Wacker Neuson 6503-2 Manuel utilisateur

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Operator’s Manual
Mobile Excavator
Notice d’Emploi
Pelle sur pneumatiques
5200008666 50 0912
EN / FR
5200008666
1000271814
1000158220
50
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
All rights reserved
No part of this publication may be reproduced, translated or used in any form or by any means – graphic, electronic
or mechanical including photocopying, recording, taping or information storage or retrieval systems – without prior
permission in writing from the manufacturer.
The cover features the machine with possible optional equipment.
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
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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Wacker Neuson 6503-2 Manuel utilisateur

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