................3-62

Front Guard (option) .....................................................................3-62

Engine cover ........................................................................................3-72

Equipment ..............................................................................................1-7

F

Fields Of Application of Attachments .....................................................1-5

Fire extinguisher ..................................................................................1-23

Fluids and lubricants ............................................................................5-48

H

Hammer operation ...............................................................................2-10

Heating ................................................................................................3-50

Hydraulic quickhitch (option) ..............................................................3-102

I

Important Operator Information .............................................................1-1

Indicator lights ......................................................................................3-14

Interior light ..........................................................................................3-49

Interlocks .............................................................................................3-77

L

Light system ............................................................................... 3-46, 3-52

Load indicator ....................................................................................3-116

Loading the machine ...........................................................................3-84

Lowering the boom with the engine stopped .......................................3-90

Lubricating the ball bearing race of the live ring ..................................5-30

Lubricating the teeth of the live ring .....................................................5-31

M

Machine

Fields of application ........................................................................ 1-5

Machine Overview ................................................................................. 1-3

Maintenance

Adding coolant .............................................................................. 5-12

Adding engine oil .......................................................................... 5-10

Biodegradable oil .......................................................................... 5-23

Bleeding the fuel system ................................................................ 5-7

Boost pressure filter ..................................................................... 5-24

Checking the coolant level ........................................................... 5-12

Checking the engine oil level .......................................................... 5-9

Checking the hydraulic oil level .................................................... 5-21

Electrical system .......................................................................... 5-42

Engine and hydraulics cooling system ......................................... 5-11

Fluids and lubricants .................................................................... 5-48

Fuel system .................................................................................... 5-3

General maintenance work .......................................................... 5-45

Instructions concerning specific components ............................... 5-42

Pivots and hinges ......................................................................... 5-46

Screw connections ....................................................................... 5-46

Screw connections and attachments ............................................ 5-46

Service and maintenance work at regular intervals ...................... 5-42

Tires ............................................................................................. 5-35

Maintenance plan ................................................................................ 5-52

Mirrors ................................................................................................. 3-59

N

Noise levels ......................................................................................... 1-13

O

Operating on Slopes ............................................................................ 3-37

Operating the Excavator ...................................................................... 3-11

Operation

Before starting the engine ............................................................ 3-17

Cab overview ................................................................................ 3-10

Parking the machine ..................................................................... 3-45

Starting the engine ....................................................................... 3-17

Triple articulation boom (option) ........................................3-89, 3-106

Operator Protection System .................................................................. 2-7

P

Parking the machine on slopes ........................................................... 3-46

Powertilt (option) ............................................................................... 3-104

Preparing for Changing Over to Road Travel ...................................... 3-28

Preparing for maintenance and repair work ........................................ 2-12

Preparing To Use The Machine ............................................................ 2-3

Putting the machine into operation for the first time ............................ 3-11

R

Re-equipping attachments .................................................................. 3-99

Regulations ........................................................................................... 1-7

Rotating beacon .................................................................................. 3-49

Index

I-10 BA 9503 US - Edition 3.0 * *Ba9503en2_1SIX.fm

Index

S

Safety instructions .................................................................................2-1

Applications with lifting gear ...........................................................2-8

General conduct .............................................................................2-3

Identification ....................................................................................2-1

Maintenance .................................................................................2-12

Special hazards ............................................................................2-14

Transport ......................................................................................2-11

Safety Labels .......................................................................................1-18

Seat (air suspension option) ................................................................3-55

Seat (standard) ....................................................................................3-52

Seat adjustment ...................................................................................3-52

Backrest adjustment ........................................................... 3-54, 3-58

Horizontal adjustment ......................................................... 3-53, 3-56

Seat depth adjustment ........................................................ 3-53, 3-56

Weight adjustment .............................................................. 3-53, 3-56

Special Instructions for Traveling on Public Roads ...............................2-7

Specific Safety Instructions ....................................................................5-1

Specifications .........................................................................................6-1

Coolant compound table .................................................................6-8

Electrical system .............................................................................6-5

Engine .............................................................................................6-1

Hydraulics .......................................................................................6-4

Noise levels ....................................................................................6-7

Stabilizer legs or stabilizer blade (option) .......................................6-7

Tires ................................................................................................6-8

Undercarriage .................................................................................6-1

Starting aid ...........................................................................................3-22

Starting and stopping .............................................................................2-5

Starting checklis ...................................................................................3-12

Steering modes ....................................................................................3-31

T

Tilting the cab ......................................................................................3-74

Tires .....................................................................................................5-35

Troubleshooting .....................................................................................4-1

Hydraulics .......................................................................................4-5

Type labels ............................................................................................1-9

V

V-belts ..................................................................................................5-16

Ventilation ............................................................................................3-50

Ventilation, fresh air ......................................................................3-50

W

Warranty ................................................................................................2-2

Washer system ....................................................................................3-52

Tank ..............................................................................................5-13

Wheel chocks ......................................................................................3-79

BA 9503 US – Edition 3.0 *9503b110.fm 1-1

Introduction

1 Introduction

1.1 Important Operator Information

Store the Operator's Manual in the storage compartment behind the seat.

This Operator's Manual contains important information on how to work safely, correctly

and economically with the machine. This Operator's Manual provides information and

instructions for all operators regardless of experience. It helps to avoid risky 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. Thoroughly read and understand the information in this

Operator's Manual before operating the machine for the first time. This Operator's Manual

will help to familiarize yourself more easily with the machine, thereby enabling you to use it

more safely and efficiently.

Before operating this machine for the first time, carefully read the section "Safety Instruc-

tions" to learn how to operate the machine safely.

Important

Careful and prudent working is the best way to avoid accidents.

• Instructions are provided for bucket attachments. No instructions are provided for other

attachments. Refer to the specific attachment operator's manual for safe operation.

• Wacker Neuson reserves the right to make product improvement changes during the

course of series production of this machine.

• Modifying the manufacturer specification and configuration of this machine, or using

unapproved attachments, can cause personal hazards and damage the machine.

Contact your Wacker Neuson dealer for additional information and clarification

regarding modifications.

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 ser-

vice work is absolutely necessary. Extensive maintenance and repair work must always be

performed by an expert with appropriate training. Use only original spare parts for repairs.

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

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.

1-2 BA 9503 US – Edition 3.0 * *9503b110.fm

Introduction

Abbreviations/symbols

• This symbol stands for a list.

• Subdivision within lists or an activity. Follow the steps in the recommended order.

☞ This symbol requires you to perform 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 9503 US – Edition 3.0 *9503b110.fm 1-3

Introduction

1.2 Machine Overview

Fig. 1: Machine outside views

1 Road lights

2 Boom mounted work light

3 Handrail

4 Front stabilizer leg (option)

5 Auxiliary hydraulics

6 Lifting/tying down point

7 Door arrester

8 Door handle and lock

9 Rotating beacon

10 Rear working light

11 Hydraulic oil filler inlet

12 Exhaust pipe

13 Counterweight

14 Fuel tank filler inlet

15 Rear lights

16 Stabilizer blade

17 Boom interlock

18 Transport bar for clamshell bucket

19 Maintenance door

20 Tool kit

3

9

10

13

12

5

7

11

8

6

1

6

4

3

14

15

16

17

19

20

5

2

4

18

1-4 BA 9503 US – Edition 3.0 * *9503b110.fm

Introduction

1.3 Brief description

The Wacker Neuson Model 9503WD is a rubber tired self propelled hydraulic excavator.

Before operating the excavator, read the instruction manual, understand the instruction

and practice operation until confident of operating familiarity and competence. Know and

comply with regulations for operation and use of the excavator on the worksite or traveling

on public roads. This excavator is intended for use as an earth-moving machine. Attach-

ments described in Chapter 1.4 “Fields Of Application of Attachments” are approved to

expand the utility of the 9503WD as an earth-moving machine. Do not use any other

attachments with the excavator. Contact the Wacker Neuson dealer for attachment advice

for equipment not described in 1.4.

Major excavator assemblies are:

• Rotating upper structure.

• Undercarriage supporting the upper structure.

• Propulsion system consisting of wheels, axles, brakes and motor for machine

mobility.

• Earthmoving structures (boom, stick and bucket).

The upper structure consists of the following major components or systems:

• Diesel engine/ pump drive.

• Pressure compensated hydraulic system.

• Operator compartment.

• Control systems for work and machine propulsion.

• Swing bearing and hydraulic coupling for upper and lower structure connection.

• Swing gear box and motor.

• Boom mounting points.

• Fuel and hydraulic oil tanks.

• Counterweight.

• Engine and component enclosure.

The lower structure supports the upper structure through a large bearing permitting 360

degree continuous rotation:

• Welded structure.

• Large support bearing.

• Stabilizers.

•Axles.

• Wheels.

• Drive motor.

• Brake system.

Hydraulic systems are supplied power from pumps mounted to a drive box bolted to the

diesel engine. The system is pressure compensated automatically adjusting speed and

force to the working conditions and engine power. The following functions are hydraulically

actuated:

• Upper structure rotation.

• Excavator mobility.

• Steering during excavator movement on the worksite or public roads.

• Stabilizer extension and retraction.

• Boom vertical movement.

• Stick movement in and out.

• Auxiliary hydraulics for attachments.

• Excavator propulsion brakes/park brake.

BA 9503 US – Edition 3.0 *9503b110.fm 1-5

Introduction

• Optional horizontal boom slewing motion.

The diesel engine speed will automatically reduce to the low idle setting if the work cycle is

interrupted for a few seconds to reduce fuel consumption, noise and exhaust emissions.

Movement of a control lever will restore engine speed to the high idle setting in preparation

for work.

Travelling drive

The diesel engine permanently drives the twin axial variable displacement pump whose oil

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 indicator lights in the instrument panel of the machine ensure constant monitoring of

the engine and hydraulic oil temperature, as well as of the coolant temperature and level.

Cab (ROPS and FOPS)

The cab has been specially designed for protection in case of an accident.

• ROPS (Roll Over Protective Structure) tested cab

• FOPS (Falling Object Protective Structure) – option

Do not modify or attempt to repair the ROPS cab or ROPS structure. Any permanent

deflection of the ROPS is a failure mode and the cab or structure must be replaced to

ensure future protection to the operator space in the event of a tipping incident. Contact a

Wacker Neuson dealer for instruction or clarification.

The ROPS is a special safety device designed and produced to exacting material and

assembly standards for certification. Bending, heating, welding, cutting, or drilling holes in

the ROPS will reduce the protection performance in a tipping incident.

Fasten your seat belt, otherwise you can be thrown around or even outside the cab and

crushed. Therefore always fasten your seat belt as you drive and work with the machine.

Tighten the seat belt before starting work with the machine.

1.4 Fields Of Application of 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.

• Contact your Wacker Neuson dealer if you wish to use other attachments.

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.

1-6 BA 9503 US – Edition 3.0 * *9503b110.fm

Introduction

Use: Attachment

The measurements are Metric (Imperial)

Description of attachment Weight Capacity

Remarks

Mechanical quickhitch 73 kg (160.94 lbs)

Required for operation of Wacker Neuson quick-

hitch systems

Easy Lock quickhitch 83 kg (182.98 lbs)

Powertilt with Easy Lock quickhitch 231 kg (509.27 lbs)

Hammer console 50 kg (110.23 lbs) Mechanical quickhitch mount

Bucket 300 mm (11.81 in)

137 kg (302.03 lbs)

0.096 m³ (3.39 ft³)

100 kg (220.46 lbs) Mechanical quickhitch mount

Bucket 350 mm (13.78 in) 141 kg (310.85 lbs) 0.127 m³ (4.48 ft³) Easy Lock quickhitch mount

Bucket 400 mm (15.75 in) 144 kg (317.46 lbs) 0.148 m³ (5.23 ft³) Easy Lock quickhitch mount

Bucket 450 mm (17.72 in)

160 kg (352.74 lbs)

0.154 m³ (5.44 ft³)

131 kg (288.80 lbs) Mechanical quickhitch mount

Bucket 500 mm (19.68 in) 161 kg (354.94 lbs) 0.183 m³ (6.46 ft³) Easy Lock quickhitch mount

Bucket 600 mm (23.62 in)

189 kg (416.67 lbs)

0.221m³ (7.80 ft³)157 kg (346.12 lbs) Mechanical quickhitch mount

186 kg (410.06 lbs) Easy Lock quickhitch mount

Bucket 700 mm (27.56 in) 204 kg (449.74 lbs) 0.256 m³ (9.04 ft³) Easy Lock quickhitch mount

Bucket 750 mm (29.52 in)

216 kg (476.20 lbs)

0.279 m³ (9.85 ft³)

182 kg (401.24 lbs) Mechanical quickhitch mount

Bucket 800 mm (31.50 in) 228 kg (502.65 lbs) 0.292 m³ (10.31 ft³) Easy Lock quickhitch mount

Bucket 900 mm (35.43 in)

238 kg (524.70 lbs)

0.339 m³ (11.97 ft³)

206 kg (454.15 lbs) Mechanical quickhitch mount

246 kg (542.34 lbs) 0.328 m³ (11.58 ft³) Easy Lock quickhitch mount

Bucket 1m (39.37 in) 264 kg (582.02 lbs) 0.365 m³ (12.89 ft³) Easy Lock quickhitch mount

Ditch cleaning bucket 1.2 m (47.24 in)

195 kg (429.90 lbs)

0.241 m³ (8.51 ft³)

300 kg (661.39 lbs) Mechanical quickhitch mount

Ditch cleaning bucket 1.5 m (59.05 in)

225 kg (496.04 lbs)

0.314 m³ (11.09 ft³)

295 kg (650.36 lbs) Mechanical quickhitch mount

238 kg (524.70 lbs) 0.342 m³ (12.08 ft³) Easy Lock quickhitch mount

Offset bucket 1.5 m (59.05 in.)

325 kg (716.50 lbs)

0.280 m³ (9.89 ft³)

280 kg (617.29 lbs) Mechanical quickhitch mount

358 kg (789.25 lbs) 0.342 m³ (12.08 ft³) Easy Lock quickhitch mount

Hydraulic hammer NE42 438 kg (965.62 lbs)

Hydraulic hammer NE50 467 kg (1029.56 lbs)

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