Wacker Neuson 6503-2 Manuel utilisateur

Operator’s Manual

Mobile Excavator

Notice d’Emploi

Pelle sur pneumatiques

5200008666 50 0912

EN / FR

5200008666

1000271814

1000158220

50

1111

2012

Mobile Excavator

6503

OPERATOR'S MANUAL

1000271814 5.0

1111

www.wackerneuson.com

1000271814

Documentation

Description Order no.

Operator's Manual 1000271814

Spare parts catalogue up to serial number

AD07227

Spare parts catalogue from serial number

AH00708

1000158616

1000182718

Legend

Edition Issued

5.0 11 / 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.

The cover features the machine with possible optional equipment.

Wacker Neuson Linz GmbH

Haidfeldstr. 37

A-4060 Linz-Leonding

Document: BA 6503 US

Order no.: 1000271814

Edition: 5.0

BA 6503 US – Edition 5.0 * Ba6503en4_0IVZ.fm 1-1

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 6503-2 ................................................................ 1-8

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

Overview of adhesive labels (from serial no. AJ03112) .................................. 1-13

Symbols ................................................................................................................. 1-14

Overview of safety labels (from serial no. AJ03112) ....................................... 1-19

Safety Labels ......................................................................................................... 1-20

Fire extinguisher .................................................................................................... 1-25

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 (from serial no. AJ02730) ........................................... 2-7

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

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

Conditions for safe operation ............................................................................. 2-9

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

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

Installation notes .............................................................................................. 2-10

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

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

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

Working with a hammer ................................................................................... 2-11

Table of contents

1-2 BA 6503 US – Edition 5.0 * * Ba6503en4_0IVZ.fm

Table of contents

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 ..................................................... 2-13

Performing maintenance and repairs ............................................................... 2-14

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

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

Underground electric lines ............................................................................... 2-15

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

Gas, dust, steam, smoke ................................................................................. 2-16

Hydraulics ........................................................................................................ 2-16

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

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

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

Battery ............................................................................................................. 2-17

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. AH00707) ................................................................ 3-2

Instrument panel overview (up to serial no. AH00707) ............................................ 3-4

Cab overview (from serial no. AH00708 up to serial no. AH02844) ........................ 3-6

Instrument panel overview (from serial no. AH00708 up to serial no. AH02844) .... 3-8

Cab overview (from serial no. AJ03112) ................................................................ 3-10

Instrument panel overview (from serial no. AJ03112) ............................................ 3-12

Operating the Excavator ........................................................................................ 3-14

Safety instructions ........................................................................................... 3-14

Putting the machine into operation for the first time ........................................ 3-14

Running-in period ............................................................................................ 3-14

Checklists ........................................................................................................ 3-15

Starting checklist .............................................................................................. 3-15

Operation checklist .......................................................................................... 3-16

Parking checklist .............................................................................................. 3-16

Indicator lights and warning lights Overview ......................................................... 3-17

Before starting the engine ...................................................................................... 3-20

Starting the engine (general information) ............................................................... 3-20

Throttle (up to serial no. AH02844) .................................................................. 3-22

Throttle (from serial no. AJ03112) ................................................................... 3-22

Steering system ..................................................................................................... 3-23

Starting with the drive interlock (option) (up to serial no. AH02844) ...................... 3-24

Starting with the drive interlock – internal transponder (option) (from serial no. AJ03112)

BA 6503 US – Edition 5.0 * Ba6503en4_0IVZ.fm 1-3

Table of contents

3-25

Starting at low temperatures .................................................................................. 3-26

When the engine has started ................................................................................. 3-26

Engine warm-up ..................................................................................................... 3-26

Jump-starting the engine (supply battery) ............................................................. 3-27

Hydraulic brake effect ............................................................................................ 3-28

Service brake (up to serial no. AH02844) .............................................................. 3-28

Service brake (from serial no. AJ03112) ............................................................... 3-28

Release lever ......................................................................................................... 3-29

Parking brake (up to serial no. AH02844) .............................................................. 3-29

Parking brake (from serial no. AJ03112) ............................................................... 3-30

Preparing for Changing Over to Road Travel ........................................................ 3-30

Moving the machine ............................................................................................... 3-31

Drive pedal ............................................................................................................. 3-31

High speed ............................................................................................................. 3-32

Locking the oscillating axle .................................................................................... 3-32

Automatic engine speed setting (option) ............................................................... 3-33

Operating on Slopes .............................................................................................. 3-34

Specific safety instructions .............................................................................. 3-34

Operating on slopes ........................................................................................ 3-35

Stabilizer blade operation ...................................................................................... 3-36

Parking the machine .............................................................................................. 3-37

Parking the machine on slopes ....................................................................... 3-38

Locking the Operating hydraulic system ................................................................ 3-38

Multifunctional lever (up to serial no. AH02844) .................................................... 3-39

Multifunctional lever (from serial no. AJ03112) ...................................................... 3-40

Adjusting the steering column ................................................................................ 3-41

Hazard warning system ......................................................................................... 3-41

Light system ........................................................................................................... 3-42

Light system (up to serial no. AH02844) ......................................................... 3-42

Light system (from serial no. AJ03112) ........................................................... 3-42

Working lights (up to serial no. AH02844) ....................................................... 3-43

Roof working lights (option) (up to serial no. AH02844) .................................. 3-44

Working lights/roof working lights (option) (from serial no. AJ03112) ............. 3-45

Interior light ...................................................................................................... 3-46

Rotating beacon (option) ................................................................................. 3-46

Cab heating and ventilation ................................................................................... 3-47

Heating adjustment .......................................................................................... 3-48

Air conditioning (option) ......................................................................................... 3-48

Recirculated air mode ...................................................................................... 3-48

Washer system ...................................................................................................... 3-49

Tank for washer system .................................................................................. 3-49

Seat (standard) ...................................................................................................... 3-50

Weight adjustment ........................................................................................... 3-51

Horizontal adjustment ...................................................................................... 3-51

Seat depth adjustment ..................................................................................... 3-51

Backrest adjustment ........................................................................................ 3-51

Head rests ....................................................................................................... 3-52

Height adjustment ............................................................................................ 3-52

Seat (air suspension option) .................................................................................. 3-53

Weight adjustment ........................................................................................... 3-54

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

Horizontal adjustment ...................................................................................... 3-54

Seat depth adjustment ..................................................................................... 3-54

Backrest adjustment ........................................................................................ 3-55

Head rests ....................................................................................................... 3-55

Horizontal suspension ..................................................................................... 3-55

1-4 BA 6503 US – Edition 5.0 * * Ba6503en4_0IVZ.fm

Table of contents

Seat belt ................................................................................................................. 3-56

Fastening the seat belt .................................................................................... 3-56

Unfastening the seat belt ................................................................................. 3-57

Longer/shorter lap belt adjustment .................................................................. 3-57

Mirrors .................................................................................................................... 3-57

Safety instructions ........................................................................................... 3-57

Road travel position ......................................................................................... 3-58

Adjusting the mirrors ........................................................................................ 3-58

Emergency exit ...................................................................................................... 3-59

Emergency exit on machines equipped with protective Front Guard structures

(option) ............................................................................................................. 3-59

Front window (up to serial no. AH02441) ............................................................... 3-60

Front window (from serial no. AH02444) ............................................................... 3-61

Opening/closing the front window .................................................................... 3-61

Closing the front window .................................................................................. 3-62

Opening/closing the lower front window .......................................................... 3-62

Closing the lower front window ........................................................................ 3-63

Opening/closing the whole front window ......................................................... 3-63

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

Closing the whole front window ....................................................................... 3-64

Opening the front window to a gap .................................................................. 3-65

Side window ........................................................................................................... 3-66

Engine cover .......................................................................................................... 3-66

Battery master switch ............................................................................................. 3-66

Tilting the cab ......................................................................................................... 3-67

Door ....................................................................................................................... 3-70

Opening the door from the outside .................................................................. 3-70

Opening the door from the inside .................................................................... 3-70

Securing an open door .................................................................................... 3-70

Releasing the door opener .............................................................................. 3-71

Exit through the door (up to serial no. AH02844) ................................................... 3-71

Exit through the door (from serial no. AJ03112) .................................................... 3-72

Armrest adjustment (up to serial no. AH02844) ..................................................... 3-73

Armrest adjustment (from serial no. AJ03112) ...................................................... 3-73

Interlocks ................................................................................................................ 3-74

Alignment marks (up to serial no. AH02844) ................................................... 3-74

Alignment marks (from serial no. AJ03112) ..................................................... 3-74

Interlock for boom and attachment .................................................................. 3-75

Interlock for boom and upper carriage (version up to year of construction 2007) ...

3-75

Interlock for boom and upper carriage ............................................................. 3-75

Stabilizer blade interlock .................................................................................. 3-75

Bucket position for road travel ............................................................................... 3-76

Stick light for road travel ........................................................................................ 3-76

Wheel chocks ......................................................................................................... 3-76

Towing the mobile excavator (up to serial no. AH02844) ...................................... 3-77

Safety instructions ........................................................................................... 3-77

Towing ............................................................................................................. 3-77

Towing the mobile excavator (from serial no. AJ03112) ........................................ 3-79

Safety instructions ........................................................................................... 3-79

Towing ............................................................................................................. 3-79

Lifting the excavator ............................................................................................... 3-82

Safety instructions ........................................................................................... 3-82

Crane handling ................................................................................................ 3-82

Loading and transporting the machine ................................................................... 3-83

Safety instructions ........................................................................................... 3-83

BA 6503 US – Edition 5.0 * Ba6503en4_0IVZ.fm 1-5

Table of contents

Tying down the machine ........................................................................................ 3-84

Installing and removing the Front Guard ............................................................... 3-84

Operating the machine .......................................................................................... 3-85

General safety instructions .............................................................................. 3-85

Control levers/control pattern ’’A’’: overview .......................................................... 3-86

Left-hand control lever ..................................................................................... 3-86

Boom swivel controls/triple articulation boom (option) .................................... 3-86

Right-hand control lever .................................................................................. 3-88

Lowering the boom with the engine stopped ................................................... 3-88

Rotating the upper carriage ............................................................................. 3-88

Rotating upper carriage brake ......................................................................... 3-89

Changeover valve for control pattern ’’B’’ (option) ................................................. 3-90

Left-hand control lever ..................................................................................... 3-90

Right-hand control lever .................................................................................. 3-90

Directional valve position ................................................................................. 3-91

Directional valve .............................................................................................. 3-91

Control lever with proportional controls (option): overview .................................... 3-92

Function ........................................................................................................... 3-92

Diagnosis display ............................................................................................. 3-93

Operating the boom/auxiliary hydraulics ......................................................... 3-93

Hammer operation ........................................................................................... 3-94

Adjusting control response .............................................................................. 3-94

Characteristic curves – status indicator ........................................................... 3-94

Control lever if equipped with 3rd control circuit (option): overview ....................... 3-95

Right-hand control lever .................................................................................. 3-95

Releasing the pressure on the Operating Hydraulics ............................................ 3-96

Releasing pressure .......................................................................................... 3-96

Pressure release with proportional controls (option) ....................................... 3-96

Attaching attachments ........................................................................................... 3-97

Specific safety instructions .............................................................................. 3-97

Removing a bucket .......................................................................................... 3-98

Attaching a bucket ........................................................................................... 3-98

Quickhitch (option) ................................................................................................. 3-99

Hydraulic quickhitch (option) ................................................................................ 3-100

Picking up an attachment .............................................................................. 3-100

Powertilt (option) .................................................................................................. 3-102

Operation ....................................................................................................... 3-103

Right-hand control lever (Powertilt) ............................................................... 3-103

Enabling the 3rd control circuit ...................................................................... 3-104

Auxiliary hydraulics connections .......................................................................... 3-105

Quick-connect couplings ............................................................................... 3-105

Attachments ................................................................................................... 3-105

Load indicator (option) ......................................................................................... 3-106

Load holding control device safety feature (option) ............................................. 3-107

Applications with lifting gear ................................................................................ 3-107

Lifting gear applications ................................................................................. 3-108

Fastening loads ............................................................................................. 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

1-6 BA 6503 US – Edition 5.0 * * Ba6503en4_0IVZ.fm

Table of contents

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

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

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

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

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

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

Working alongside trenches .......................................................................... 3-115

Stabilizer blade at rear ................................................................................... 3-115

Troubleshooting

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

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

Engine error codes: .................................................................................................. 4-4

Malfunctions of the Powertilt unit ............................................................................. 4-8

Maintenance

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

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

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

Fuel system .............................................................................................................. 5-2

Refuelling ........................................................................................................... 5-3

Fuel-filling pump (option) ................................................................................... 5-4

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

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

Bleeding the fuel system .................................................................................... 5-6

Fuel prefilter with water separator ..................................................................... 5-7

Engine lubrication system ........................................................................................ 5-8

Checking the oil level ......................................................................................... 5-8

Adding engine oil ............................................................................................... 5-9

Engine and hydraulics cooling system ................................................................... 5-10

Specific safety instructions .............................................................................. 5-10

Checking/adding coolant ................................................................................. 5-11

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

Air filter ................................................................................................................... 5-13

Replacing the filter ........................................................................................... 5-14

V-belt ...................................................................................................................... 5-15

Checking V-belt tension ................................................................................... 5-15

Retightening the V-belt .................................................................................... 5-16

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

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

Hydraulic system .................................................................................................... 5-18

Specific safety instructions .............................................................................. 5-18

Checking the hydraulic oil level ....................................................................... 5-19

Adding hydraulic oil .......................................................................................... 5-20

Important information for the use of biodegradable oil .................................... 5-21

Checking hydraulic pressure lines ................................................................... 5-22

Overview of lubrication points ................................................................................ 5-23

Standard boom ................................................................................................ 5-23

Triple articulation boom (option) ...................................................................... 5-24

Powertilt (option) .............................................................................................. 5-26

Lubrication points on control lever base (from serial no. AJ 02775) ................ 5-26

Hydraulic quickhitch system ............................................................................ 5-27

Tires ....................................................................................................................... 5-28

Inspection work ................................................................................................ 5-28

Changing wheels ............................................................................................. 5-29

Axle Final Drive ...................................................................................................... 5-31

Checking the oil level and filling up oil (up to serial no. AH02844) .................. 5-31

Draining oil (up to serial no. AH02844) ............................................................ 5-31

BA 6503 US – Edition 5.0 * Ba6503en4_0IVZ.fm 1-7

Table of contents

Checking the oil level and filling up oil (from serial no. AJ03112) ................... 5-32

Draining oil (from serial no. AJ03112) ............................................................. 5-32

Electrical system .................................................................................................... 5-33

Service and maintenance work at regular intervals ......................................... 5-33

Instructions concerning specific components .................................................. 5-33

Alternator ......................................................................................................... 5-33

Battery ................................................................................................................... 5-34

General maintenance work .................................................................................... 5-35

Cleaning .......................................................................................................... 5-35

General instructions for all areas of the machine ............................................ 5-35

Inside the cab .................................................................................................. 5-35

Cleaning the seat belt: ..................................................................................... 5-36

Exterior of the machine .................................................................................... 5-36

Engine compartment ....................................................................................... 5-36

Screw connections and attachments ............................................................... 5-36

Pivots and hinges ............................................................................................ 5-36

Maintenance if the machine is out of service for a longer period of time ............... 5-37

Preparatory work before taking the machine out of service ............................ 5-37

Putting the machine into operation again ........................................................ 5-37

Fluids and lubricants .............................................................................................. 5-38

Additional oil change and filter replacement (hydraulics) ................................ 5-39

Maintenance plan (overview) ................................................................................. 5-41

Maintenance label .................................................................................................. 5-45

Explanation of symbols on the maintenance label ......................................... 5-45

Maintenance label (up to serial no. AH02844) ................................................ 5-46

Maintenance label (from serial no. AJ03112) .................................................. 5-47

Specifications

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

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

Hydraulic system ..................................................................................................... 6-1

Brakes (from serial no. AJ03112) ............................................................................ 6-2

Steering system....................................................................................................... 6-2

Undercarriage and swivel unit (up to serial no. AH02844) ...................................... 6-3

Undercarriage and swivel unit (from serial no. AJ03112) ........................................ 6-3

Stabilizer blade ........................................................................................................ 6-3

Electrical system ...................................................................................................... 6-3

Fuse box under the seat on the left ................................................................... 6-4

Main fuse box with relays underneath the cab .................................................. 6-4

Relays ................................................................................................................ 6-5

Noise level (up to serial no. AH02844) .................................................................... 6-5

Noise level (from serial no. AJ03112) ...................................................................... 6-5

Tires (up to serial no. AH02844) .............................................................................. 6-6

Tires (from serial no. AJ03112) ............................................................................... 6-6

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

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

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

Dimensions model 6503 WD one-piece boom (up to serial no. AH02844) ............. 6-7

Dimensions model 6503 WD with triple articulation boom (up to serial no. AH02844)

(option) ..................................................................................................................... 6-8

Dimensions model 6503 WD one-piece boom (from serial no. AJ03112) ............... 6-9

Dimensions model 6503 WD with triple articulation boom (from serial no. AJ03112) (op-

tion) ........................................................................................................................ 6-11

Lift capacity table 6503 WD (up to serial no. AH02844) ........................................ 6-13

Lift capacity table 6503 WD with twin tires (up to serial no. AH02844) ................. 6-14

Lift capacity table 6503 WD with triple articulation boom (up to serial no. AH02844) (op-

1-8 BA 6503 US – Edition 5.0 * * Ba6503en4_0IVZ.fm

Table of contents

tion) ........................................................................................................................ 6-15

Lift capacity table 6503 WD with twin tires and triple articulation boom (up to serial no.

AH02844) (option) .................................................................................................. 6-16

Lift capacity table 6503 WD with long stick (up to serial no. AH02844) (option) .... 6-17

Lift capacity table 6503 WD with twin tires and long stick (up to serial no. AH02844) (op-

tion) ........................................................................................................................ 6-18

Lift capacity table 6503 WD with long stick (option) and triple articulation boom (option)

(up to serial no. AH02884) ..................................................................................... 6-19

Lift capacity table 6503 WD with twin tires, long stick (option) and triple articulation

boom (option) (up to serial no. AH02884) .............................................................. 6-20

Lift capacity table 6503 one-piece boom, standard tires, short stick (from serial no.

AJ03112) ................................................................................................................ 6-21

Lift capacity table 6503 one-piece boom, standard tires, long stick (from serial no.

AJ03112) ................................................................................................................ 6-22

Lift capacity table 6503 one-piece boom, twin tires, short stick (from serial no. AJ03112)

6-23

Lift capacity table 6503 one-piece boom, twin tires, long stick (from serial no. AJ03112)

6-24

Lift capacity table 6503 triple articulation boom, standard tires, short stick (from serial

no. AJ03112) .......................................................................................................... 6-25

Lift capacity table 6503 triple articulation boom, standard tires, long stick (from serial no.

AJ03112) ................................................................................................................ 6-26

Lift capacity table 6503 triple articulation boom, twin tires, short stick (from serial no.

AJ03112) ................................................................................................................ 6-27

Lift capacity table 6503 triple articulation boom, twin tires, long stick (from serial no.

AJ03112) ................................................................................................................ 6-28

BA 6503 US – Edition 5.0 * Ba6503en4_0SIX.fm 1-1

Index

A

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

adding coolant .....................................................................................5-11

Adding engine oil ...................................................................................5-9

Adjusting the mirrors ............................................................................3-58

Air filter .................................................................................................5-13

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

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

Automatic engine speed setting (option) .............................................3-33

B

Battery master switch ..........................................................................3-66

Before starting the engine ....................................................................3-20

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

C

Cab ....................................................................................... 3-2, 3-6, 3-10

Check lists ...........................................................................................3-15

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

D

Designated Use .....................................................................................2-2

Drive interlock (option) .........................................................................3-24

Driving on slopes .................................................................................3-34

E

Electrical system ..................................................................................5-33

Emergency exit

Front Guard (option) .....................................................................3-59

Engine cover ........................................................................................3-66

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

F

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

Fire extinguisher ..................................................................................1-25

Fluids and lubricants ............................................................................5-38

G

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

General maintenance work ..................................................................5-35

H

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

Heating ................................................................................................3-48

Hydraulic quickhitch ...........................................................................3-100

I

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

Indicator lights and warning lights ........................................................3-17

Instructions concerning specific components ......................................5-33

Instrument panel ................................................................... 3-4, 3-8, 3-12

Instrument panel overview .....................................................................3-5

Interior light ..........................................................................................3-46

Interlocks .............................................................................................3-74

L

Legal regulations ...................................................................................1-7

Light system ............................................................................... 3-43, 3-45

Load indicator ....................................................................................3-106

Loading and transporting the machine ................................................3-83

Lowering the boom with the engine stopped .......................................3-88

M

Machine

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

Machine overview ................................................................................. 1-3

Maintenance

Biodegradable oil .......................................................................... 5-21

Bleeding the fuel system ................................................................ 5-6

Checking the coolant level ........................................................... 5-11

Checking the engine oil level .......................................................... 5-8

Checking the hydraulic oil level .................................................... 5-19

Engine and hydraulics cooling system ......................................... 5-10

Filling up coolant .......................................................................... 5-11

Fluids and lubricants .................................................................... 5-38

Fuel system .................................................................................... 5-2

Tyres ............................................................................................ 5-28

Maintenance plan ................................................................................ 5-41

Mirrors ................................................................................................. 3-57

N

Noise levels ......................................................................................... 1-14

O

Operating on Slopes ........................................................................... 3-34

Operating the Excavator ..................................................................... 3-14

Operation .............................................................................................. 3-1

Before starting the engine ............................................................ 3-20

Hose burst valve (option) ........................................................... 3-105

Instrument panel overview .............................................3-4, 3-8, 3-12

Parking the machine ..................................................................... 3-37

Triple articulation boom (option) ........................................ 3-86, 3-104

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

P

Parking the machine on slopes ........................................................... 3-38

Pivots and hinges ................................................................................ 5-36

Powertilt ............................................................................................ 3-102

Preparing for Changing Over to Road Travel ...................................... 3-30

Preparing for maintenance and repair work ........................................ 2-13

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

Putting the machine into operation for the first time ............................ 3-14

R

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

Rotating beacon .................................................................................. 3-46

Index

I

1-2 BA 6503 US – Edition 5.0 * * Ba6503en4_0SIX.fm

Index

S

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

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

Safety Information ..................................................................................2-1

Safety Instructions Regarding Operation ...............................................2-4

Seat (air suspension option) ................................................................3-53

Seat (standard) ....................................................................................3-50

Seat adjustment

Backrest adjustment .....................................................................3-51

Horizontal adjustment ......................................................... 3-51, 3-54

Seat depth adjustment ........................................................ 3-51, 3-54

Weight adjustment .............................................................. 3-51, 3-54

Seat belt ...............................................................................................3-56

Side marker lights ................................................................................3-42

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

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

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

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

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

Dimensions model 6503 WD ..........................................................6-7

Dimensions model 6503 WD with triple articulation boom (option) 6-11

Electrical system .............................................................................6-3

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

Hydraulic system ............................................................................6-1

Noise levels ....................................................................................6-5

Stabiliser blade ...............................................................................6-3

Tyres ...............................................................................................6-6

Undercarriage and swivel unit ........................................................6-3

Various lift capacity tables ............................................................6-13

Work hydraulics ..............................................................................6-3

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

Starting checklist ..................................................................................3-15

T

Tilting the cab ......................................................................................3-67

Tires .....................................................................................................5-28

Towing .................................................................................................3-79

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

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

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

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

V

V-belt ...................................................................................................5-15

Ventilation

Ventilation, fresh air ......................................................................3-47

W

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

Washer system

Tank ..............................................................................................3-49

Wheel chocks ......................................................................................3-76

BA 6503 US – Edition 5.0 * 6503b110.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

authorisation, otherwise warranty and product liability for possible damage caused by

these modifications shall not be applicable.

• Subject to modifications and printing errors.

Your Wacker Neuson dealer will be pleased to answer any further questions regarding the

machine or the Operator's Manual.

1-2 BA 6503 US – Edition 5.0 * * 6503b110.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.

Important

Unless otherwise specified, all indications made in this Operator's Manual

refer to models 6503 and 6503-2.

BA 6503 US – Edition 5.0 * 6503b110.fm 1-3

Introduction

1.2 Machine overview

Fig. 1: Machine outside views

1 Road lights

2 Boom mounted work light

3 Forward work light

4 Handrail

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 Transport bar for clamshell bucket

16 Tool kit

17 Rear lights

18 Stabilizer blade

19 Boom interlock

4

5

10

9

12

5

7

11

8

6

1

3

15

16

19

2

6

13

14

17

18

1-4 BA 6503 US – Edition 5.0 * * 6503b110.fm

Introduction

1.3 Brief description

The Wacker Neuson Model 6503WD 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 6503WD 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.

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 6503 US – Edition 5.0 * 6503b110.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. A bent or damaged

ROPS will no longer protect the operator in the event of a tipping incident and must be

replaced. Contact your Wacker Neuson dealer for instructions 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 6503 US – Edition 5.0 * * 6503b110.fm

Introduction

Use: Attachment

The measurements are Metric (Imperial)

Description of attachment Weight Capacity Remarks

Mechanical quickhitch 71 kg (156.53 lbs)

Required for operation of the Wacker Neuson

quickhitch system

Easy Lock quickhitch 81 kg (178.57 lbs)

Powertilt with Easy Lock quickhitch 187 kg (412.26 lbs)

Hammer console 50 kg (110.23 lbs)

Bucket 340 mm (13.39 in)

92 kg (202.83 lbs) 0.058 m³ (2.05 ft³)

104 kg (229.28 lbs) 0.058 m³ (2.05 ft³) Mechanical quickhitch mount

Bucket 370 mm (14.57 in) 114 kg (251.33 lbs) 0.123 m³ (4.34 ft³) Easy Lock quickhitch mount

Bucket 400 mm (15.75 in)

100 kg (220.46 lbs) 0.074 m³ (2.61 ft³)

112 kg (246.91 lbs) 0.074 m³ (2.61 ft³) Mechanical quickhitch mount

116 kg (255.74 lbs) 0.140 m³ (4.94 ft³) Easy Lock quickhitch mount

Bucket 500 mm (19.68 in)

114 kg (251.33 lbs) 0.095 m³ (3.35 ft³)

126 kg (277.78 lbs) 0.095 m³ (3.35 ft³) Mechanical quickhitch mount

132 kg (291 lbs) 0.176 m³ (6.21 ft³) Easy Lock quickhitch mount

Bucket 600 mm (23.62 in) 146 kg (321.87 lbs) 0.210 m³ (7.42 ft³) Easy Lock quickhitch mount

Bucket 650 mm (25.59 in)

132 kg (291 lbs) 0.130 m³ (4.59 ft³)

144 kg (317.46 lbs) 0.130 m³ (4.59 ft³) Mechanical quickhitch mount

Bucket 700 mm (27.56 in) 160 kg (352.74 lbs) 0.245 m³ (8.65 ft³) Easy Lock quickhitch mount

Bucket 800 mm (31.50 in) 176 kg (388.01 lbs) 0.280 m³ (9.89 ft³) Easy Lock quickhitch mount

Bucket 850 mm (33.46 in)

160 kg (352.74 lbs) 0.175 m³ (6.18 ft³)

172 kg (379.19 lbs) 0.175 m³ (6.18 ft³) Mechanical quickhitch mount

Bucket 900 mm (35.43 in) 190 kg (418.88 lbs) 0.314 m³ (11.08 ft³) Easy Lock quickhitch mount

Ditch cleaning bucket 1.2 m (47.24 in)

126 kg (277.78 lbs) 0.205 m³ (7.24 ft³)

169 kg (372.58 lbs) 0.205 m³ (7.24 ft³) Mechanical quickhitch mount

132 kg (291 lbs) 0.174 m³ (6.14 ft³) Easy Lock quickhitch mount

Ditch cleaning bucket 1.4 m (55.11 in)

145 kg (319.67 lbs) 0.238 m³ (8.40 ft³)

187 kg (412.26 lbs) 0.238 m³ (8.40 ft³) Mechanical quickhitch mount

147 kg (324.08 lbs) 0.205 m³ (7.24 ft³) Easy Lock quickhitch mount

Ditch cleaning bucket 1.5 m (59.05 in) 155 kg (341.72 lbs) 0.220 m³ (7.77 ft³) Easy Lock quickhitch mount

Offset bucket 1.2 m (47.24 in)

237 kg (522.49 lbs) 0.150 m³ (5.30 ft³)

187 kg (412.26 lbs) 0.150 m³ (5.30 ft³) Mechanical quickhitch mount

Offset bucket 1.4 m (55.11 in)

255 kg (562.18 lbs) 0.180 m³ (6.36 ft³)

234 kg (515.88 lbs) 0.180 m³ (6.36 ft³) Mechanical quickhitch mount

Offset bucket 1.5 m (59.05 in) 253 kg (557.77 lbs) 0.217 m³ (7.66 ft³) Easy Lock quickhitch mount

Hydraulic hammer NE 36 350 kg (771.62 lbs)

Hydraulic hammer NE 42 438 kg (965.62 lbs)

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