Wacker Neuson 3503 Tracked Conventional Tail Excavator Operator's Manual
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1000183730
0113
4.3.1
Track Excavator
2503, 3003
3503, 3703
OPERATOR’S MANUAL
1 0 0 0 1 8 3 7 3 0
This Operator's Manual include s t he AEM
3af et y
-anual #%
www.wackerneuson.com
Documentation
Description
Operator's Manual
Service manual
Spare parts catalogue 2503
3003
3503
3703
Order no.
1000183730
1000081433
Up serial number AC01814: 1000015263
Up to serial number AD01501: 1000099320
From serial number AD01502: 1000128057
Up to serial number AC01793: 1000015264
Up to serial number AD01819: 1000099323
From serial number AD01820: 1000128060
Up to serial number AC01770: 1000142100
Up to Seriennummer AD01552: 1000133027
From serial number AD01553: 1000128072
Up to serial number AC01770: 1000142112
Up to serial number AD01553: 1000133029
From serial number AD01554: 1000128077
Legend
Edition
4.1
4.1
4.2
4.3
4.3.1
Issued
03 / 2008
04 / 2008
11 / 2008
03 / 2009
01 / 2013
Copyright – 2013 Wacker Neuson Baumaschinen GmbH, Hörsching
Printed in Michigan, USA
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
Flughafenstraße 7
A-4063 Hörsching
Document:
Order no.:
Edition:
OM 25-3703 us
1000183730
4.3.1
Supplementary Operator’s Manual for Protective Structures for Excavators
Supplementary Operator’s Manual for Protective Structures for Excavators
Supplementary Operator’s Manual for Protective Structures for
Excavators
Edition
Language
Article number
Valid for machine model
1.0
us
1000293107
803, 1403, 1404, 1503, 1703, ET18, 1903, 2003, ET20, 2203, 2404, ET24, 2503, 28Z3,
3003, 3503, 3703, 38Z3, 5002, 50Z3, 6002, 6003, 6502, 6503, 75Z3, 8002, 8003, 9503,
12002, 14504
1.1
Supplementary Operator’s Manual
Important
This Supplementary Operator’s Manual must be added to the original Operator’s Manual of which it forms part. Read, understand and follow this Supplementary Operator’s Manual and all other manuals supplied with the machine.
Legend
Supplementary Operator’s Manual for original
Operator’s Manual
Supplementary Operator’s Manual for translation of original Operator’s Manual
– x
Copyright – 2012 Wacker Neuson Linz GmbH, Hörsching
Printed in Michigan U.S.A.
All rights reserved, in particular the globally applicable copyright, right of reproduction and right of distribution.
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.
No reproduction or translation of this publication, in whole or part, without the written consent of Wacker Neuson Linz GmbH.
Violations of legal regulations, in particular of the copyright protection, will be subject to civil and criminal prosecution.
Wacker Neuson Linz GmbH keep abreast of the latest technical developments and constantly improve their products. For this reason, we may from time to time make changes to diagrams and descriptions in this documentation which do not reflect products which have already been delivered and which will not be implemented on these machines.
Technical data, dimensions and weights are given as an indication only. Responsibility for errors or omissions not accepted.
Wacker Neuson Linz GmbH
Flughafenstr. 7
A-4063 Hörsching
Phone +43 7221 63000
E-mail: [email protected]
www.wackerneuson.com
Edition 1.0 Supplementary Operator’s Manual for Protective Structures for Excavators
1-1
Supplementary Operator’s Manual for Protective Structures for Excavators
Definition of the term “Protective Structure”
Protective structures are additional elements that protect the operator or user against risk.
These elements can be installed later on or as standard equipment.
Explanation of abbreviations
ROPS:
Roll Over Protective Structure
TOPS:
Tip Over Protective Structure
FOPS:
Falling Objects Protective Structure
FGPS:
Front Guard Protective Structure. Called “Front Guard” in this Supplementary Operator’s
Manual.
1-2
Edition 1.0 * Supplementary Operator’s Manual for Protective Structures for Excavators
Supplementary Operator’s Manual for Protective Structures for Excavators
1.2
Safety Symbols Found In This Manual
Important indications regarding the safety of the personnel and the machine are identified in this Supplementary Operator’s Manual with the following terms and symbols:
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
Potential consequences of the hazard.
• Obey all safety messages that follow this symbol to avoid injury or death.
WARNUNG
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
Potential consequences of the hazard.
• Obey all safety messages that follow this symbol to avoid possible injury or death.
CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
Potential consequences of the hazard.
• Obey all safety messages that follow this symbol to avoid possible minor or moderate injury.
NOTICE
NOTICE
indicates a situation which, if not avoided, could result in property damage.
Important
Important identifies an instruction that, when followed, provides for a more efficient and economical use of the machine.
Edition 1.0 Supplementary Operator’s Manual for Protective Structures for Excavators
1-3
Supplementary Operator’s Manual for Protective Structures for Excavators
1.3
Mechanical integrity
WARNUNG
Accident hazard due to modified cab and protective structures.
Incorrect work on the cab and protective structures could causes serious injury or death.
• No drilling, cutting or grinding on the cab and protective structures.
• Welding, straightening or bending work on the cab and protective structures is prohibited.
• Immediately have a damaged cab or protective structure replaced.
Important
Check the cab/canopy/rollbar and all protective structures once a day for damage.
Important
Protective structures may only be installed or removed by an authorized
Wacker Neuson Service Center.
1-4
Edition 1.0 * Supplementary Operator’s Manual for Protective Structures for Excavators
Supplementary Operator’s Manual for Protective Structures for Excavators
1.4
Differentiation of protective structures
Important
• Machine operation is only allowed with a correctly installed and intact cab , correctly installed and intact canopy or rollbar for the 803 (option).
• For additional protection, only use correctly installed and intact Wacker Neuson protective structures that have been released for the machine.
Rollbar (valid for 803)
The rollbar has been specially designed for protection in case of an accident.
• ROPS/TOPS tested rollbar (option).
• Shatter protection (option from AI00967); protective structure against falling objects
(fragments or splinters) projected from front of machine.
Cab/canopy (valid for 1403/1404/1503/1703/ET18/1903/2003/ET20/2203/2404/
ET24/2503/28Z3/3003/3503/3703/38Z3/50Z3)
The cab/canopy have been specially designed for protection in case of an accident.
• ROPS/TOPS tested canopy (open version).
• ROPS/TOPS tested cab (closed version/option).
• Protective FOPS structure (option) for cab/canopy; protective structure against falling objects.
• Front Guard (option) for cab/canopy; protective structure against objects from the front (for instance pipes, tree trunks etc.).
• Shatter protection (option) for canopy; protective structure against falling objects
(fragments or splinters) projected from front of machine.
Important
Unless otherwise specified, the term “Cab” refers both to the open and closed variants.
Cab (valid for 5002/6002/6003/6502/6503/75Z3/8002/8003/9503/12002/14504)
The cab has been specially designed for protection in case of an accident:
• ROPS/TOPS tested cab.
• Protective FOPS structure (option) for cab; protective structure against falling objects.
• Front Guard (option) for cab; protective structure against objects from the front (for instance pipes, tree trunks etc.).
Not all protective structures are available for all machines, and not all protective structures can be combined with each other. If you are not sure, contact a Wacker Neuson service center.
Edition 1.0 Supplementary Operator’s Manual for Protective Structures for Excavators
1-5
Supplementary Operator’s Manual for Protective Structures for Excavators
Definition of FOPS/Front Guard categories
Category I:
FOPS and Front Guard to protect against small falling objects or small objects penetrating the cab from the front of the machine, such as bricks, small pieces of concrete, tools, for machines that are used for repairing roads, landscaping work and for working on other construction sites, for instance.
Category II:
FOPS or Front Guard to protect against heavy falling objects or heavy objects penetrating the cab from the front of the machine, such as trees, pieces of rock, for machines that are used for clearance work, demolition work and forestry work.
Responsibility for machine equipped with protective structures
The decision regarding the necessary protective structures (type and category I or II) must be made by the machine operator and depends on the specific work situation.
The operator must observe the national regulations and he must inform the user on the protective structure to be used in a specific work situation.
1-6
Edition 1.0 * Supplementary Operator’s Manual for Protective Structures for Excavators
Supplementary Operator’s Manual for Protective Structures for Excavators
Protective FOPS structure/small screen – category I (option)
Crushing hazard. Falling objects.
Objects will cause severe injury or death.
• Machine operation is prohibited in areas with risks of falling objects, without a protective FOPS structure.
Important
The protective FOPS structure corresponds to category I according to ISO
3449:1992 (valid for 1404 from AG02423) or ISO 10262:1998 (valid for ET18/
ET20/ET24/2503/28Z3/3503/38Z3/50Z3/6003/6503/75Z3/8003/9503/14504).
• Follow all local, state, or national regulations covering falling objects.
• The operator must ensure that only work is performed that does not require any higher protection.
• Accidents cannot be fully avoided despite equipping a machine with protective structures.
Important
Protective structures may only be installed or removed by an authorized
Wacker Neuson Service Center.
Fig. 1: FOPS category I (symbolic representation)
Edition 1.0 Supplementary Operator’s Manual for Protective Structures for Excavators
1-7
Supplementary Operator’s Manual for Protective Structures for Excavators
Protective FOPS structure/large screen – category I (option)
Crushing hazard. Falling objects.
Objects will cause severe injury or death.
• Machine operation is prohibited in areas with risks of falling objects, without a protective FOPS structure.
Important
The protective FOPS structure corresponds to category I according to ISO
3449:1992 (valid for 38Z3) or according to ISO 3449:2008 (valid for 28Z3).
• Follow all local, state, or national regulations covering falling objects.
• The operator must ensure that only work is performed that does not require any higher protection.
• Accidencts cannot be fully avoided despite equipping a machine with protective structures.
Important
Protective structures may only be installed or removed by an authorized
Wacker Neuson Service Center.
Fig. 2: FOPS category I (symbolic representation)
1-8
Edition 1.0 * Supplementary Operator’s Manual for Protective Structures for Excavators
Supplementary Operator’s Manual for Protective Structures for Excavators
Protective FOPS structure/canopy – category I (option)
Crushing hazard. Falling objects.
Objects will cause severe injury or death.
• Machine operation is prohibited in areas with risks of falling objects, without a protective FOPS structure.
Important
The protective FOPS structure corresponds to category I according to ISO
3449:1992 (valid for 1403/1503/1703 (up to AF05530)/1903/2003 (up to
AF05530)/2203/2503/3003/3503/3703/5002/6002/6502).
• Follow all local, state, or national regulations covering falling objects.
• The operator must ensure that only work is performed that does not require any higher protection.
• Accidencts cannot be fully avoided despite equipping a machine with protective structures.
Important
Protective structures may only be installed or removed by an authorized
Wacker Neuson Service Center.
Fig. 3: FOPS category I (symbolic representation)
Edition 1.0 Supplementary Operator’s Manual for Protective Structures for Excavators
1-9
Supplementary Operator’s Manual for Protective Structures for Excavators
Protective FOPS structure/large screen – category II (option)
Crushing hazard. Falling objects.
Objects will cause severe injury or death.
• Machine operation is prohibited in areas with risks of falling objects, without a protective FOPS structure.
Important
The protective FOPS structure corresponds to category II according to ISO
3449:1992 (valid for 1404/1703 (from AG02503)/2003 (from AG02503)/2404 /
50Z3/6003/6503/75Z3/8002/8003/9503/12002) or according to ISO 3449:2005
(valid for 14504).
• Follow all local, state, or national regulations covering falling objects.
• The operator must ensure that only work is performed that does not require any higher protection.
• Accidencts cannot be fully avoided despite equipping a machine with protective structures.
Important
Protective structures may only be installed or removed by an authorized
Wacker Neuson Service Center.
Fig. 4: FOPS category II (symbolic representation)
1-10
Edition 1.0 * Supplementary Operator’s Manual for Protective Structures for Excavators
Supplementary Operator’s Manual for Protective Structures for Excavators
Protective Front Guard structure with integrated FOPS/category I respectively (option)
Stabbing/puncture/crushing hazard from falling objects
(fragments or splinters) projected from front of machine.
Objects will cause severe injury or death.
• Machine operation is prohibited in areas with risks of objects penetrating the cab from the front of the machine, for instance pipes, tree trunks etc. and of falling objects, without a protective Front Guard structure with an integrated
FOPS.
Important
The protective Front Guard structure with integrated FOPS corresponds to category I according to ISO 10262:1998 (valid for ET18/ET20/ET24).
• Follow all local, state, or national regulations covering falling objects.
• The operator must ensure that only work is performed that does not require any higher protection.
• Accidencts cannot be fully avoided despite equipping a machine with protective structures.
Important
Protective structures may only be installed or removed by an authorized
Wacker Neuson Service Center.
Fig. 5: Front Guard with integrated FOPS
(symbolic representation)
Edition 1.0 Supplementary Operator’s Manual for Protective Structures for Excavators
1-11
Supplementary Operator’s Manual for Protective Structures for Excavators
Protective Front Guard structure category I (option)
Stabbing/puncture/crushing hazard from falling objects
(fragments or splinters) projected from front of machine.
Objects will cause severe injury or death.
• Machine operation is prohibited in areas with risks of objects penetrating the cab from the front of the machine, for instance pipes, tree trunks etc. and of falling objects, without a protective Front Guard structure with an integrated
FOPS.
Important
The protective Front Guard structure corresponds to category I according to
ISO 10262:1998 (valid for 2503/28Z3/3003/3503/3703/38Z3).
• Follow all local, state, or national regulations covering falling objects.
• The operator must ensure that only work is performed that does not require any higher protection.
• Accidencts cannot be fully avoided despite equipping a machine with protective structures.
Important
Protective structures may only be installed or removed by an authorized
Wacker Neuson Service Center.
Fig. 6: Protective Front Guard structure (symbolic representation)
1-12
Edition 1.0 * Supplementary Operator’s Manual for Protective Structures for Excavators
Supplementary Operator’s Manual for Protective Structures for Excavators
Protective Front Guard structure category II (option)
Stabbing/puncture/crushing hazard from falling objects
(fragments or splinters) projected from front of machine.
Objects will cause severe injury or death.
• Machine operation is prohibited in areas with risks of objects penetrating the cab from the front of the machine, for instance pipes, tree trunks etc. and of falling objects, without a protective Front Guard structure with an integrated
FOPS.
Important
The protective Front Guard structure corresponds to category II according to
ISO 10262:1998 (valid for 50Z3/6003/6503/75Z3/8002/8003/9503/12002/
14504).
• Follow all local, state, or national regulations covering falling objects.
• The operator must ensure that only work is performed that does not require any higher protection.
• Accidencts cannot be fully avoided despite equipping a machine with protective structures.
Important
Protective structures may only be installed or removed by an authorized
Wacker Neuson Service Center.
Fig. 7: Protective Front Guard structure (symbolic representation)
Edition 1.0 Supplementary Operator’s Manual for Protective Structures for Excavators
1-13
Supplementary Operator’s Manual for Protective Structures for Excavators
Emergency exit for cab equipped with protective Front Guard structure
WARNUNG
Cutting Hazard. Risk of injury due to broken glass.
Risk of personal injury.
• Only smash windows in an absolute emergency.
• Protect face and eyes sufficiently from glass splinters before breaking a window pane.
• Remove all broken glass from the window frame before exiting the cab.
WARNUNG
Tripping/Slipping/Falling hazard. Use the rear window as an exit only in an emergency.
Risk of personal injury.The machine has no footholds or handles at the rear for a safe exit. Therefore injuries may arise when exiting in an emergency.
• Exit the machine through the rear window only in an absolute emergency.
Meaning (option)
This label identifies the emergency exit for a cab equipped with protective Front Guard structure.
Position
Inside the cab, above the rear window
Fig. 8: Emergency exit label
The rear window can be used as an exit if the door is blocked.
Smash the rear window with emergency hammer
A
.
A
Fig. 9: Position of emergency hammer (symbolic representation)
1-14
Edition 1.0 * Supplementary Operator’s Manual for Protective Structures for Excavators
Supplementary Operator’s Manual for Protective Structures for Excavators
Shatter protection (option)
Stabbing/puncture/crushing hazard from falling objects
(fragments or splinters) projected from front of machine.
Objects will cause severe injury or death.
• A shatter protection must be installed on a canopy version if an attachment (a hammer, for instance) causes fragments to fly. This shatter protection takes over the function of a front window.
• Pay attention to the restricted work range (see fig. 13 and 14).
• For 803 machines up to serial number AI00966, operation with an attachment causing fragments to fly is absolutely prohibited.
WARNUNG
Accident hazard in conditions of restricted visibility due to rain, snowfall, dust etc..
Could causes severe injury or death.
• Stop work immediately.
Important
The shatter protection (canopy option) protects the driver against fragments from the front.
• Follow all local, state, or national regulations covering falling objects.
• The operator must ensure that only work is performed that does not require any higher protection.
• Accidents cannot be fully avoided despite equipping a machine with protective structures.
Important
Do not use brushes, steel wool or other abrasive cleaners for cleaning the polycarbonate disc. Do not wipe dust in a dry state.
Important
Protective structures may only be installed or removed by an authorized
Wacker Neuson Service Center.
Edition 1.0 Supplementary Operator’s Manual for Protective Structures for Excavators
1-15
Supplementary Operator’s Manual for Protective Structures for Excavators
Important
A shatter protection must be installed on a canopy version if an attachment (a hammer, for instance) causes fragments to fly. Pay attention to the restricted work range (see fig. 13 and 14).
Work area with shatter protection
Height of work area
A
: 120 cm (47 in).
Figures 13 and 14 refer to work with a Wacker Neuson hydraulic hammer.
Important
Working with another attachment can modify the height of the work area.
A
Fig. 10: Work area with shatter protection
Fig. 11: Work area with shatter protection (top view)
1-16
Edition 1.0 * Supplementary Operator’s Manual for Protective Structures for Excavators
Table of contents
Table of contents
OM 25-3703 us - Edition 4.3.1 * Ba2503_3703us4_3_1IVZ.fm
I
Introduction
EC declaration of conformity (Yanmar engine up to serial number AG00579) ........ 1-8
EC declaration of conformity (Yanmar engine from serial number AG00580) ......... 1-9
Safety Information
Operator’s and Technician Qualifications and Basic Responsibilities ..................... 2-3
General information regarding attachments ...................................................... 2-6
Preparing for maintenance and repair work ...................................................... 2-8
I-1
Table of contents
I-2
Safety Guidelines while using Internal Combustion Engines ................................. 2-10
Operation
Putting the machine into operation for the first time .......................................... 3-8
OM 25-3703 us - Edition 4.3.1 * * Ba2503_3703us4_3_1IVZ.fm
OM 25-3703 us - Edition 4.3.1 * Ba2503_3703us4_3_1IVZ.fm
Table of contents
Lowering the boom with the engine switched off ............................................. 3-42
Measures to be taken in case of malfunctions ................................................ 3-47
Lowering the boom with the engine switched off ............................................. 3-49
I-3
Table of contents
I-4
Troubleshooting
Maintenance
Important information for the use of biodegradable oil .................................... 5-19
Service and maintenance work at regular intervals ......................................... 5-25
Instructions concerning specific components .................................................. 5-26
OM 25-3703 us - Edition 4.3.1 * * Ba2503_3703us4_3_1IVZ.fm
OM 25-3703 us - Edition 4.3.1 * Ba2503_3703us4_3_1IVZ.fm
Table of contents
General instructions for all areas of the machine ............................................ 5-28
Maintenance if the machine is out of service for a longer period of time ............... 5-31
Preparatory work before taking the machine out of service ............................ 5-31
Additional oil change and filter replacement (hydraulics) ................................ 5-33
Specifications
I-5
Table of contents
I-6
OM 25-3703 us - Edition 4.3.1 * * Ba2503_3703us4_3_1IVZ.fm
Index
I
Index
A
Abbreviations ..............................................................................1-1
Air filter ....................................................................................5-11
B
Biodegradable oil ......................................................................5-19
C
Chain maintenance ....................................................................5-22
Check lists ...................................................................................3-9
Crane-handling the machine .....................................................3-37
D
Driving on public roads ............................................................3-19
Driving the excavator ...............................................................3-11
F
Fire extinguisher .......................................................................1-19
Fluids and lubricants .................................................................5-32
H
Heating ......................................................................................3-25
Hose burst valve (option) ..........................................................3-57
I
Indicator lights and warning lights ...........................................3-12
Instrument panel overview ................................................. 3-5, 3-7
Interior light ..............................................................................3-25
L
Legal regulations ........................................................................1-6
Light system ..............................................................................3-24
Lowering the boom with the engine switched off .......... 3-42, 3-49
M
Machine
Brief description .................................................................. 1-3
Fields of application ............................................................. 1-4
Loading and transporting ................................................... 3-38
Overview .............................................................................. 1-2
Maintenance
Air filter ............................................................................. 5-12
Biodegradable oil ............................................................... 5-19
Bleeding the fuel system ...................................................... 5-4
Chain maintenance ............................................................. 5-22
Checking the coolant level ................................................... 5-8
Checking the engine oil level ............................................... 5-5
Checking the hydraulic oil level ........................................ 5-16
Cleaning ............................................................................. 5-28
Electric system ................................................................... 5-25
Engine and hydraulics cooling system ................................. 5-7
Engine lubrication system .................................................... 5-5
Filling in engine oil .............................................................. 5-5
Filling up hydraulic oil ...................................................... 5-18
Fluids and lubricants .......................................................... 5-32
Fuel system .......................................................................... 5-2
General maintenance work ................................................ 5-28
Hydraulic pressure lines ..................................................... 5-21
Hydraulic system ............................................................... 5-15
Instructions concerning specific components .................... 5-26
Maintenance plan ............................................................... 5-34
Pivots and hinges ............................................................... 5-29
Screw connections ............................................................. 5-29
Service and maintenance work at regular intervals ........... 5-25
V-belt ................................................................................. 5-13
N
Noise levels .............................................................................. 1-13
O
Operation .................................................................................... 3-1
Before starting the engine .................................................. 3-15
Cab overview ....................................................................... 3-3
Hammer operation ............................................................. 3-48
Instrument panel overview ............................................3-5, 3-7
Moving off ......................................................................... 3-19
Parking the machine ........................................................... 3-23
Seat belt height adjustment ................................................ 3-29
Starting the engine ............................................................. 3-15
P
Preheating start switch ............................................................. 3-11
Putting into operation ................................................................. 3-2
Check lists ............................................................................ 3-9
Putting the machine into operation for the first time ........... 3-8
Safety instructions ................................................................ 3-8
R
Refuelling ................................................................................... 5-2
Releasing pressure .................................................................... 3-42
Rotating beacon ........................................................................ 3-25
Running-in period ...................................................................... 3-8
OM 25-3703 us - Edition 4.3.1 * Ba2503_3703us4_3_1SIX.fm
I-7
S
Seat adjustment ........................................................................ 3-27
Backrest adjustment ........................................................... 3-28
Horizontal adjustment ........................................................ 3-28
Weight adjustment ............................................................. 3-28
Seat belt .................................................................................... 3-29
Seat belt height adjustment ...................................................... 3-29
Signs and symbols .................................................................... 1-13
Specifications ............................................................................. 6-1
Coolant compound table .................................................... 6-10
Dimensions ......................................................6-12, 6-13, 6-14
Electric system ..................................................................... 6-9
Engine ............................................................ 6-1, 6-3, 6-5, 6-7
Noise levels .......................................................................... 6-9
Vibration .............................................................................. 6-9
Work hydraulics ............................................. 6-2, 6-4, 6-6, 6-8
Starting aid ............................................................................... 3-18
V
Ventilation ................................................................................ 3-25
Ventilation, fresh air .......................................................... 3-25
W
Washer system ......................................................................... 3-26
Tank ................................................................................... 3-27
Working
Freeing the machine ........................................................... 3-63
Practical hints ..................................................................... 3-63
I-8
OM 25-3703 us - Edition 4.3.1 * * Ba2503_3703us4_3_1SIX.fm
Introduction
1 Introduction
1.1
Important operator information
Store the Operator's Manual in the storage compartment at the rear of the seat.
This Operator's Manual contains important information on how to work safely, correctly and economically with the machine. It provides information and instruction for all operators regardless of experience. It helps to avoid dangerous situations and reduce repair costs and downtimes. Furthermore, the reliability and the service life of the machine will be increased by following the instructions in the Operator's Manual. This is why the Operator's
Manual must always be kept at hand in the machine.
Your own safety, as well as the safety of others, depends to a great extent on how the machine is moved and operated. 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 Instructions" to learn how to operate the machine safely. As a rule, keep the following in mind:
Careful and prudent working is the best way to avoid accidents!
Special Instructions
• 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 service work is absolutely necessary. Extensive maintenance and repair work must always be performed by an expert with appropriate training. Insist on using original spare parts when performing maintenance and repair work. This ensures operational safety and readiness of your machine, and maintains its value.
• Special equipment and superstructures are not described in this Operator's Manual.
• We reserve the right to improve the technical standard of our machines.
• Modifying Wacker Neuson products and fitting them with additional equipment and tools not included in our delivery program requires Wacker Neuson's written authorization, otherwise warranty and product liability for possible damage caused by these modifications shall not be applicable.
Your Wacker Neuson dealer will be pleased to answer any further questions regarding the machine or the Operator's Manual.
Abbreviations/symbols
• This symbol stands for a list.
• Subdivision within lists or an activity. Follow the steps in the recommended sequence.
☞
This symbol requires you to perform the activity described.
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.
OM 25-3703 us – Edition 4.3.1 * 2503_3703b110.fm graphics.
This symbol shows the driving direction – for better orientation in figures and
1-1
Introduction
1.2
Machine overview
1 Boom light
2 Boom
3 Stick
4 Rubber tracks
5 Undercarriage
6 Stabilizer blade
7 Cab
8 Valve cover
9 Handle
7
8
2
3
9
5
14
7
6
13
Muffler pipe
14 Lifting and tie down point
15 Lubrication point for track tension
16 Engine cover
15
1
16
13
13
Fig. 1: Machine outside views
5
14
1-2
4
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b110.fm
1.3
Brief description
Travelling drive
Work hydraulics
Cooling system
Cab
Introduction
The model 2503/3003/3503/3703 excavators are self-propelled work machines.
Get informed on and follow the legal regulations of your country.
This machine is a versatile and powerful tool for moving earth, gravel and debris on construction sites and elsewhere. A wide range of attachments accounts for the numerous
applications of the machine, among others hammer and grab applications. See chapter
Chapter “Fields of application, attachments”
The main components of the machine are:
• TOPS (Tip Over Protective Structure) and ROPS (Roll Over Protected Structure) tested closed cab (standard)
• TOPS (Tip Over Protective Structure) and ROPS (Roll Over Protected Structure) tested open cab (option)
• Water-cooled Yanmar four cylinder diesel engine
• Sturdy steel sheet chassis; rubber-mounted engine
The diesel engine permanently drives the twin axial variable displacement pump whose oil flow is sent to a hydraulic motor for each track drive.
The diesel engine also drives the joint gear pump for the work hydraulics. The oil flow of this pump depends on the diesel engine speed only.
Coolant temperature is monitored on the machine's instrument panel.
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 seatbelt, otherwise you can be thrown around or even outside the cab and crushed. Therefore always fasten your seatbelt as you drive and work with the machine.
Tighten the seatbelt before taking up work with the machine.
OM 25-3703 us – Edition 4.3.1 * 2503_3703b110.fm
1-3
Introduction
1.4
Fields of application, attachments
The attachments installed determine the intended use of this machine.
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 tool and its maximum payload with the indications in the lift capacity table. Never exceed the maximum payload stated in the lift capacity table.
Use: attachment
Description of attachment
Complete quickhitch
Bucket B=260 mm (10.2’’)
Bucket B=300 mm (11.8’’)
Bucket B=400 mm (1’4’’)
Bucket B=500 mm (1’8’’)
-
-
Capacity
36 l (1.3 ft
3
)
36 l (1.3 ft
3
)
43 l (1.5 ft
3
)
43 l (1.5 ft
3
)
50 l (1.8 ft
3
)
50 l (1.8 ft
3
)
59 l (2.1 ft
3
)
59 l (2.1 ft
3
)
69 l (2.4 ft
3
)
69 l (2.4 ft
3
)
75 l (2.6 ft
3
)
75 l (2.6 ft
3
)
88 l (3.1 ft
3
)
88 l (3.1 ft
3
)
The measurements are Metric (Imperial).
Possible attachments
Item no.:
Excavator Remarks
1000004049 2503
1000018479 3503
Required for operation of
WackerNeuson quickhitch systems
1000093539 2503
1000093543 2503
1000093534 2503
For quickhitch
For quickhitch 1000017122 2503
1000093755 3503
1000017130 3503
1000093536 2503
For quickhitch
For quickhitch 1000093542 2503
1000093756 3503
1000017125 3503
1000093535 2503
1000093541 2503
1000093757 3503
1000017127 3503
For quickhitch
For quickhitch
For quickhitch
1-4
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b110.fm
Description of attachment
Bucket B=600 mm (2’)
Bucket B=700 mm (2’4’’)
Offset bucket B=850 mm (2’9’’) short stick
Offset bucket B=1000 mm (3’4’’) short stick
Offset bucket B=1400 mm (4’7’’) short stick
Offset bucket B=850 mm (2’9’’) long stick
Offset bucket B=1000 mm (3’4’’) long stick
Offset bucket B=1400 mm (4’7’’) long stick
Grabenräumlöffel B=850 (2’9’’) mm
Ditch cleaning Bucket B=1000 mm (3’4’’)
Capacity
91 l (3.2 ft
3
)
91 l (3.2 ft
3
)
107 l (3.8 ft
3
)
Item no.:
Excavator Remarks
1000093537 2503
1000017121 2503
1000093758 3503
107 l (3.8 ft
3
)
1000017134 3503
107 l (3.8 ft
3
)
1000093538 2503
107 l (3.8 ft
3
)
1000093540 2503
127 l (4.5 ft
3
)
1000093759 3503
For quickhitch
For quickhitch
For quickhitch
127 l (4.5 ft
3
)
1000017128 3503
73 l (2.6 ft
3
)
1000093462 2503
73 l (2.6 ft
3
)
87 l (3.1 ft
3
)
1000017105 2503
1000096529 2503
87 l (3.1 ft
3
)
1000017106 2503
111 l (3.9 ft
3
)
1000096567 3503
111 l (3.9 ft
3
)
1000017131 3503
158 l (5.6 ft
3
)
1000096568 3503
For quickhitch
For quickhitch
For quickhitch
For quickhitch
158 l (5.6 ft
3
)
1000017132 3503
73 l (2.6 ft
3
)
1000093546 2503
73 l (2.6 ft
3
)
87 l (3.1 ft
3
)
1000093548 2503
1000096541 2503
87 l (3.1 ft
3
)
1000096542 2503
111 l (3.9 ft
3
)
1000096569 3503
111 l (3.9 ft
3
)
1000096571 3503
158 l (5.6 ft
3
)
1000096570 3503
158 l (5.6 ft
3
)
1000096572 3503
69 l (2.4 ft
3
)
1000093460 2503
69 l (2.4 ft
3
)
82 l (2.9 ft
3
)
82 l (2.9 ft
3
)
1000093335 2503
1000096528 2503
1000096518 2503
For quickhitch
For quickhitch
For quickhitch
For quickhitch
For quickhitch
For quickhitch
For quickhitch
OM 25-3703 us – Edition 4.3.1 * 2503_3703b110.fm
Introduction
1-5
Introduction
Description of attachment
Ditch cleaning Bucket B=1000 mm (3’4’’)
Ditch cleaning Bucket B=1200 mm (3’11’’)
Ditch cleaning Bucket B=1400 mm (4’7’’)
Hammer mount console
Capacity Item no.:
Excavator Remarks
117 l (4.1 ft
3
)
1000096563 3503
116 l (4.1 ft
3
)
1000096549 3503
98 l (3.5 ft
3
)
98 l (3.5 ft
3
)
1000096540 2503
1000096539 2503
For quickhitch
For quickhitch
-
-
166 l (5.9 ft
3
)
1000096564 3503
164 l (5.8 ft
3
)
1000096550 3503
1000020344 2503
1000070743 3503
For quickhitch
1.5
Operator Qualifications
Requirements to be met by the driver
Earth moving machines may be driven and serviced only by persons who meet the following requirements:
• 18 years or older
• Physically and mentally suited for this work
• Persons have been instructed in driving and servicing the earth moving machine and have proven their qualifications to the contractor
• Persons are expected to perform work reliably.
They have been appointed by the contractor for driving and servicing the earth moving machine.
Get informed on and follow the legal regulations of your country.
1-6
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1.6
EC declaration of conformity (Kubota engine)
EC Declaration of Conformity
According to Machine Directive 98/37/EC, appendix II A
Wacker Neuson Linz GmbH
Haidfeldstr. 37
A-4060 Linz-Leonding
certifies that the construction machine
Type
Make
Track excavator
Wacker Neuson
Models 2503/3703
Number within the machine's series - - - - - - - - - - corresponds to the following pertinent guidelines98/37/EC
89/336/EC
00/14/EC
Applied harmonised standardsEN 292-1:1991, EN 292-2:1995
EN 474-1:1994, EN 474-5:1996
EN 982:1996
National standards and technical specifications
Type Measured sound power level Guaranteed sound power level
2503
3003
3503
3703
92.7
95.1
95.5
95.5
94.0
96.0
97.0
97.0
Certificate no.:
OR/01513/01
OR/01514/01
OR/01515/01
OR/01515/01
Inspection body involved (German Industrial Supervisory Board for Technical
Facilities and Environmental Issues)TÜV Anlagen und Umwelt GmbH
Westendstr. 199
D-80686 Munich
The registered body according to appendix VII
Technical construction engineering committee
Landsberger Str. 309
D-80687 Munich has been consulted for a voluntary design test Type-examination certificate no.: 00198-E
00199-E
00200-E
00201-E
Linz-Leonding, (date) _ _
.
_ _
.
_ _ _ _
Introduction
Josef Erlinger
Wacker Neuson Linz GmbH
OM 25-3703 us – Edition 4.3.1 * 2503_3703b110.fm
1-7
Introduction
1.7
EC declaration of conformity (Yanmar engine up to serial number AG00579)
EC Declaration of Conformity
According to Machine Directive 98/37/EC, appendix II A
Wacker Neuson Linz GmbH
Haidfeldstr. 37
A-4060 Linz-Leonding
certifies that the construction machine
Type
Make
Track excavator
Wacker Neuson
Models 2503/3703
Number within the machine's series - - - - - - - - - - corresponds to the following pertinent guidelines98/37/EC
89/336/EC
00/14/EC
Applied harmonised standardsEN 292-1:1991, EN 292-2:1995
EN 474-1:1994, EN 474-5:1996
EN 982:1996
National standards and technical specifications
Type Measured sound power level Guaranteed sound power level
2503
3003
3503
3703
94.2
95.3
95.4
95.4
94.0
95.0
95.0
95.0
Certificate no.:
OR/01590
OR/01591
OR/01592
OR/01592
Inspection body involved (German Industrial Supervisory Board for Technical
Facilities and Environmental Issues)TÜV Anlagen und Umwelt GmbH
Westendstr. 199
D-80686 Munich
The registered body according to appendix VII
Technical construction engineering committee
Landsberger Str. 309
D-80687 Munich has been consulted for a voluntary design test Type-examination certificate no.: 00198-E
00199-E
00200-E
00201-E
Linz-Leonding, (date) _ _
.
_ _
.
_ _ _ _
Josef Erlinger
Wacker Neuson Linz GmbH
1-8
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b110.fm
Introduction
1.8
EC declaration of conformity (Yanmar engine from serial number AG00580)
EC Declaration of Conformity
according to EC Directive 98/37/EC, 2000/14/EC Appendix 6
Wacker Neuson Linz GmbH
Haidfeldstr. 37
A-4060 Linz-Leonding
declare, under their own responsibility, that the product
Product name
Models
Versions
Serial no.
Wacker Neuson track excavators 25-3703
25-3703
25-3703
- - - - - - - - - - to which this declaration refers, corresponds to the pertinent fundamental requirements regarding safety and health of
EC Directive 98/37/EC, and the requirements of further pertinent EC Directives and standards.
ISO 3471 and
EN 13510
2000/14/EC
Tested information
Noise level
Measured value
Guaranteed value dBA
Administrative unit reported according to Appendix 6
TÜV München
(Munich/Germany
Industrial Supervisory
Board) Westendstr. 199
D-80686 Munich
The following standards and/or technical specifications have been used for the proper application of the requirements regarding safety and health stated in the EC Directives:
EN 474-1, EN 474-3, EN292-1, EN 292-2, ISO 3471, EN 13510;
Place of storage of technical documentation:
Wacker Neuson Linz GmbH
Department: R & D
Haidfeldstr. 37
A-4060 Linz-Leonding
Linz-Leonding, (date) _ _
.
_ _
.
_ _ _ _
Josef Erlinger
Wacker Neuson Linz GmbH
OM 25-3703 us – Edition 4.3.1 * 2503_3703b110.fm
1-9
Introduction
1.9
Type labels and component numbers
Serial number AG00580
The serial number is stamped on the machine chassis. It is also located on the Product
Identification Number plate riveted to the front left chassis of the machine.
Type label information
Example: 3703
Fig. 1: Type label: location
Model:
Year:
PIN:
3703
2007
AG00580
Power, SAE:
Mass:
Load:
Max. gross mass:
Max. axle load:
23.7 kW (31.8 hp)
3726 kg (8214 lbs)
---------------
---------------
---------------
---------------
– see chapter 6 Specifications
Fig. 2: Type label
Cab certification number
The certification label (arrow) is located on the chassis of the cab, at the upper left beside the door.
Fig. 3: Cab type label
1-10
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b110.fm
Fig. 4: Diesel engine type label up to serial number
AG00579
Engine serial number
The type label (arrow) is located on the cylinder-head cover (engine).
Example:
Yanmar 46557
Introduction
Fig. 4: Diesel engine type label from serial number
AG00580
OM 25-3703 us – Edition 4.3.1 * 2503_3703b110.fm
1-11
Introduction
Label overview
1-12
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Introduction
1.10 Symbols
Fig. 5: Eye hook label
Fig. 6: Label for points used for strapping down the machine
Description
Tie down points.
Location points designated for tie down of the machine during transport to prevent movement during transport.
Location
On either side of the stabilizer blade, and on either side of the undercarriage.
Description
Noise levels produced by the machine.
L
WA
= sound power level
Location
Cabin: On left window.
Canopy: On the left side of the seat console.
Fig. 7: Noise level label
The following symbols are displayed on the machine to provide pictorial information to the user. The information and explanations are provided to avoid misinterpretation by the user.
The symbols have been chosen to provide important information to those involved with operating, adjusting, maintaining, and repairing this machine.
Description
Locates the lifting points for hoisting the excavator with lifting devices (slings, tracks, or cables).
Location
On either side of the stabilizer blade, and on either side of the boom near the cylinder end of the stick hydraulic cylinder mounting.
Description
This label shows the
forward
driving direction.
Location
On each undercarriage at the idler end of the structure.
Fig. 8: Direction arrows
Description
Fill location for diesel fuel only.
Location
On the fuel filler neck in engine room.
Fig. 9: Diesel
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1-13
Introduction
Fig. 10: Hydraulic oil
Fig. 11: Cable control engine hot
Fig. 12: Cable control valve cover
Description
Hydraulic oil reservoir. Use hydraulic fluid only.
Location
On the hydraulic oil reservoir.
Description
Indicate the cable control to open the engine cover.
Location
On the front side of the seat console.
Description
Indicate the cable control to open the valve cover.
Location
On the front side of the seat console.
Description
Explains the functions of the joysticks (control pattern "A") and of other controls. If the machine is fitted with the "selection valve" check before starting the machine which control pattern you have chosen!
Location
On the cabin roof.
Fig. 13: Functions of joysticks
Fig. 14: Position of the ball valve
Fig. 15: Interval for greasing
1-14
Description
Explains the position of the ball valve for different attachments.
Location
On the hydraulic oil tank.
Description
Shows the interval for greasing.
Location
On the front of the upper carriage.
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b110.fm
Fig. 16: (Opt.) Functions of the joysticks
Safety Labels
Fig. 17: Tighten tracks
Fig. 18: Prohibitory label
Introduction
Description (Opt.)
Explains the functions of the joysticks (control pattern "B"). Check before starting the machine which control pattern you have chosen!
Location
On the cab roof.
Always follow the instructions on the safety labels!
Description
The label means the following:
• Potential high pressure grease discharge from the track tension adjustment fitting.
• Read the Operator’s Manual before releasing or tightening the tracks to avoid potential injury from ejected grease.
Location
On the undercarriage near the opening or dismounting to insert the grease fitting.
Description
Stop the engine before opening the safety devices ( like engine hoot, fan guard,..)
Location
On the engine hood.
Description
This safety label warns of the following hazards:
Cutting hazard. Cooling fan can cut when rotating. Stop engine before working on the engine or cooling system.
Entanglement hazard. You can be pinched or entangled in the engine V-belt when the engine is running. Stop engine before working on the engine.
Hot surface and burn hazards. Do not touch.
Contents are under pressure. Do not remove cap.
Location
In the engine compartment.
Fig. 19: Rotating V-belt
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1-15
Introduction
Fig. 20: Hot surfaces
Fig. 21: Hydraulic oil tank under pressure
Fig. 22: Front window
Fig. 23: Read the operator’s manual
Fig. 24: Keep distance 1
Description
Hot surface! Do not touch.
Location
Engine compartment near muffler system.
Description
The tank is hot and under pressure!
• Allow the fluids to cool down!
Carefully and slowly open the cover only after the cooler fluids has cooled down, to allow the pressure to escape.
Location
On the top of the hydraulic tank.
Description
Pinch point hazard. Always use the handles to open and close the front window.
Always fasten the front window with both locks.
Location
On the front window.
Description
Attention! Read and understand the Operator's Manual before starting, operating, adjusting, maintaining, or repairing the machine.
Location
On the b-pillar in the cabin.
Description
Crushing hazard. Bystanders must stay clear of the machine when it is being operated.
Location
On either side of the boom structure.
Description
Accumulator is under high pressure. Always read Service Manual before maintaining or repairing the machine.
Location
On the bracket near to the accumulator.
Fig. 25: Under pressure
1-16
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b110.fm
Fig. 26: Keep distance 2
Fig. 27: Keep distance 3
Fig. 28: Read and understand
Introduction
Description
Crushing hazard. Bystanders must stay clear of the machine when it is being operated.
Location
On the left and right side of the boom swing console on the chassis.
Description
Collision hazard. Bystanders must stay clear of the machine when it is being operated.
Location
On the rear window.
Description
Crushing hazard. Do not lose this bolt!
Read and understand the operator’s and service manual.
Location
On the rear of chassis on both sides of the machine.
Description
Before performing maintenance or repairs on the machine, stop the engine, remove the starter key, and read and understand the Operator's Manual and the service manual.
Fig. 29: Read manual before maintaining or repairing
OM 25-3703 us – Edition 4.3.1 * 2503_3703b110.fm
Before leaving the machine lower all equipment to the ground, remove the starter key and lock the controls.
Location
On the B pillar in the cab.
1-17
Introduction
Description
Operate only from the seat and fasten the seat belt to prevent falling out of the machine.
Fig. 30: Operator’s seat and fasten seat
Operate within the stability limits of machine, do not overload, use only approved attachments and operate only on solid ground. Follow the instructions in the Operator's Manual.
Location
On the B pillar in the cab.
1-18
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b110.fm
Introduction
1.11 Fire extinguisher
The fire extinguisher is not supplied with the machine.
☞
Retrofitting a fire extinguisher according to NFPA must be performed by an authorized
Wacker Neuson service center.
☞
Location:
➥
In the cab, on the left in driving direction behind the seat.
☞
Installation:
• Mount the fire extinguisher on the cab profile according to the manufacturer’s instructions.
• The maximum hole diamenter is 6mm (0.24’’)
• The maximum number of holes is two.
Important!
Check the fire extinguisher at regular intervals, also make sure it is safely mounted.
OM 25-3703 us – Edition 4.3.1 * 2503_3703b110.fm
1-19
Introduction
1-20
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b110.fm
Safety Information
2 Safety Information
2.1
Safety Symbols Found in this Manual
.
This is the safety alert symbol. It is used to alert you to potential personal hazards.
• Obey all safety messages that follow this symbol..
OM 25-3703 us – Edition 4.3.1 * 2503_3703b210.fm
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
Obey all safety messages that follow this symbol to avoid injury or death.
Warning!
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
Obey all safety messages that follow this symbol to avoid possible injury or death.
Caution!
CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
Obey all safety messages that follow this symbol to avoid possible minor or moderate injury.
NOTICE
Used without the safety alert symbol. NOTICE indicates a situation which, if not avoided, could result in property damage.
Note
:
Contains additional information important to a procedure.
Important!
“Important” identifies an instruction that, when followed, provides for a more efficient and economical use of the machine
.
Environment!
Failure to observe the instructions identified by this symbol can result in damage to the environment. The environment is in danger if environmentally hazardous material, such as waste oil, is not subject to proper use or disposal.
2-1
Safety Information
2.2
Warranty
Warranty claims must be submitted to your Wacker Neuson dealer only.
2.3
Designated Use
1. In accordance with its designated use, the machine may be used ONLY for moving earth, gravel, coarse gravel or ballast and rubble. It may also be used for working with the attachments approved in the “Fields of Application” chapter.
2. No other applications are designated for the use of the machine. Wacker Neuson Linz
GmbH will not be liable for damage resulting from use other than mentioned above.
The user alone will bear the risk.
3. “Designated use” also includes observing the instructions set forth in this Operator’s
Manual and observing the maintenance schedule.
4. Machine safety can be negatively affected by performing machine modifications without proper authority and by using spare parts, equipment, attachments and optional equipment which have not been checked and released by
Wacker Neuson Linz GmbH. Wacker Neuson Linz GmbH will not be liable for damage resulting from unapproved parts or unauthorized modifications.
5. Wacker Neuson Linz GmbH shall not be liable for personal injury and/or damage to property caused by failure to observe the safety instructions on labels and in this Operator’s Manual, and by the negligence of the duty to exercise due care when:
• transporting the machine
• operating the machine
• servicing the machine and performing maintenance work
• repairing the machine
This is also applicable when special attention has not been drawn to the duty to exercise due care.
6. Read and understand this Operator’s Manual before starting up, moving, operating, servicing or repairing the machine. Observe all safety instructions.
7. The machine shall NOT be used for transport jobs on public roads!
2.4
Preparing to use the Machine
Conditions for use
• The machine has been designed and built in accordance with state-of-the-art standards and recognized safety regulations. Nevertheless, its use can constitute a risk to the user or to third parties, or cause damage to the machine and to other material property.
• Read and follow this Operator’s Manual and other manuals that accompany the machine.
• The machine must only be used in accordance with its designated use and the instructions set forth in this Operator’s Manual.
• The machine must only be used by qualified operators who are fully aware of the risks involved in operating the machine.
• Do not start, move or operate a damaged or defective machine. Any mechanical dysfunctions, especially those affecting the safety of the machine, must be repaired immediately. Only qualified technicians shall determine how to move a damaged or defective machine to a safe place for diagnoses and repair.
• The user/owner commits himself to operate and keep the machine in serviceable condition and, if necessary or required by law, to require the operating or servicing persons to wear protective clothing and safety equipment.
2-2
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b210.fm
User training and knowledge
Preparing for use
Safety Information
• Always keep this Operator’s Manual and other manuals that accompany the machine in their storage compartment provided in the operator’s station on the machine.
Immediately replace an incomplete or illegible Operator’s Manual.
• All persons working on or with the machine must read and understand the safety information in this Manual before beginning work. This applies especially to persons working only occasionally on the machine, such as performing set-up or maintenance tasks.
• Follow, and instruct the operator’s in, legal and other mandatory regulations relevant to accident prevention and environmental protection.These may include handling hazardous substances, issuing and/or wearing personal protective equipment, or obeying traffic regulations.
• The user/owner must regularly ensure that all persons entrusted with operation or maintenance of the machine are working in compliance with this Operator's Manual and are aware of the risks and safety factors of the machine.
• Before starting the machine, ALWAYS inspect the machine to make sure that it is ready for safe work and travel operation.
• Wear close-fitting work clothes that do not hinder movement. Tie back long hair and remove all jewelry (including rings).
Modifications and spare parts
• NEVER make any modifications, additions or conversions to the machine and its superstructures (for example, cab, etc.), or the machine’s attachments, without the approval of Wacker Neuson! Such modifications may affect safety and/or machine performance. This also applies to the installation and adjustment of safety devices and valves, as well as to welding work on load-bearing elements.
• Spare parts must comply with the technical requirements specified by Wacker Neuson.
Contact your Wacker Neuson dealer for assistance.
2.5
Operator’s and Technician Qualifications and Basic Responsibilities
User/owner responsibility
• Only allow trained and experienced individuals to operate, maintain, or repair the machine. NEVER let unauthorized or underaged persons operate the machine.
• Clearly and unequivocally define the individual responsibilities of the operator’s and technician for operation, maintenance, and repair.
• Define the machine operator’s responsibilities on the job site and for observing traffic rules. Give the operator’s the authority to refuse instructions by third parties that are contrary to safety.
• Do not allow persons to be trained or instructed by anyone other than an experienced person. Also, NEVER allow persons taking part in a general training course to work on or with the machine without being supervised by an experienced person.
Repair person qualifications
• Work on the electric system and equipment, on the undercarriage and the steering and brake systems shall be performed only by skilled individuals who have been specially trained for such work.
• Work on the hydraulic system of the machine must be performed only by a technician with special knowledge and experience in hydraulic equipment.
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2-3
Safety Information
2.6
Safety instructions Regarding Operation
Preparing for use
• Keep the machine clean. This reduces the risk of fire hazards (such as from combustible materials like rags), and reduces the risk of injury or operational accidents that can be caused by dirt build-up on the drive pedals or foot rests and steps.
• Observe all safety, warning, and informational signs and labels on the machine.
• Start and operate the machine from the seat only.
• The operator’s must sit in the seat, fasten and adjust the seat belt before putting the machine into operation.
• Always adjust the seal position before starting work. Never change the seat position when driving or working!
• Make sure that all safety devices are properly installed and functional before starting work.
• Before putting the machine/attachment into operation (startup/moving), make sure that no one in the immediate vicinity will be at risk.
Starting and stopping
Work area awareness
Danger area awareness
• Perform starting and stopping procedures according to this Operator’s Manual.
• Observe all indicator lights.
• Do not use starting fluid (for example, ether) especially in those cases in which a heater plug (intake air pre-heating) is used at the same time.
• Make sure the control levers, the signaling and the light systems are functional before operating the machine, and also before restarting after an interruption of work.
• Fold up the control lever base before releasing the seat belt in order to avoid unintentional operation.
• Familiarize yourself with the surroundings and circumstances of the work site before beginning work. Be aware of:
• obstacles in the working and traveling area
• the soil weight-bearing capacity
• any necessary barriers separating the work site from public roads
• Always keep at a safe distance from the edges of building pits and slopes.
• Look out for the following when working in buildings or in enclosed areas:
• height of the ceiling/clearances
• width of entrances
• maximum load of ceilings and floors
• sufficient room ventilation—danger of carbon monoxide poisoning!
• Observe the danger area. See “Danger area awareness”.
• Use the rearview mirror to stay aware of work area obstacles and personnel.
• Always use the work lights in conditions of poor visibility and after dark. However, make sure that users of public roads will not be temporarily blinded by the work lights.
• Provide additional lighting of the work area if the lights of the machine are not sufficient for performing work safely.
• The danger area is the area in which persons are in danger due to the movements of the machine, work equipment, additional equipment, or material.
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Operating the machine
Carrying passengers
Mechanical integrity
Traveling
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Safety Information
• The danger area also includes the area affected by falling material, equipment or construction debris. The danger area must be extended by 0.5 m (20 inches) in the immediate vicinity of buildings, scaffolds, or other elements of construction.
• Seal off the danger area if it is not possible to keep a safe distance. Stop work immediately if persons do not leave the danger area in spite of warnings!
• Never operate the machine if you are standing on the ground.
• Operate the machine ONLY when you are seated and you have fastened your seat belt. Stop the engine before releasing the seat belt.
• During operation on slopes, drive or work uphill or downhill. If traveling across a slope cannot be avoided, bear in mind the tilting limit of the machine. Always keep the attachments/work equipment close to the ground. This also applies to traveling downhill. When traveling or working across a slope, the load must be on the uphill side of the machine.
• On sloping terrain, adapt your travel speed to the prevailing ground conditions.
• Never get on or off a moving machine, and do not jump off the machine.
• The travel control levers require practice before a user becomes familiar with the control response. Therefore, adjust the travel speed to your abilities and the surroundings.
• When traveling across a slope with the telescopic undercarriage extended, position the boom facing down the slope, and the bucket about 10–20 cm (4’’–8’’) above the ground. This will help to minimize the possibility of personal injuries and equipment damage caused by a hydraulic hose/connector failure in the telescopic undercarriage actuation system. The weight of the machine will cause the undercarriage to retract to the narrow configuration if hydraulic system pressure decreases due to lost fluid.
• Do not transport people on the machine or in the attachment.
• Never install a man basket or a working platform to the machine.
• Take the necessary precautions to make sure the machine is used only when in a safe and serviceable state.
• Operate the machine ONLY if all protective and safety-oriented devices (ROPS, removable safety devices, soundproofing elements, mufflers, etc.) are in place and fully functional.
• Check the machine before entering the cab to operate the machine for visible damage and defects. Report any changes, including changes in the machine’s function and response, to your supervisor immediately!
• If the machine is functioning unpredictably, stop the machine immediately, lock it, and report the malfunction to a qualified tecnician or supervisor. Safety-relevant damage or malfunctions of the machine must be rectified immediately.
• When traveling on or in public areas, observe all applicable regulations. Make sure beforehand that the machine is in compliance with these regulations.
• Installed work lights must NOT be used for travel.
• When crossing underpasses, gates, bridges and tunnels, or when passing under overhead lines, make sure the clearance height and width are sufficient to avoid contact.
• Empty the bucket before traveling on public roads.
2-5
Safety Information
2.7
Applications with Lifting Gear
General information
• Craning applications are procedures involving raising, transporting and lowering loads with the help of slings and load-securing devices (for example, ropes and chains). In doing so, the help of persons is necessary for securing and detaching the load. This applies, for example, to lifting and lowering pipes, shaft rings or containers.
• The excavator may be used for applications with lifting gear ONLY if the prescribed safety devices are in place and functional.
Criteria
Conditions for safe operation
• When used for craning applications, the machine must meet the following criteria:
• Proper equipment for slinging and securing the load
• Proper lift capacity per tables in this Operator’s Manual
• In addition, a safe load indicator is required for machines bearing loads of over 1000 kg
(2205 lbs) or an overturning moment of over 40000 Nm (29502 lbf ft).
• Secure the load to prevent it from falling or slipping. Install an OSHA-approved load hook after removing the bucket or other approved attachment to provide a secure attachment point for the lifting sling, chain, or cable.
• Have loads fastened, and crane operators instructed, by a qualified person competent in craning operation and standard hand signals. The person giving instructions to the operator must be within sight of the operator during load attachment and load disconnection.
• The load shall be kept as close to the surface as practical to accomplish the craning operation. The operator shall gently move the controls and machine to avoid swing or oscillating motion of the load. A tether line is recommended to dampen the tendency of the load to swing or oscillate during the craning operation.
• Machine travel with a raised load must be done very carefully on a level surface moving very slowly to avoid sudden motion that can cause swinging or oscillating motion of the load.
• The person(s) attaching the load to the excavator shall approach only if the operator is in visual contact with them. No one shall approach the machine or attempt to attach the load until the excavator has stopped and the operator has signaled for the attachment.
2.8
Attachments
General information regarding attachments
• Prior to traveling remove all attachments which cannot be secured in compliance with the legal regulations of your country.
• The machine operating characteristics including steering vary with different option attachments and counter weights. The operator shall be familiar with the variations and act accordingly.
• Use only approved attachments and connecting hardware.
• Attach and remove attachments carefully to avoid damage and potential injury.
• Confirm that the attachment has been properly and securely attached to the machine according to the instructions. Before using the attachment, the operator shall confirm that the attachment performs correctly in response to control actuation.
• Do not attach the attachment with the engine running and the machine moving.
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Safety Information
• Before putting the machine/attachment into operation (startup/moving), make sure that no one in the immediate vicinity will be at risk.
• Before leaving the seat, always secure the machine against unintentional movement and unauthorized use. Lower the attachments to the ground.
Installation notes
• Couple and uncouple hydraulic hoses/lines (hydraulic quick couplers) only if the engine is stopped and the controls actuated to release the hydraulic pressure remaining in the circuit. Follow the operating instructions for releasing the pressure.
• Operate the machine only if all protective devices for the attachments have been installed and are functional, and if all brake, light and hydraulic connections have been connected.
• If an optional attachment is installed, make sure that all lights and associated indicator lights are installed and functional.
• The lock pin of the quick hitch attachment shall be visible at each end of the pin to confirm that the attachment is securely locked in place. The operator shall perform a check operation to confirm the latching integrity before operating at a production pace.
• Prior to fitting attachments to the stick (the mobile extension of the boom), secure the control lever of the hydraulic control unit against unintentional movement. Raise the left arm rest to avoid unintentional activation for the ISO/SAE operating mode. Avoid actuating the right hand control if the alternative control mode is selected.
2.9
Transport and Towing
Towing
The machine must be towed, loaded and transported according to the procedures
described within this Operator’s Manual. See “Towing” on page 36
and
“Tying down the excavator” on page 39
.
Transporting
• The transporting vehicle must have sufficient load capacity and platform size to safely transport the machine. Refer to section 6 of this manual to determine the physical characteristics of the machine before loading and transporting.
• Use OSHA-approved straps, chains or cables to securely fastened the machine to the surface of the transport.
• Use the tie down points provided on the load surface of the transport.
• Attach the tie down devices to the excavator at the designated tie down points.
• Confirm that the excavator tie down procedures will prevent sideways, forward, rearward and upward motion of the excavator in the event the transport vehicle is involved in an incident or sudden avoidance maneuver.
2.10 Safety Guidelines for Maintenance
General maintenance notes
• Adhere to prescribed intervals or those specified in this Operator’s Manual for routine checks/inspections and maintenance work.
• For inspection and maintenance work, ensure that all tools and workshop equipment are capable of performing the tasks prescribed. Do not use defective or broken tools.
Use certified measuring devices that are routinely calibrated for accuracy (torque wrench, pressure gauge, ammeter, etc.).
• Replace hydraulic hoses within stipulated and appropriate intervals even if no safetyrelevant defects have been detected.
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2-7
Safety Information
• Recycle scrapped parts and drained fluids according to environmental and hazardous material requirements. To avoid fire and health hazards, dispose of soiled shop towels by approved methods.
• Always tighten any screws, electrical connections, or hose connections that may have been loosened during maintenance.
• Upon completion of the maintenance and repair work, immediately refit and check any safety devices removed for set-up or maintenance purposes.
Personal safety measures
• Brief the technician and the operator before beginning maintenance or repair work.
Appoint someone to supervise the activities.
• Always work in groups of two when diagnosing a machine problem requiring the engine to be running. Both persons must be trained on the machine—one person must be seated on the seat and maintain visual contact with the other person.
• Observe the specific safety instructions in the maintenance section of this Operator’s
Manual.
• Always keep a safe distance from all rotating and moving parts, for example, fan blades, V-belt drives, PTO shaft drives, fans, etc.
• Before starting work on the machine, always ensure safe blocking/support.
• Apply special care when working on the fuel system due to the increased danger of fire.
• Engine and muffler system become very hot during operation and require cool-down time after machine is shut off. Avoid contact with hot parts. Wait for the machine to cool before touching components.
• Retainer pins can fly out or splinter when struck with force. Avoid striking the pins during operation, repair, or maintenance.
• Do not use starting fluid (for example, ether), especially in those cases in which a heater plug (intake air pre-heating) is used at the same time.
Preparing for maintenance and repair work
• Prior to performing repair and maintenance work, always attach a warning label such as “Repair work—do not start machine!” to the control elements as a precautionary measure.
• Observe the starting and stopping procedures set forth in this Operator’s Manual. This applies to any work concerning the operation, conversion or adjustment of the machine and its safety-oriented devices, or any work related to inspection and maintenance.
• Prior to performing assembly work on the machine, stabilize the area under repair and use proper lifting and support devices to change parts weighing more than 9 kg (20 lbs).
• Perform maintenance work ONLY if:
• the machine is positioned on firm and level ground
• secured against unintentional movement
• all hydraulically movable attachments and working equipment have been lowered to the ground
• the engine is stopped
• the starting key has been removed
• the pressure accumulator is discharged
• Perform maintenance work beneath a raised machine, attachments or additional equipment ONLY if a safe and secure support has been provided. The use of hydraulic rams or jacks as the sole method of support does NOT sufficiently secure raised machines or equipment/attachments!
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Safety Information
Performing maintenance and repairs
• Observe the adjustment, maintenance and inspection activities and intervals set forth in this Operator’s Manual, including information on the replacement of parts and partial equipment. These activities must be performed only by qualified personnel.
• Disconnect the negative battery terminal when working on the electrical system.
• Do not allow the machine to be serviced, repaired, or test-driven by unauthorized personnel.
• If maintenance with the engine running cannot be avoided, lower the stabilizer blade and raise the control lever base.
• Wear a safety harness when performing elevated maintenance work. Keep all handles, steps, handrails, platforms, landings, and ladders free from dirt, snow and ice.
• Always use specially designed or otherwise safety-oriented ladders and working platforms to perform overhead assembly work. NEVER use machine parts or attachments/superstructures as a climbing aid!
• Do not use the work equipment as lifting platforms for persons.
• In accordance with this Operator’s Manual and instructions for the respective assembly, release the pressure in all system sections and pressure lines (hydraulic system) before performing any maintenance work.
2.11 Special Hazards
Battery
• In case of a frozen battery or of an insufficient electrolyte level, do not try starting the machine with battery jumper cables. The battery can burst or explode.
• Batteries contain caustic sulphuric acid. When handling the battery, observe the specific safety instructions and regulations relative to accident prevention.
• A volatile oxyhydrogen mixture forms in batteries during normal operation and especially when charging. Always wear gloves and eye protection when working with batteries.
• Starting the machine with a battery jumper cable can be dangerous if performed improperly. Observe the safety instructions regarding the battery.
Tracks
Electric energy
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• Repair work on the tracks must be performed only by trained technical staff or by an authorized workshop.
• Defective tracks reduce the machine's operational safety. Therefore, check the tracks regularly for cracks, cuts or other damage.
• Check track tension at regular intervals.
• Use only original fuses with the specified current rating.
• In case of electrical system malfunctions, stop the machine immediately, disconnect the battery (by using the battery master switch), and perform troubleshooting procedures.
• When working with the machine, maintain a safe distance from overhead electric lines!
If work must be performed close to overhead lines, the equipment and attachments must be kept well away from them.
• If the machine comes into contact with a live wire:
• Immediately move the machine out of the danger area.
• Warn others against approaching and touching the machine.
• Do not leave the machine until the line that has been touched or damaged has been safely de-energized!
• Make sure that work on the electric system is performed only by a technician with appropriate training, in accordance with applicable electrical engineering codes.
2-9
Safety Information
• Inspect and check the electrical equipment of the machine at regular intervals. Defects such as loose connections or scorched cables must be repaired immediately.
• Observe the operating voltage of the machine/attachments. The voltages must be compatible (12 volts) and confirm that an appropriate fuse or circuit breaker is incorporated in the system to prevent damage from malfunction or short circuit.
• Always remove the grounding strap from the battery when working on the electric system.
Hydraulics
Noise
• Check all lines, hoses, and threaded couplers and fittings regularly for leaks and obvious damage. Repair any damage and leaks immediately. Splashed oil can cause injury and fire!
• Close all doors and windows if practical.
• Wear ear protection. This is especially important when performing hammer operations or working in enclosed areas.
MSDS
• When handling oil, grease, and other chemical substances such as battery electrolyte or hydraulic fluid, observe the product-related safety regulations (Material Safety Data
Sheet (MSDS).
2.12 Safety Guidelines while using Internal Combustion Engines
Warning!
Internal combustion engines present special hazards during operation and fueling. Failure to follow the warnings and safety guidelines could result in severe injury or death.
Read and follow the warning instructions in the engine owner’s manual and the safety guidelines below.
Running the engine
When running the engine:
• Keep the area around the muffler and exhaust pipe free of flammable materials.
• Check the fuel lines and the fuel tank for leaks and cracks before starting the engine.
Do not run the machine if fuel leaks are present or the fuel lines are loose.
When running the engine:
• Engine exhaust CAN KILL YOU IN MINUTES. Engine exhaust contains carbon monoxide. This is a poison you cannot see or smell. Never run the machine indoors or in an enclosed area such as a deep trench unless adequate ventilation, through such items as exhaust fans or hoses, is provided.
• Do not smoke while operating the machine.
• Do not run the engine near open flames.
• Do not touch the engine or exhaust while the engine is running or immediately after it has been turned off.
• Do not operate a machine when its fuel cap is loose or missing.
• Do not remove the radiator cap when the engine is running or hot. The radiator fluid is hot and under pressure, and may cause severe burns!
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Fueling the engine
When fueling the engine:
• Clean up any spilled fuel immediately.
• Refill the fuel tank in a well-ventilated area.
• Replace the fuel tank cap after refueling.
When fueling the engine:
• Do not smoke.
• Do not refuel a hot or running engine.
• Do not refuel the engine near an open flame.
Safety Information
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Safety Information
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3 Operation
Operation
This chapter describes the controls, and contains information on the function and handling of the indicator lights and controls in the cab.
The pages stated in the table refer to the description of the controls.
A combination of digits, or a combination of digits and letters (e.g. 40/
18
or 40/
A
) used for identifying the control elements, means: fig. no. 40/control element no. 18 or position
A
in fig. no. 40
Figures carry no numbers if they are placed to the left of the text.
The symbols used in the description have the following meanings:
• This symbol stands for a list
• Subdivision within lists or an activity. Follow the steps in the recommended sequence
☞
This symbol requires you to 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.
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3-1
3
1
5
16
15
11
Operation
28
13
10 24 22 23 25
7
18
17
8
20
2
27
26
6
19
14
21
3-2
12
9 12
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Operation
3.1
Cab overview
28
29
30
31
11
12
13
14
8
9
5
6
3
4
7
Pos.
Description
1
For more information see page
Control lever (left)
2 Control lever (right)
Control lever base (left)
Control lever base (right)
Armrest (left)
Armrest on the right (not shown)
Lever (horizontal seat adjustment)
............................................................................................................................................3-3
Air vents
................................................................................................................................................................................3-3
Radio (option)
10
15
16
17
18
19
20
21
22
23
24
25
26
27
Seat (backrest adjustment)
......................................................................................................................................................3-3
Seat belt (lock)
.......................................................................................................................................................................3-3
Cup holder
Document storage (underneath the seat console)
Right-hand side switch panel
...................................................................................................................................................3-3
Left-hand side switch panel
......................................................................................................................................................3-3
Throttle
Stabilizer blade lever
...............................................................................................................................................................3-3
Auxiliary hydraulics pedal
........................................................................................................................................................3-3
Preheating start switch
Cigarette lighter
Round display element
............................................................................................................................................................3-3
Travel pedal (left)
....................................................................................................................................................................3-3
Travel pedal (right)
..................................................................................................................................................................3-3
Travel lever (left)
.....................................................................................................................................................................3-3
Travel lever (right)
...................................................................................................................................................................3-3
Travel interlock status indicator light (option)
Travel interlock emitter/receiver unit
Changeover valve for A/B controls (option, underneath the base plate)
.......................................................................................3-44
Weight adjustment for seat
Proportional controls indicator lights (option)
Lever for engine and valve cover
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3-3
Operation
Up to serial number: AD03524
34
33
35
42
36
32
?
R
00000 00 h
38
39
Right-hand side control elements
37
43
40
44 45
41
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Operation
3.2
Instrument panel overview
Pos.
Description
32
For more information see page
Indicator light (red) – hydraulic oil filter
33
34
35
Indicator light (red) – alternator charge function
Indicator light (red) – engine oil pressure
Indicator light (red) – coolant temperature
................................................................................................................................3-12
36
37
38
39
40
41
Indicator light (yellow) – cold starter
Indicator light (red) – safe load indicator (option)
Fuel level indicator
Hour meter
Ventilation
Safe load indicator (option)
42
Indicator light for air filter contamination
43
44
45
Washer system
Working light
Rotating beacon (option)
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3-5
Operation
From serial number: AD03525
46
50
47
48
49
Left-hand side control elements
53
Right-hand side control elements
52
54
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Operation
3.3
Instrument panel overview
Pos.
Description
46
For more information see page
Indicator light (red) – hydraulic oil filter
47
48
49
Indicator light (red) – alternator charge function
Indicator light (red) – engine oil pressure
Indicator light (red) – coolant temperature
................................................................................................................................3-12
50
51
52
53
54
55
56
57
Indicator light (yellow) – cold starter
Indicator (red) – safe load indicator (option)
Fuel level indicator
Hour meter
High speed
Ventilation
Safe load indicator (option)
Proportional control status indicator lights (option)
58
59
60
61
62
Washer system
Working light
Rotating beacon (option)
Automatic revs setting (option)................................................................................................................................................................
Indicator for air filter contamination
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3-7
Operation
3.4
Operating the excavator
Caution!
Slipping or falling hazard when entering or leaving the operator station.
Inspect and confirm that the handholds and steps are undamaged and free of mud and debris.
Always use a three point technique with both hands and one foot supporting entry and exit at all times.
Face the operator station when using the handholds and steps to enter and exit the machine.
Only use the steps and handholds provided when entering and leaving the cab.
Never use the controls or movable lines and cables as handholds.
Never get on or off a moving machine!
Never jump off the machine!
NOTICE
Refer to the corresponding load diagrams for the boom.
Putting the machine into operation for the first time
Important information
• The machine may be put into operation by authorized staff only
Operator’s and Technician Qualifications and Basic Responsibilities
– see chapter 2 Safety Information
on page 2-1 of this Operator's Manual.
• The staff must have read and understood this Operator's Manual before putting the machine into operation
• The machine must only be used in serviceable condition in accordance with its designated use and the instructions set forth in the Operator's Manual, and only by safety-conscious persons who are fully aware of the risks involved in operating the machine.
• Go through the “Start-up” checklist in the following chapter
Running-in period
Operate the machine carefully during its first 50 operating hours.
The future performance and service life of the machine are heavily dependent on the observance of the following recommendations during the running-in period.
• Do not change engine speed abruptly
• Avoid using the machine under heavy loads and/or at high speeds.
• Avoid abrupt acceleration, braking and changing driving direction.
• Do not run the engine at high speed for extended periods
• Strictly observe the maintenance schedules in the appendix
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Check lists
Start-up checklist
Operation
The checklists below are intended to assist you in checking and monitoring the machine before, during and after operation.
These checklists cannot claim to be exhaustive; they are merely intended as an aid for you in fulfilling your duties as a conscientious operator.
The checking and monitoring jobs listed below are described in greater detail in the following chapters.
If the answer to one of the following questions is NO, first rectify the cause of the fault before starting or continuing work.
Check the following points before putting the machine into operation or starting the engine:
No. Question
1 Enough fuel in the tank? (
➠
2 Coolant level OK? (
➠
)
3 Water drained from the water separator? (
➠
)
4 Engine oil level OK? (
➠
5 Oil level in hydraulic tank OK? (
➠
6 Water level in washer tank OK? (
➠
)
7 V-belt condition and tension checked? (
➠
8 Lubrication points greased? (
➠
9 Tracks checked for cracks, cuts etc. ? (
➠
10 Lights, signals, indicators, warning lights OK? (
➠
)
11 Windows, mirrors, lights and steps clean?
12 Control lever base folded down? (
➠
)
13 Attachment safely locked? (
➠
)
14 Engine cover safely locked? (
➠
15
Especially after cleaning, maintenance or repair work:
➥
Rags, tools and other loose objects removed?
16 Correct seat position? (
➠
)
17 Seat belt fastened? (
➠
✔
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3-9
Operation
Operation checklist
Parking checklist
After starting the engine and during operation, check and observe the following points:
✔
No. Question
1 Anyone dangerously close to the machine?
2
Indicator lights for engine oil pressure and alternator charge function gone out?
(
➠
)
3 Temperature indicator for engine coolant in normal range? (
➠
3-12
)
4 Drive pedals working correctly? (
➠
)
Check and observe the following points when parking the machine:
No. Question
1 Attachments lowered to the ground? (
➠
)
2 Control lever base folded up? (
➠
)
3 Cab locked, especially if the machine cannot be supervised? (
➠
When parking on public roads:
4 Machine adequately secured?
When parking on slopes:
4
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Operation
3.5
Operating the excavator
Preheating/start switch: overview
1
0
2
3
19
Fig. 31: Preheating start switch
Important!
The engine can only be started if the left-hand side control lever base is folded down.
Position Function
0
Insert or remove the starter key
1
2
3
ON/drive position
Preheats the engine (10 – 15 seconds)
Starts the engine
Power consumer
None
All functions are operational
➥
Indicator lights illuminate
➥ Shrill sound
➥
➥
Starter is actuated
Indicator lights must go out
Throttle lever: overview
The throttle lever controls the speed as follows:
• Moving the throttle lever (
16
) up („turtle“) reduces engine speed. Moving the throttle
lever down („rabbit“) increases the engine speed.
16
Fig. 32: Revs control
Automatic engine speed setting (option)
From serial number AG00580
Diesel engine speed is automatically reduced to idling after 5 seconds if no hydraulic functions are performed and if the automatic engine speed setting (option) is enabled.
As soon as a hydraulic function is performed with the control levers, diesel engine speed is automatically increased again to the engine speed adjusted with the throttle.
Automatic revs setting (option)
ON
☞
Press the arrow symbol on switch
➥
Indicator light in switch
61
OFF
☞
Press the ribbed end of switch
➥ Indicator light in switch
61
goes out
Fig. 33: Automatic engine speed setting from serial number AG00580
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3-11
Operation
Indicators lights and warning lights: overview
46 Indicator light (red) – hydraulic oil filter
Indicates inadmissibly high pressure in the hydraulic return line to the tank. In this case:
☞
Have the hydraulic oil return filter checked and, if necessary, replaced by an authorized workshop
☞
The indicator light can illuminate briefly if the hydraulic oil is cold, but goes out again once operating temperature is reached
47 Indicator light (red) – alternator charge function
NOTICE
Possible engine damage.The coolant pump no longer runs if the V-belt is faulty. Engine may overheat or break down.
If the indicator light illuminates with the engine running:
Stop the engine immediately.
Have the cause repaired by an authorized service center.
The V-belt or the charging circuit of the alternator is faulty if the indicator light illuminates with the engine running. The battery is no longer charged.
48 Indicator light (red) – engine oil pressure
Illuminates if the engine oil pressure is too low. In this case:
☞
Stop the machine
☞
Stop the engine immediately and check the oil level
The indicator light illuminates when the engine is turned on and goes out as soon as the engine runs.
49 Indicator light (red) – coolant temperature
Warning!
Burn hazard. The engine coolant is under pressure at high temperature.
Failure to observe specific instructions to check the coolant level in the radiator of the cooling system can cause serious injury from burns or pressure spray of the coolant.
Do not attempt to remove the radiator filler cap or drain the radiator coolant until the coolant temperature is less than 43°C (110°F).
Stop the engine and wait at least 10 minutes or until the cap is comfortable to the touch before attempting removal.
Wear protective gloves and eye protection.
After determining the temperature is low enough to avoid burns, slowly turn the cap counter-clockwise to the first notch stopping cap rotation. Wait to confirm that any pressure has been relieved. Depress the cap and continue to rotate the cap in a counter-clockwise motion until the cap is free and can be removed.
3-12
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b320.fm
Operation
50 Indicator light (yellow) – cold starter
Comes on if the key in the preheating/start switch is in position
2
.
A glow plug preheats the air in the combustion chamber of the engine when the key is in this position.
56 Indicator light (red) – safe load indicator (option)
This optical warning device tells the operator whether he has reached the admissible
(pay)load or load moment according to the (pay)load diagram.
☞
Reduce the load until the indicator light goes out
52 Fuel level indicator
Refuel immediately if the fuel level indicator reaches minimum. Otherwise the fuel system must be bled if it is run dry.
53 Hour meter
Records the engine service hours with the engine running.
OM 25-3703 us – Edition 4.3.1 * 2503_3703b320.fm
3-13
Operation
3-14
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b320.fm
Operation
3.6
Before starting the engine
☞
Adjust seat position and rearview mirror – see Seat adjustment on page 3-27
Important!
Adjust the seat so that the operator controls are comfortable to use and can be moved throughout the full range of motion without restriction.
☞
Fasten your seat belt – see Seat belt on page 3-29.
☞
Fold the left-hand side control lever base down.
☞
Check whether all levers and pedals are in neutral position.
☞
Move the throttle to the center position (between minimum and maximum) if the engine is cold.
3.7
Starting the engine (general information)
• The starter cannot be actuated if the engine is already running (start repeat interlock).
• Do not engage the starter for more than 10 seconds.
• Wait about 1 minute so the battery can recover before trying again.
Procedure
0
1
Fig. 34: Preheating start switch
2
3
NOTICE
Possible preheater damage. Actuating the preheating system too long can damage the preheater.
Never preheat the engine more than 20 seconds.
After you have completed the starting preparations:
☞
Insert the starter key in preheating start switch
19.
☞
Turn the starter key to position “
1
”
☞
Check whether all indicator lights illuminate.
☞
Replace defective indicator lights immediately.
☞
Turn the starter key to position “
3
” and hold it in this position until the engine starts.
➥
If the engine does not start after 10 seconds
☞ Interrupt the start procedure and try again after about 1 minute.
➥
If the engine still does not start after the second try
☞ Contact a Wacker Neuson service center for troubleshooting.
➥
As soon as the engine engages:
☞
Release the starter key.
Fig. 35: Indicators lights
OM 25-3703 us – Edition 4.3.1 * 2503_3703b330.fm
3-15
Operation
3.8
Starting with the drive interlock (option)
Fig. 36: Drive interlock
0
Fig. 36: Preheat/start switch
1
2
3
After you have completed the starting preparations:
☞
Approach the transponder key to about 2 cm (0.8’’) to the emitter/receiver unit
27.
☞
The machine can be started as soon as the red indicator light
26
goes out.
☞
Insert the starter key in the preheating start switch
19
☞
Turn the starter key at least to position “
1
”.
☞
Check whether all indicator lights illuminate.
☞
Replace defective indicator lights immediately.
☞
Turn the starter key to position “
2
” and hold it in this position for about 5 seconds.
➥ The intake air is preheated
☞
Turn the starter key to position “
3
” and hold it in this position until the engine starts
➥ If the engine does not start after 10 seconds
☞
Interrupt the start procedure and try again after about 1 minute.
➥ If the engine still does not start after the second try
☞
Contact a Wacker Neuson workshop for troubleshooting.
➥ As soon as the engine runs:
☞
Release the starter key.
Fig. 36: Indicator lights
3.9
Starting at low temperatures
☞
Turn the starter key to position “
2
” and hold it in this position for about 5 seconds
➥ Engine is preheated
☞
Turn the starter key to position “
3
” and hold it in this position until the engine starts.
➥ If the engine does not start after 10 seconds
☞
Interrupt the start procedure and try again after about 1 minute.
➥ If the engine still does not start after the second try
☞
Contact a Wacker Neuson service service center for troubleshooting
☞
Release the starter key
When the engine runs smoothly (increased engine speed):
Important!
In general, a battery delivers less energy in cold conditions. Therefore make sure the battery is always well charged.
3-16
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b330.fm
Operation
3.10 When the engine has started ...
☞
Check whether all indicator lights have gone out:
☞
Let the engine warm up.
At cold temperatures:
☞
Increase the engine speed slowly.
☞
Do not run the engine at full load until it has reached its operating temperature.
Engine warm-up
After the engine has started, allow it to warm up at slightly increased idling speed until it reaches its operating temperature of 70 °C (158 °F) (coolant). Run the engine with no load during the warm-up phase (fold left-hand side control lever base up). During the warm-up phase, check for unusual noise, muffler colour, leaks, malfunctions or damage. In case of malfunctions, damage or leaks, park and secure the machine, and find out the cause for the damage and have it repaired.
OM 25-3703 us – Edition 4.3.1 * 2503_3703b330.fm
3-17
Operation
3.11 Jump-starting the engine (supply battery)
Warning!
Explosion hazard. A frozen battery may explode during a jump-starting operation.
Do not jump-start the engine if the battery is frozen.
Dispose of the frozen battery in accordance with local environmental regulations.
Replace the battery.
Discharged battery
12 V
12 V
Starting battery
Caution!
Possibility of equipment damage or injury from improper jump-starting.
Make sure the jumper cables are rated for 12 V and the maximum CCA rating of the battery.
The cable clamping ends shall be colored red for positive post connectors, and black for the negative post connectors.
To avoid sparking, the excavator must not touch the jump-starting vehicle when connected with jumper cables.
Use a 12 volt source, either in the form of another battery or a charger equipped for jump starting. Using higher or lower voltage sources can damage the electrical system and potentially cause injury.
To avoid short circuits, the jumper cable connected to the positive
+
terminal of the starting battery must never be brought into connection with electrically conductive vehicle parts.
Route the jumper cables so they do not become entangled in rotating components in the engine compartment.
Procedure
☞
Move the jump-starting vehicle close enough to the machine so that the jump leads can reach to connect the two batteries.
☞
Let the engine of the jump-starting vehicle run.
☞
First connect one end of the red jump lead (
+
) to the
+
terminal of the discharged battery, then connect the other end to the
+
terminal of the starting battery.
☞
Connect one end of the black jump lead (
–
) to the
–
terminal of the starting battery.
☞
Connect the other end of the black jump lead (
–
) onto a solid metal component fimly mounted on the engine block or onto the engine block itself. Do not connect it to the negative terminal of the flat battery, as otherwise explosive gas emerging from the battery can ignite if sparks are formed!
☞
Start the engine of the machine with the discharged battery.
Once the engine has started:
☞
With the engine running, disconnect both jump leads in exactly the reverse order (first remove the
–
terminal, then the
+
terminal) – this prevents sparking in the vicinity of the battery!
3-18
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b330.fm
Operation
3.12 Special instructions for driving on public roads
The machine is subject to the:
• Applicable legal regulations of your country
Also observe the applicable regulations for accident prevention of your country.
3.13 Traveling
Important!
The machine will not travel unless the left-hand side control lever is folded down.
After starting the engine:
☞
The alternator charge indicator light goes out.
☞
Press the drive pedal slowly.
➥ Machine moves off
3.14 Drive levers
Fig. 38: Drive lever/drive pedal
1
2
3 4
Important!
Possible loss of machine control. Rotating through 180° (stabilizer blade now at the rear) inverts the drive lever functions.
Confirm the location of the stabilizer with respect to the operator station and compensate before attempting to move the machine.
The stabilizer blade side is the front side.
Raise the bucket and the stabilizer blade.
The machine can be moved either with the drive levers or with the pedals. Lock the upper carriage when travelling over longer distances.
Position Function
• 1
• 2
Push forwards
Push forwards
• 3
• 4
• 3
• 2
• 1
• 4
Pull backwards
Pull backwards
Pull backwards
Push forwards
Push forwards
Pull backwards
Track excavator moves forwards
Track excavator moves backwards
Track excavator turns to the left
Track excavator turns to the right
Forwards or reverse drive speed depends on the position of the drive levers or drive pedals.
Important!
Make sure both tracks move as you change direction, otherwise the tracks are subject to increased abrasion.
OM 25-3703 us – Edition 4.3.1 * 2503_3703b330.fm
3-19
Operation
3.15 High speed
3.16 Hydraulic brake
3.17 Mechanical brake
The machine has two speed ranges which can be selected as follows:
☞
➥ The machine now moves at higher speed
The drive gear shifts to second speed after high speed is selected, causing the machine to move at higher speed. In case of increased resistance (grading, changing direction, travelling uphill), the drive gear shifts to the lower speed. The machine automatically shifts back to second speed is soon as there is no resistance.
The pedals automatically return to their neutral positions as soon as they are released, which creates sufficient hydraulic braking effect.
When traveling downhill, the automatic hydraulic brake valves prevent the machine from
“racing”. The machine does not run any faster than the admissible drive speed.
However, the automatic hydraulic brake valves in the undercarriage circuit no longer work properly if the diesel engine does not run at full speed.
Important!
Therefore, make sure you drive downhill at full engine speed under all circumstances. Use the drive pedals to reduce the travel speed as required.
The parking brake is automatically applied by mechanical springs when the hydraulic propulsion control is set to neutral, releasing the hydraulic pressure to the motors.
Actuating the propulsion control to move the machine provides hydraulic pressure to automatically release the brake.
3-20
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b330.fm
Operation
3.18 Operating on slopes
Traveling on slopes
Warning!
Tip-over hazards. Follow these safety instructions carefully when operating on slopes.
Raise the bucket about 20 – 30 cm (8’’—12’’) off the ground as you move the machine. Avoid reversing downhill.
When traveling through hollows or crossing obstacles, keep the attachment close to the ground and travel slowly.
Do not steer or drive across slopes.
Always change your driving direction on level ground. This may take more time but is decisively safer.
When operating the machine, make sure you can stop safely any time if the machine starts to skid or if it becomes unstable.
Swivelling or operating the attachment on slopes can cause the machine to lose its balance and to tip over. Avoid this under all circumstances.
Rotating the upper carriage when traveling downhill with a full bucket is especially dangerous. Should this be nevertheless necessary, create a platform of level ground so that the machine can work in horizontal position.
Do not operate on slopes steeper than 15°, otherwise the machine can tip over.
If the sliding blocks slip as you travel uphill and if it is no longer possible to move on with the force of the tracks alone do not apply pressure with the boom to move the machine.
Proceed as follows to prevent the machine from tipping over or slipping sideways.
☞
When traveling uphill, keep the attachment about 20 – 30 cm (8’’—12’’)above the ground. In an emergency, lower the attachment immediately to the ground so you can stop the machine more easily.
20 – 30 cm
Fig. 39: Uphill, attachment above the ground
20 – 30 c m
Fig. 40: Uphill/downhill
☞
Place the cab with the front side upward as you travel uphill, and downward as you travel downhill. Always check the ground's firmness underneath the front part of the machine as you drive.
☞
When traveling downhill, extend the attachment to improve stability, and keep it about
20 – 30 cm (8’’—12’’) above the ground. Move slowly.
☞
Reduce engine speed when traveling downhill. Keep the drive lever next to neutral position and travel slowly.
☞
Always travel straight ahead when traveling uphill or downhill. Traveling diagonally or at an angle to the slope is hazardous.
☞
Never change direction on slopes or travel across slopes. Always change position on level ground before continuing to travel on a slope.
☞
Travel slowly in meadows, on leaves or wet steel plates. The machine can slip even if the ground is level. If the engine stops as you travel across a slope, immediately put the control levers to neutral position and start the engine again.
Fig. 41: Driving diagonally or at an angle
OM 25-3703 us – Edition 4.3.1 * 2503_3703b330.fm
3-21
Operation
3.19 Stabilizer blade operation
Important!
Possible loss of machine control. Stabilizer blade lever is unprotected and can be moved unintentionally.
Avoid moving the stabilizer blade lever inadvertently.
NOTICE
Possibility of equipment damage. Lowering the stabilizer blade too deeply into the ground can create resistance.
on page 3-64.
Slightly raise the stabilizer blade.
1
2
Position Function
• 1
Push forwards
• 2
Pull backwards
stabilizer blade is lowered stabilizer blade is raised
Important!
Check the position of the stabilizer blade before driving the machine.
Fig. 42: stabilizer blade operation
3-22
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b330.fm
Operation
Parking the machine
3.20 Stop the machine
Important!
Possibility of inadvertent machine movement. To avoid unintentional movement of the machine once it has been parked:
Park the machine on level, stable ground.
Place stop chocks at the ends of the rubber track.
☞
Lower the bucket and the stabilizer blade to the ground.
☞
Reduce engine speed to low idle setting.
☞
Turn off the starter.
☞
Fold up the control lever base.
NOTICE
Possible engine damage due to overheating.
Never stop the engine under full load.
Except in case of an emergency, always make sure the engine can cool down before it is stopped.
Let the engine run at idling speed with no load for at least 5 minutes before you stop it.
Important!
Secure the machine against unauthorized operation.
Lock the cab
Parking the machine on slopes
☞
Avoid stopping the machine abruptly. Always make sure there is enough space for stopping the machine.
• Park the machine on level ground with sufficient bearing capacity. Never park on slopes. If you cannot avoid parking the machine on a slope:
☞ Place chocks (
) under the tracks and lower the attachment
into
the ground to prevent the machine from moving.
• To prevent inadvertent machine or attachment movement, avoid moving the controls unintentionally.
☞ Always fold the control lever base up before leaving the seat.
☞
Place the stabilizer blade downhill and lower it to the ground.
Fig. 43: Parking the machine on slopes
OM 25-3703 us – Edition 4.3.1 * 2503_3703b330.fm
3-23
Operation
3.21 Light system
Working light
The switch panel for the light system is located on the instrument panel.
Boom light
ON
☞
Press the light symbol on switch
59
➥ Indicator light in switch
59
OFF
☞
Press the ribbed end of switch
➥
Indicator light in switch
59
Fig. 44: Light system switches
Roof lights (option)
Warning!
Traffic accident hazard. Working lights can temporarily blind motorists on public roads.
Do not switch on the working lights when traveling on public roads.
When operating the machine near public roads, only switch the working lights on when there is no possibility of blinding oncoming traffic.
Roof lights
☞
Press the light symbol on switch
Position
1
ON
☞
Press the light symbol on switch
Position
2
OFF
☞
Press the ribbed end of switch
➥
Indicator light in switch illuminates
➥
Indicator in switch goes out
Fig. 45: Switch for roof lights
3-24
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b330.fm
Operation
Interior light
Interior light
ON
☞
Press switch to the left or right
OFF
☞
Return the switch to center position
Fig. 46: Switch for interior light
Rotating beacon (option)
Rotating beacon (option)
ON
☞
Press the beacon symbol on
OFF
➥
Indicator light in switch
☞
Press the ribbed end of switch
➥ Indicator light in switch
Important!
Observe the legal regulations of your country for operating the rotating beacon.
Fig. 47: Switch for rotating beacon
3.22 Cab heating and ventilation
Important!
The cab is fitted with five air nozzles. Each nozzle can be closed and directed separately. In order to achieve best results for defrosting the front window, open both front right nozzles and the leg room nozzle.
Direct the nozzles to the front window
Open or close the nozzles as required to vent or heat the cab.
Do not place flammable or explosive material or objects near the nozzles.
Air the cab from time to time
Ventilation (fresh air)
1st speed
☞
Press the fan symbol on switch
Position
1
2nd speed
OFF
➥
Low fan speed
☞
Press the fan symbol on switch
Position
2
➥ High fan speed
☞
Press the ribbed end of switch
➥
Fan OFF
Fig. 48: Air circulation in cab
OM 25-3703 us – Edition 4.3.1 * 2503_3703b330.fm
3-25
Operation
3.23 Summer/winter operation
A
Fig. 49: Heating adjustment
B
H
Warning!
Pinching, crushing or cutting hazard. Moving engine parts can cause injury.
Always stop the engine before changing from summer to winter operation and vice versa.
Open the engine cover only if the engine is stopped.
Adjust cab temperature as follows:
Position Function
A
Summer operation
B
Winter operation
Cools
Heating water circuit open
☞
Open the engine compartment.
☞
Turn ball-type cock
H
as described, to summer or winter operation.
☞
Close the engine compartment
Important!
Summer and winter operation does not depend on the season. Therefore, adjust according to your personal requirements.
3.24 Washer system
Fig. 50: Front wiper switch
Front window
ON
OFF wiper
☞
Press the wiper symbol on
☞
Press the ribbed end of
1st speed
2nd speed
☞
Press the wiper symbol on
1
☞
Press the wiper symbol on
2
➥ Front wiper is on
➥
Front wiper returns to base position
➥ Front wiper is on
➥ Pump sprays washer water on the window
Important!
Do not actuate the washer system with the front window folded up. Do not actuate the washer system if the reservoir is empty. Doing so can damage the electric pump.
3-26
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b330.fm
Reservoir for washer system
Fig. 51: Reservoir for washer system
3.25 Seat adjustment
Operation
The reservoir's filler inlet is located in the engine compartment.
Important!
Use a blended mix of water and windshield washer fluid. A blended mix will minimize freeze damage, prolong wiper life, and reduce streaking.
In winter: add antifreeze for washer systems to the water.
Refer to the antifreeze instructions for further information on concentrations.
The rubber diaphragm in the non-return valve in the housing sticks to itself if stored in a dry condition over a longer period of time. In order to restore this valve's function, moisten this non-return valve, dip it briefly in water and then blow air through it.
Caution!
Possible loss of machine control while adjusting the seat.
Do not adjust the seat position during machine operation or travel.
Adjust the seat before moving the machine.
See “Before starting the engine” on page 3-15
.
NOTICE
Possible window damage from adjusting the backrest.
Make sure the backrest does not touch the rear window or the removable part of the front window as you adjust backrest inclination.
Select a seat position which will not damage the window panels when working with the machine.
Fig. 52: Seat adjustment
OM 25-3703 us – Edition 4.3.1 * 2503_3703b330.fm
3-27
Operation
Weight adjustment
Important!
Adjust the seat suspension correctly to ensure a high level of ride comfort. Use the lever to adjust the seat suspension. Adjust the seat only without load!
Adjust the seat to the operator's weight as follows:
➥ Less spring action:
☞
29
down.
➥ More spring action:
☞
29
up.
Fig. 53: Weight adjustment
Horizontal adjustment
☞
Sit in the seat.
☞
Pull lever
upward and, at the same time, move the seat forward or backward.
Fig. 54: Horizontal seat adjustment
Backrest adjustment
☞
Sit in the seat.
☞
forwards and, at the same time, lean back to push the backrest into the
required position.
☞
Release handle
and allow it to lock into place.
Fig. 55: Backrest adjustment
3-28
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b330.fm
Operation
3.26 Seat belt
A
B
Fig. 56: Fastening the seat belt
Warning!
Personal injury hazard. The seat belt provides positive support in the operator seat during operation and travel that keeps the operator located within the comfort zone for control operation. It also reduces the risk of injury in the event a tipping incident occurs during use.
Always buckle up before moving or working with the machine.
Seat belt must not be twisted.
Seat belt must run over the hips – not over the stomach – and must always be applied tightly.
Do not place the seat belt over hard, edged or fragile items (tools, meter rule, glasses, pen) carried inside your clothes.
Never buckle up 2 persons with one seat belt.
Check seat belts each time the operator uses the machine. Have damaged parts immediately replaced by an authorized workshop before using the machine.
Always keep the seat belt and buckle clean, as dirt and debris can cause the buckle to malfunction and accelerate internal webbing abrasion in the belt.
Seat belt buckle must not be obstructed by foreign bodies (paper or similar); otherwise the buckle latch cannot lock into place!
Warning!
Personal injury hazard. The seat belt strap will be stretched after an accident and is no longer serviceable.The seat belt will NOT provide adequate protection in the future!
Replace the seat belt after an accident.
Have fastening points and seat fixture examined for damage or failure.
Repair or replace if damaged.
11
is for the driver's safety during work on construction sites and during road
travel.
Fastening the seat belt:
☞
as follows before moving the machine:
• Hold belt on buckle latch
A
and run it slowly and steadily over the hips to buckle
B.
• Insert buckle latch
A
into buckle
B
with an audible click
(pull test).
• Tighten the seat belt by pulling at its end.
➥ The seat belt must always be tightly in place over the hips!
OM 25-3703 us – Edition 4.3.1 * 2503_3703b330.fm
3-29
Operation
Fig. 57: Unfastening the seat belt
A
C
B
Unfastening the seat belt:
☞
as follows:
• Hold the seat belt.
• Press red lock release
C
on buckle
B.
➥ Latch
A
is released from buckle
B
by spring pressure.
• Slowly return the seat belt to the retractor.
A
Longer/shorter lap belt adjustment:
☞
Lengthen the lap belt as follows:
• Hold buckle latch
A
at a right angle to the seat belt and pull the seat belt to the required length.
• To shorten the lap belt, just pull the free end
D
of the belt.
D
Fig. 58: Longer/shorter seat belt adjustment
3.27 Emergency exit
You can enter and exit the cab through the front window in an emergency.
Caution!
Personal injury hazard. Do not use the side or front window as routine exits from the machine. Windows are to be used as exits only if the access opening
(door for cab option) is blocked or cannot be opened through normal operating procedures.
The controls are active if the engine is not stopped. Inadvertent control movement with the engine running during an emergency exit can increase the risk of injury. Stop the engine before exiting through an emergency exit.
Enter and exit the cab through the side and front windows in an emergency only!
Opening the front window completely:
☞
– see Front window on page 3-31
3-30
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b330.fm
3.28 Front window
F
C
A
B
B
Operation
Caution!
Crush hazard. Sliding window can pinch or crush extremities.
Keep extremities and clothing free of the window run.
Always pull the front window upwards with both handles
B
!
Always let levers
A
lock into place on either side in locks
F
or
C
!
Important!
Fold up the control lever base before opening or closing the front window, in order to avoid any unintentional operation or movement of the machine!
Open the front window as follows:
• The front window is fitted with handles and small levers on either side.
☞
Push levers
A
upwards on either side.
☞
Pull the front window upwards with handles
B
.
➥ The front window must lock into rails
C
on either side.
☞
Lock levers
A
on either side in
C
.
☞ Pull lock levers
A
rearward to lock the window handles
B
in rail
C
.
Lower the front window as follows:
☞
Push the locking lever
A
forward to release the window handle
B
from rail
C
.
☞
Pull the front window downwards with handles
B
.
☞
Pull lever
A
upward to lock the window in place (
).
B
Fig. 59: Front window
OM 25-3703 us – Edition 4.3.1 * 2503_3703b330.fm
3-31
Operation
3.29 Door
Important!
Possibility of equipment damage or injury to others. An open door on a moving machine may slam against the machine, damaging the door frame or window glass. The door may also strike nearby objects or people.
Always make sure that doors and windows are securely closed before moving the machine.
Opening the door from the outside:
☞
Press door lock A.
Locking the door:
☞
Turn the key in door lock
A
counter-clockwise.
☞ The door is locked.
Unlocking the door:
☞
Turn the key in door lock
A
clockwise.
☞ The door is unlocked.
Opening the door from the inside:
☞
Push the latch lever
B
to unlatch the door.
B
Fig. 60: Inside door opener (left/right)
C
D
Securing an open door:
☞
Press the door against bracket
C
of latch
D
with an audible click
Fig. 61: Door arrester
3-32
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b330.fm
E
Releasing the door opener:
Turn button
E
to release the door from the arrester.
Operation
Fig. 62: Releasing the door arrester
F
Opening the side window:
☞
Push button F up
☞
At the same time, move the window to one of the positions marked with seven arrows
Fig. 63: Side window
OM 25-3703 us – Edition 4.3.1 * 2503_3703b330.fm
3-33
Operation
3.30 Exit through the door
4
3
A
D
5
A
5
B
C
Caution!
Personal injury hazard. Before entering or leaving the operator station confirm that the stepping surfaces are clean and firm to avoid slipping or tripping.
Take the following steps before leaving the cab:
• Stop the machine and follow the parking procedures provided in
"Parking the machine"
• Move all controls to neutral.
☞
Raise control lever base 4 with handle
A
to position
B
➥
The gas strut keeps the control lever base in the top position
Important!
The control lever and console are not designed as a hand hold for exiting the cab.
Do not use the control handle in the console for assistance entering or leaving the cab.
Use the hand hold brackets positioned at the front and rear of the cab door opening for support.
☞
Fold control lever base 4 down to position
C
once you are in the cab
➥ The gas strut keeps the control lever base in the lower position
Important!
The height of the control lever base can be set with stop bolt
D
!
Important!
Enter and leave the cab only through the door as a rule. You can enter and exit the cab through the front and the right-hand side window in an emergency.
Fig. 64: Control lever base
3-34
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b330.fm
3.31 Engine cover
L
A
Operation
Opening:
☞
Pull out the lower handle
A
.
☞
Open the engine cover upwards.
Closing:
☞
Firmly press down the engine cover until the lock engages with an audible click.
Fig. 65: Engine cover lock
3.32 Valve compartment cover
L
B
Opening:
☞
Pull out the lower handle
B
.
☞
Open the valve compartment cover upwards.
Closing:
☞
Firmly press down the valve compartment cover until the lock the engages with an audible click.
Fig. 66: Valve compartment cover lock
OM 25-3703 us – Edition 4.3.1 * 2503_3703b330.fm
3-35
Operation
3.33 Towing the track excavator
Towing
Warning!
Personal injury hazard. Use extreme caution during towing operations.
Keep people away from the danger zone around the towed and towing machine.
Important!
Follow the following instructions under all circumstances:
Towing a disabled machine can damage the propulsion drive system. Do not tow a disabled machine.
The manufacturer's warranty shall not apply to accidents or damage caused by towing the excavator.
No towing away other machines with towing bracket
A
.
Fig. 67: Towing bore
A
B
NOTICE
Towing the machine is not recommended. Damage to the machine may occur. If the machine must be towed, follow the guidelines and procedures below.
Possibility of overload on towing bracket.
Observe the maximum admissible load on towing bracket = 1.5 x excavator dead weight.
☞
Make sure the excavator can be towed safely.
☞
Use towing bracket
A
for towing the machine.
☞
Do not use towing bracket
A
to tow another machine, other equipment, or trailers.
☞
Secure clevis
B
with the clevis pin and a lock pin.
☞
Mount a towing bar or cable of adequate size to the towing bracket.
☞
Make sure no one is close to the towing equipment (towing bar, cable).
☞
Do not jerk the machine.
☞
When towing the machine, do not exceed the maximum operating speed of the excavator.
– see 2 speed ranges on page 6-2
3-36
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b330.fm
Operation
3.34 Lifting excavator
Fig. 68: Crane handling
OM 25-3703 us – Edition 4.3.1 * 2503_3703b330.fm
Lifting instructions
• The crane and the lifting gear must have suitable dimensions
• Lifitng the machine requires suitable lifting gear
• Secure the machine against unintentional movement!
Warning!
Crushing hazard.
Do not lift the machine with someone in the operator seat/station or on the machine.
Persons responsible for attaching the lifting devices to the machine shall be experienced with crane operations and hand signals.The crane operator shall maintain sight of the personnel attaching, guiding, and unhooking the excavator.
Use OSHA rated and approved lifting devices capable lifting the excavator, attachments, options and accumulated debris. Refer to the general weight guidelines in the specification section of this manual.
Do not lift the machine with material in the bucket attachment.
The crane operator shall observe the lift zone and lift the machine when the area is clear of people.
Do not attempt to lift the excavator with any type of crane including wheel loaders unless the crane operator is qualified to lift loads in craning operations. The crane operator shall be knowledgable of OSHA 1910 craning regulations.
The lifting devices must be the specified lengths shown as L1 and L2 in the table.
• Load the machine as follows:
☞
Fit the standard bucket and lock it safely.
☞
Empty the standard bucket.
☞
Tilt in the standard bucket..
☞
Stop the engine.
☞
Fold the control lever base up.
☞
Remove the starter key.
☞
Do not allow anyone to stay in the cab, and close the doors and the engine cover.
☞
Use suitable lifting gear, tracks etc.
☞
Mount the lifting gear at the point on the boom provided for lifting the machine.
☞
Mount the lifting gear at the points on the stabilizer blade provided for lifting the machine.
☞
Make sure the lifting gear has the required lengths L1 and L2.
☞
Slowly raise the machine.
Required lengths L1 and L2 of the lifting gear:
Excavator
2503
2503
3003 / 3503 / 3703
3003 / 3503 / 3703
Length
L1
L2
L1
L2
Dimension
2240 mm (7’4’’)
3670 mm (12’)
2270 mm (7’5’’)
4000 mm (13’1’’)
3-37
Operation
Authorized loads
Boom lift eye
Stabilizer blade lift eye
Force
40 kN (8992 lbf)
40 kN (8992 lbf)
3.35 Loading and transport instructions
Loading and transporting instructions
• The transport vehicle must be of adequate size – refer to
the machine's dimensions and weights!
• Remove any mud, snow or ice from the tracks so that the machine can be safely driven onto the ramps
• Secure the machine against unintentional movement
– see chapter Parking the machine
Warning!
Improper loading and transporting can be hazardous.
Always make sure to load and transport the machine properly.
Read the safety instructions at the beginning of this chapter and follow any other applicable safety instructions.
☞
Load as follows:
• Secure the transport vehicle with chocks to prevent it from rolling.
• Place the access ramps at the smallest possible angle. Make sure the grade does not exceed 17° (30 %). Use access ramps with an antiskid surface only.
• Make sure the loading area is clear and access to it is not obstructed – e.g. by superstructures.
• Make sure the ramps and the tracks of the excavator are free of oil, grease and ice.
• Start the engine of the excavator.
• Raise the bucket sufficiently so that it will not touch the ramps.
• Carefully drive the excavator onto the middle of the transport vehicle.
• Lower the bucket to the loading area.
• Switch off the engine.
• Fold the control lever base up.
• Remove the starter key.
• Do not allow anyone to stay in the cab, and close the doors and the engine cover.
Important!
The manufacturer's warranty shall not apply to accidents or damage caused by loading or transporting the excavator.
3-38
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b330.fm
Operation
3.36 Tying down the excavator
A
Fig. 69: Strapping down the excavator
Warning!
Improper loading, strapping, and transporting of the machine can be hazardous.
Ensure that the machine is properly strapped down.
Read the safety instructions at the beginning of this chapter and follow any other applicable safety instructions.
• Make sure the authorized maximum height is not exceeded
• Secure the tracks of the excavator at the front, rear and at the sides
• Lower the stabilizer blade and the boom
• Firmly strap down the excavator at the eye hooks
A
onto the platform, with belts or chains of adequate size
• Before transporting the machine through heavy rain, close the outlet of the muffler with a simple cap or suitable adhesive tape
• Make sure the driver of the transport vehicle knows the overall height, width and weight of his vehicle (incl. excavator) before departure, as well as the legal transport regulations of the country or countries where transport is to take place!
OM 25-3703 us – Edition 4.3.1 * 2503_3703b330.fm
3-39
Operation
3.37 Operating the machine
General safety instructions
Avoiding cave-in or collapse:
• Do not operate at the edge of an open excavation.
• Do not undermine wall foundations.
Preventing tip-overs:
• Do not excavate deeply under the front side of the machine. The ground under the machine could collapse and cause the machine to tip.
• Do not perform demolition work below the machine.
• Doing so can cause the machine to tip over.
• In general the machine is more likely to tilt if the attachment is positioned laterally than if it is positioned at the front or rear of the machine.
• The machine can become unstable and tip if a demolition hammer or other heavy attachment is used. To perform work both on level ground and on slopes:
Do not move the attachment rapidly in any direction.
Avoid use on slopes.
Avoiding falling debris:
• Do not create an overhang above the excavator
– see Avoid tipping the machine while excavating
• Do not create an overhang of debris during demolition.
• Install a front guard when working in areas with a risk of objects falling from the front
(e.g. demolition work).
Increasing operator safety:
• In order to leave the cab more easily under especially difficult circumstances, position the tracks perpendicularly to the roadside or to the uphill slope with the drive pinion behind the driver.
• Prior to working on the structure surface, confirm that the floor or roof of a building is strong enough to support the excavator and any loads lifted by the excavator.
• Do not raise the bucket over the heads of other workers or over the driver seats of trucks or of other means of transport. The material can tilt, or the bucket can knock against the truck and cause severe injury or damage.
• Operation of the machine by unauthorized staff is prohibited!
• The hydraulic system of the machine is still pressurized even when the engine is not running! Release the pressure in the sections of the system and hydraulic lines which are to be opened before starting setup or repair work, e.g. fitting/removing an
attachment with hydraulic functions
– see Lowering the boom with the engine switched off
Preventing equipment damage:
• Do not use the impact force of the attachment to perform demolition work. Dislodged debris can cause personal injury or damage to property and/or equipment.
• Look out for high-voltage cables, underground cables, gas and water pipes during excavation work!
3-40
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b340.fm
Operation
3.38 Control levers/control pattern ’’A’’: overview
Important!
Fast actuation of the control lever for the attachment moves the attachment fast.
Slow actuation of the control lever moves the attachment slowly.
Left-hand side control lever
D
A
B
C
Fig. 70: Left-hand side control lever
Auxiliary hydraulics
Warning!
Potential loss of machine control. The attachment will move in response to movement of the left hand control lever, potentially creating a hazardous condition affecting machine control.
Do not actuate the left hand control lever while the machine is traveling at maximum speeds on the work site.
Position Lever
• A
☞
Forwards
• B
• C
• D
☞
To the right
☞
☞
Backwards
To the left
Function
➥
Stick is extended
➥ Upper carriage rotates to the right
➥ Stick is retracted
➥ Upper carriage rotates to the left
Important!
Always perform smooth control movements.
Actuating the auxiliary hydraulics:
Oil flow in 1st direction:
☞
Move hammer pedal
to the left.
Oil flow in 2nd direction:
☞
Move hammer pedal
to the right.
Fig. 71: Auxiliary hydraulics
OM 25-3703 us – Edition 4.3.1 * 2503_3703b340.fm
3-41
Operation
Right-hand side control lever
E
H
F
G
Position Lever
• E
• F
☞
☞
Forwards
To the right
• G
• H
☞
Backwards
☞
To the left
Function
➥ Boom is lowered
➥
Dumps bucket
➥ Boom is raised
➥
Fills bucket
Fig. 72: Right-hand side control lever
J
Button
☞
J
Function
➥ Horn
Fig. 73: Functions of right-hand side control lever
Lowering the boom with the engine switched off
A
E
Lower the boom as follows:
☞
Make sure no one is dangerously close to the machine.
☞
Turn the starting key to position “
1
”.
☞
Press forwards and hold the control lever (
A and E
).
➥
Until the arm system is completely lowered.
☞
Return the control lever to neutral.
Fig. 74: Lowering the arm system with the engine switched off
Releasing pressure
Proceed as follows:
☞
Stop the engine
☞
Turn the starting key to position “
1
”
☞
Move the control lever in all directions a few times
➥ This releases the pressure in the hydraulic system
3-42
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b340.fm
Rotating the upper carriage
Operation
Important!
• Until the hydraulic fluid reaches operating temperature, the upper carriage can creep slightly after the control is placed in the neutral position.
• Fast actuation of the control lever rotates the upper carriage fast, slow actuation of the control lever rotates the upper carriage slowly.
• If the upper carriage needs to be rotated on a slope, let the engine run at idling speed and actuate the control lever very slowly. Proceed with extreme care and avoid abrupt movements if the bucket is full.
Rotate the upper carriage to the left as follows:
☞
Push the left-hand side control lever
1
to the left
A.
➥ The upper carriage rotates to the left.
A
Fig. 75: Rotating the upper carriage to the left
B
Fig. 76: Rotating the upper carriage to the right
Rotating upper carriage brake
Rotate the upper carriage to the right as follows:
☞
Push the left-hand side control lever
1
to the right
B.
➥
The upper carriage rotates to the right.
Upper carriage hydraulic brake:
The upper carriage's rotation is sufficiently braked by moving control lever
1
back to the neutral position. Moving the control lever in the opposite direction (counteraction) brakes the upper carriage with maximum hydraulic output.
Upper carriage mechanical brake:
This is a multi-disk mechanical brake that provides a secondary service brake and a primary parking brake function for the upper carriage. It is operated independently from the hydraulic brake of the upper carriage.
Important!
The mechanical brake functions only to prevent upper carriage rotation. It does not function as a machine propulsion brake.
OM 25-3703 us – Edition 4.3.1 * 2503_3703b340.fm
3-43
Operation
3.39 Tilting the upper carriage (option)
A
The upper carriage can be tilted hydraulically by 15° (horizontal chassis) with lever
2
in order to be able to dig vertically on slopes.
B
Tilting the upper carriage:
☞
Press button
A
2
☞
Move control lever
2
to the right.
➥
The upper carriage is tilted.
☞
Move control lever
2
back to neutral position as soon as the required tilt angle is reached..
Leveling the upper carriage:
Fig. 77: Tilting the upper carriage
☞
Press button
A
2
☞
Move control lever
2
to the left.
➥
The upper carriage is leveled.
☞
Move control lever
2
back to neutral position as soon as the required tilt angle is reached.
3.40 Changeover valve for control pattern ’’B’’ (option)
Important!
Possible loss of machine control. Changing the control valve mode selection position will reverse the function control of the hand levers. The left hand lever controls the boom, not the stick. The right hand lever controls the stick.
Confirm the selected mode before starting the engine to avoid unintentional movement of the stick or boom.
Always secure wing nut
J
on the directional valve's changeover lever.
Left-hand side control lever
A
D
B
C
Position Lever
• A
☞
Forwards
• B
• C
• D
☞
To the right
☞
Backwards
☞
To the left
Function
➥
Boom is lowered
➥ Upper carriage rotates to the right
➥
Boom is raised
➥ Upper carriage rotates to the left
Fig. 78: Left-hand side control lever
3-44
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b340.fm
Right-hand side control lever
E
H
F
G
Position Lever
• E
• F
☞
☞
Forwards
To the right
• G
• H
☞
Backwards
☞
To the left
Function
➥ Stick is extended
➥
Dumps bucket
➥ Stick is retracted
➥
Fills the bucket
Operation
Fig. 79: Right-hand side control lever
Directional valve position
The directional valve is located at the left behind the seat.
Fig. 80: Directional valve position
Directional valve
The changeover valve switches from ISO to SAE controls and vice versa.
Position
• A
• B
Function
➥ ISO controls
➥ SAE controls
☞
Tighten wing nut
J
after changing control mode.
Warning!
Possible equipment damage or injury hazard. Never operate the machine if wing nut
J
is defective or missing!
Immediately contact your
Wacker
Neuson dealer to replace a defective or missing wing nut.
A
J
B
Fig. 81: Directional valve
OM 25-3703 us – Edition 4.3.1 * 2503_3703b340.fm
3-45
Operation
3.41 Control lever with proportional controls (option): overview
Important!
Fast actuation of the control lever for the attachment moves the attachment fast.
Slow actuation of the control lever moves the attachment slowly.
Function
This control mode offers proportional operation of the auxiliary hydraulics circuit depending on the position of slide switch
B
on the joystick.
You can also modify the properties of the characterisitic curve. Precision work, for instance with the offset bucket, does not require the full throughput of the auxiliary hydraulics.
Therefore we recommend setting the controls to the low characteristic curve 1 (slow movements).
The slide switch is not pressed fully in this position and you can move the machine more smoothly (flat characteristic curve).
current characteristic
3-46
potentiometer voltage [V]
If you require the full throughput then characteristic curve 2 will be the choice to make
(slide switch pressed as far as it will go).
NOTICE
Always use button
C
on the joystick for hammer operation.
Do not use characteristic curve 1 for hammer operation. As described above, oil throughput is not set to maximum in this case. Therefore, the hydraulic output is not fully available for hammer operation.
Pressing button
C
ensures full throughput regardless of the characteristic curve that has been selected.
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b340.fm
Operation
Measures to be taken in case of malfunctions
NOTICE
Possibility of uncontrolled valve function. The system still works correctly if only one component breaks down. However, if more than one component breaks down, the pressure regulating valves possibly run uncontrollably.
Stop the machine and call for service if more than one component breaks down.
Warning!
Personal injury hazard. In the unlikely event of a system breakdown:
Stop the machine and call for service.
Stay clear of areas with crushing hazards.
Stay clear of areas between moving hydraulic components and fixed obstacles!
Left-hand side control lever
Important!
Possible accidental machine movement. Left- and right-hand side levers must not be used when traveling.
Use only the traveling levers when traveling.
D
A
C
B
Position Lever
• A
• B
☞
☞
Forwards
To the right
• C
• D
☞
Backwards
☞
To the left
Function
➥ Stick is extended
➥
Upper carriage rotates to the right
➥ Stick is retracted
➥
Upper carriage rotates to the left
Important!
Always perform smooth control movements.
Fig. 82: Left-hand side control lever
OM 25-3703 us – Edition 4.3.1 * 2503_3703b340.fm
3-47
Operation
Auxiliary hydraulics
Actuating the auxiliary hydraulics:
Oil flow in 1st direction:
☞
to the left.
Oil flow in 2nd direction:
☞
to the right.
Fig. 83: Auxiliary hydraulics
Hammer operation
Activating hammer operation:
☞
Press and hold button C on the control lever.
Stopping hammer operation:
☞
Release button C on the control lever.
C
Fig. 84: Hammer operation
Adjusting control response
D
C
B
Fig. 85: Adjusting control response
Characteristic curve status display
1
Fig. 86: Characteristic curves – status display
Characteristic curve 1 (slow movements):
☞
Switch off the starter.
☞
Then move slide switch B
to the left
D.
☞
Hold slide switch B
to the left
D
and turn the starter key to position „
1
“ at the same time.
☞
Wait 2 seconds and then release slide switch B.
Status display
57
acknowledges by flashing once.
Characteristic curve 2 (fast movements – maximum throughput):
☞
Switch off the starter.
☞
Then move slide switch B
to the right
C.
☞
Hold slide switch B
to the right
C
and turn the starter key to position „1“ at the same time.
☞
Wait 2 seconds and then release slide switch B.
➥
Status display
57
acknowledges by flashing twice.
Displays the characteristic curve that has been selected for the control valve.
Characteristic curve 1 (slow movements):
Indicator
1
in status display
flashes once after turning the starter key to position „
1
“.
Characteristic curve 2 (fast movements – maximum throughput):
☞
Indicator
1
in status display
flashes twice after turning the starter key to position „
1
“.
Important!
The characteristic curve that has been set last is active after the machine is started again.
3-48
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b340.fm
Right-hand side control lever
E
H
F
G
Position Lever
• E
• F
☞
☞
Forwards
To the right
• G
• H
☞
Backwards
☞
To the left
Function
➥ Boom is lowered
➥
Dumps bucket
➥ Boom is raised
➥
Fills bucket
Operation
Fig. 87: Right-hand side control lever
J
Button
☞
J
Function
➥ Horn
Fig. 88: Functions of right-hand side control lever
Lowering the boom with the engine switched off
A
E
Lower the boom as follows:
☞
Make sure no one is dangerously close to the machine.
☞
Turn the starting key to position “
1
”.
☞
Push forwards and hold the control lever (
A
and
E
).
➥
Until the arm system is completely lowered.
☞
Return the control lever to neutral.
Fig. 89: Lowering the arm system with the engine switched off
Releasing pressure
Proceed as follows:
☞
Stop the engine.
☞
Move the control lever in all directions a few times.
➥ This releases the pressure in the hydraulic system.
OM 25-3703 us – Edition 4.3.1 * 2503_3703b340.fm
3-49
Operation
Rotating the upper carriage
Important!
• Until the hydraulic fluid reaches operating temperature, the upper carriage can creep slightly after the control is placed in the neutral position.
• Fast actuation of the control lever rotates the upper carriage fast, slow actuation of the control lever rotates the upper carriage slowly.
• If the upper carriage needs to be rotated on a slope, let the engine run at idling speed and actuate the control lever very slowly. Proceed with extreme care and avoid abrupt movements if the bucket is full.
Rotate the upper carriage to the left as follows:
☞
Push the left-hand side control lever
1
to the left
A.
➥ The upper carriage rotates to the left.
A
Fig. 90: Rotating the upper carriage to the left
B
Fig. 91: Rotating the upper carriage to the right
Rotating upper carriage brake
Rotate the upper carriage to the right as follows:
☞
Push the left-hand side control lever
1
to the right
B.
➥ The upper carriage rotates to the right.4
Upper carriage hydraulic brake:
The upper carriage's rotation is sufficiently braked by moving control lever
1
back to initial position. Moving the control lever in the opposite direction (counteraction) brakes the upper carriage with maximum hydraulic output.
Upper carriage mechanical brake:
This is a multi-disk mechanical brake that provides a secondary service brake and a primary parking brake function for the upper carriage. It is operated independently from the hydraulic brake of the upper carriage.
Important!
The mechanical brake functions only to prevent upper carriage rotation. It does not function as a machine propulsion brake.
3-50
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b340.fm
Operation
3.42 Coupling and uncoupling attachments
Coupling and uncoupling the attachments is described below for a bucket. If you are fitting or removing attachments with their own hydraulic functions – e.g. grab or offset bucket – you must follow the special information given in the Operator's Manual of the attachment.
Also refer to the Operator's Manual of the attachment for the procedure to follow for fitting an attachment onto a quickhitch.
Warning!
Personal injury hazard. Using improper tools or installation techniques while coupling attachments can cause injury.
Couple attachments only when the engine is stopped.
Do not attempt to couple/uncouple attachments on sloping or uneven surfaces. The excavator and the attachment to be coupled/uncoupled shall be on firm surfaces to avoid sudden unintentional movement.
Align the attachment holes in the bucket with a drift to facilitate sliding the pin into the respective holes provided for the connection between attachment and stick.
Do not attempt to correct misalignment by using the connecting pin and a hammer. Striking the pin with a hammer can result in a steel chip or splinter being released.
Always wear protective goggles, helmets, gloves, and other safety equipment when installing the attachment connecting pins.
Do not remove the connecting pins from the bucket attachment unless the bucket has been stabilized to prevent motion when the connecting pins are removed. Do not stand on the closed (back) side of the bucket attachment when disconnecting the bucket.
Do not attempt to disconnect the bucket attachment until it rests firmly on the ground or a stable surface. Removing the connecting pins of the bucket attachment with the attachment raised is an unsafe practice that will create a hazardous condition from the falling bucket.
Do not align the connecting holes with fingers. Do not place fingers and hands over the connecting brackets to align the connecting hole to avoid potential shearing, pinching or crushing injuries.
After the attachment is connected to the excavator stick and before resuming operation, make sure the
attachment
is safely locked with the stick and the tilt rod, or with the quick hitch option.
OM 25-3703 us – Edition 4.3.1 * 2503_3703b340.fm
3-51
Operation
Removing a bucket
B
A
Fig. 92: Removing a bucket
C
Mounting a bucket
D
I
H
E
G
F
K
J
Fig. 93: Mounting a bucket
☞
Proceed as follows:
• Lower the bucket to the ground with its flat side facing down.
• Stop the engine.
• Remove linch pin
A.
• First remove pin
B
, and then pin
C
. Carefully expel pins that are stuck with a hammer and a brass punch.
If pin
C
is stuck:
• Start the engine.
• Slighty raise and lower the boom to take the load off the pin.
• Switch off the engine.
Important!
Place the bucket only with minimum pressure on the ground as you remove the pins. The higher the pressure on the ground, the higher the resistance and the more difficult it is to remove the pins.
☞
Proceed as follows:
• Lower the bucket to the ground with its flat side facing down.
• Grease the joints and the pins before inserting them.
• Start the engine.
• Straighten the stick so that bores
D
and
E
are flush.
• Insert greased pin
F.
• Tighten lock screw
G.
• Actuate the stick hydraulic cylinder until bores
H
and
I
are flush.
• Insert the greased pin
J.
• Lock linch pin
K.
3-52
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b340.fm
Operation
3.43 Quickhitch (option)
M
N
L
Warning!
Possibility of crushing / striking injury from attachments. An unlocked quick hitch attachment can move unexpectedly and strike nearby people or objects.
Before using the excavator, make sure the attachment is securely locked onto the quick hitch.
The lock must be visible on either side of the mounting bore of the attachment to confirm the hitch is locked.
☞
Couple as follows:
• Move the machine to the attachment.
• Engage coupling bar
M
onto coupling claws
L
of the quickhitch to pick up the bucket.
• Engage lock mechanism
N
in mounting bores
O.
• Place the bucket on level ground.
P
O
Fig. 94: Bucket with quickhitch
S
Q
R
Fig. 95: Bucket with quickhitch
☞
Lock as follows:
• Stop the engine.
• Insert tube
P
(included in scope of delivery) in clamping sleeve
Q
.
• Push the tube downwards.
• The lock pins must be in position
R
.
☞
Unlock as follows:
• Stop off the engine.
• Insert tube
P
(included in scope of delivery) in clamping sleeve
Q
.
• Pull the tube upwards.
• The lock pins must be in position
S
.
OM 25-3703 us – Edition 4.3.1 * 2503_3703b340.fm
3-53
Operation
Connections for auxiliary hydraulics
T
U
Fig. 96: Connections for auxiliary hydraulics
Hydraulic couplings
V
Port
T
U
V
Stick (left)
☞
Pressure line
Stick (right)
☞
Large return line
☞
Pressure line
Important!
Follow the instructions in the Operator's Manual of the attachment manufacturer for connecting the auxiliary hydraulics to attachments.
A
C
Fig. 97: Hydraulic couplings
B
Connect and disconnect the hydraulic couplings as follows:
Removing the coupling:
☞
Park the machine on firm and level ground.
☞
Extend stick hydraulic cylinder
A
halfway through.
☞
Stop the engine.
☞
Turn the starter key to position “
1
”.
☞
Release the pressure on bucket hydraulic cylinder
A
by moving the right-hand side control lever to the left and right.
☞
Fold the control lever base up.
☞
Turn lock sleeve
C
towards lock ball
B
.
☞
Pull lock sleeve
C
upwards.
☞ The coupling opens.
Connecting the coupling:
☞
Clean the male and female ends of the coupling
☞ Align the male and female ends of the coupling and push them together until movement stops.
☞
Pull the coupling sleeve away from the ball (
☞
) to misalign the slot in the sleeve with the ball in the opposite half of the coupling. This will prevent unintended sleeve movement that may cause the coupling to disconnect unintentionally.
3-54
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b340.fm
Operation
B
A
Fig. 98: Grab ball-type cock
Attachments
A
B
Changing over the ball-type cock:
Bucket operation:
☞
Set the ball-type cocks to position
A.
Grab operation:
☞
Set the ball-type cocks to position
B.
Important!
Please refer to the operator's and maintenance manual of the attachment manufacturer for using and performing maintenance on attachments such as hammers, grabs etc.
OM 25-3703 us – Edition 4.3.1 * 2503_3703b340.fm
3-55
Operation
3.44 Safe load indicator (option)
Fig. 99: „Indicator“ for safe load indicator
Warning!
Possibility of personal injury or equipment damage from an inaccurate or non-functioning safe load indicator.
Always engage the safe load indicator.
Contact your Wacker Neuson dealer if the safe load indicator does not appear to be working or is incorrectly adjusted.
Engage the safe load indicator as follows:
☞
56
➥
51
illuminates the lift symbol if an overload is sensed.
The safe load indicator's indicator illuminates, and an acoustic warning is given, to alert the operator that the maximum load capacity has been reached. Any further increase of the load moment can cause the machine to overturn in this situation.
☞
Reduce the distance between the upper carriage and the load until both the acoustic signal and the indicator in the display element go out.
3-56
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b340.fm
Operation
3.45 Load holding control valve (option)
Fig. 100: Transport position
Important!
The load holding control valve limits boom drop in the event of a boom hydraulic hose assembly or fitting failure (reference ISO 8643).
☞
In the event of hydraulic system failure, proceed as follows:
• Immediately stop the machine.
• Move the boom to transport position.
• Fold up the left-hand side control lever base.
• Stop the engine.
• Remove the starter key and lock the cab.
• Lock the machine and the attachment.
• Have damage to the hydraulic system and to the hose burst valve itself immediately repaired and checked by technical staff with suitable training.
Environment!
Collect the spilled hydraulic oil in a suitable container.
☞ Dispose of spilled hydraulic oil by an ecologically safe method
☞
Always contact the relevant authorities or commercial establishments in charge of oil disposal before disposing of biodegradable oil.
OM 25-3703 us – Edition 4.3.1 * 2503_3703b340.fm
3-57
Operation
3.46 Working with the excavator
Working with the standard bucket
The following section describes work operations with the machine equipped with the standard bucket.
The standard bucket is mainly used for digging earth, and for loosening, picking up, digging and loading loose or solid material.
Inadmissible work
Working with the swivel force
☞
Do not use the swivel force of the upper carriage to compact the ground or tear down piles or walls.
☞
Do not allow the bucket teeth to penetrate into the ground as you rotate the upper carriage.
➥ Working this way damages the attachments.
Fig. 101: Working with the swivel force
Working with the drive force
☞
Do not allow the bucket to penetrate into the ground and do not excavate by using the drive force of the machine.
➥
Working this way can damage the machine or the attachments.
Fig. 102: Working with the drive force
Avoid impact during operation to avoid damage to the excavator bucket and machine components.
☞
Do not suddenly drop the bucket to increase penetration, break material, or compact material.
➥ Working this way can greatly reduce the machine's service life.
Fig. 103: Avoid impact during operation
3-58
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b340.fm
Operation
Avoid tipping the machine and then releasing the boom hydraulics to break up material or compact the work surface.
☞
This is not only hazardous operation; it is abusive operation.
Fig. 104: Avoid tipping the machine while excavating
Retracting attachments
☞
Make sure the bucket does not hit the stabilizer blade as you retract attachments for operating or transport.
Fig. 105: Retracting attachments
Working with the stabilizer blade
☞
Do not ram objects with the stabilizer blade.
☞
Do not pry objects with the stabilizer blade
☞
Do not support the excavator on one corner of the stabilizer blade.
Fig. 106: stabilizer blade fully lowered
OM 25-3703 us – Edition 4.3.1 * 2503_3703b340.fm
3-59
Operation
Excavator work position
Proceed as follows:
☞
Place stabilizer blade A on the side you want to dig.
A
Fig. 107: Excavator work position
Bucket position when digging
D
A
Fig. 108: Bucket position
B
C
☞
Move the bucket as shown in
A.
➥ Move the flat side of the bucket parallel to the ground.
Important!
Position
B
causes the bucket to penetrate into the ground. Work slows down, and the engine and the hydraulic pump are subject to overload if this position is used over a longer period of time!
Position
C
causes the bucket to be forced upwards and not to be filled completely.
This slows down work, too.
☞
Dig as follows:
• Penetrate into the ground with the bucket
D.
• Lower the stick and at the same time align bucket
D
until.
• Reaching the required digging depth and.
• The flat side of the bucket is parallel to the ground (see bucket position).
Fig. 109: Penetrating into the ground with the bucket and aligning it
E
☞
Pull bucket
E
parallel to the ground towards the excavator. At the same time, if possible:
• Move the stick towards the excavator.
• Lower the boom.
☞
With a sufficiently full bucket
E
:
• Keep on moving the stick towards the excavator and at the same time.
• Curl the bucket to complete the filling operation as the stick is moved toward the machine.
Fig. 110: Filling the bucket
3-60
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b340.fm
Excavating trenches
Operation
• Excavating trenches is more efficient
☞ By using a suitable bucket for this work and positioning the track tracks parallel to the center line of the trench.
☞
In case of large trenches, first excavate the side sections and then the center section.
Fig. 111: Excavating trenches
Loading
• Loading in confined areas with a limited angle of rotation is more efficient
☞ By positioning the truck so as to ensure maximum visibility for the driver of the excavator.
• Loading material on trucks is easier and faster if the hydraulic excavator is placed at the rear end of the truck and not at the sides.
Fig. 112: Loading
Grading
• Use the stabilizer blade to fill in trenches and to grade surfaces.
Important!
Work on level ground. Grade with the stabilizer blade first in case of sloping ground.
Fig. 113: Grading
Excavating trenches sideways
• The machine can be used for excavating trenches sideways in confined areas
☞
By rotating the upper carriage and swivelling the main boom (combined position and movement of both).
Fig. 114: Excavating trenches sideways
OM 25-3703 us – Edition 4.3.1 * 2503_3703b340.fm
3-61
Operation
Working alongside trenches
B
A
Fig. 115: Working alongside trenches
Stabilizer blade at rear
NOTICE
Possible piston rod damage. Piston rod
A
of the boom cylinder can be damaged when working alongside trenches, slopes etc. and operating the stabilizer blade and the boom incorrectly.
Always use stabilizer blade
B
for stabilization during excavation work.
Make sure stabilizer blade
B
never touches piston rod
A
(
Avoid maximum depth trench excavation from the stabilizer end of
the machine. (
Warning!
Machine tipping or falling hazard. Improper or careless operation of machine with the stabilizer blade
B
at the rear when working alongside trenches, slopes, etc., can cause the machine to tip or fall.
Use this work position only in an extreme emergency since the machine can tilt forwards into the trench.
We recommend using the first work position (
) described above.
Make sure piston rod
A
does not touch stabilizer blade
B
under any circumstances.
3-62
Fig. 116: Deep excavation
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b340.fm
Fig. 117: Loading vehicles
3.47 Grading
Operation
Recommendations for digging
When planning and performing digging work, observe the following points:
• Exits from pits must be outside the excavation face and as level as possible.
• Dig by removing adjacent strips if possible.
• Always travel out of an excavation up the grade, with the bucket on the up slope side of the machine.
• When entering an excavation down a slope with a loaded bucket, always travel with the bucket on the up slope side.
Loading vehicles
When loading vehicles, take the following into account:
• If possible, the truck and the working direction of the bucket should form an angle of
45°.
• Raise the full bucket to dump height only as you rotate towards the truck.
• If possible, dump with the wind behind you to keep the dust away from your eyes, air filters and fans.
Freeing the machine
If your machine gets stuck in the ground:
☞
Dump the contents out of the bucket.
☞
Extend the boom, stick, and bucket to the maximum reach and lower the bucket to the ground surface.
☞
Slowly uncurl the bucket to push the machine away from the bucket. While doing this, operate the track propulsion system slowly to assist the action of the bucket.
☞ Under alternate circumstances, the bucket can be curled to free the machine in the direction of the curling action.
☞
Once the machine has has reached a firm surface, maneuver away from the unstable surface conditions.
Warning!
Possibility of crushing/striking injury from a moving stabilizer blade.
Make sure no one is in the danger area when working with the stabilizer blade.
OM 25-3703 us – Edition 4.3.1 * 2503_3703b340.fm
3-63
Operation
Grading
☞
Lower the stabilizer blade to the ground
Stabilizer blade operation on page 3-22.
☞
Set the depth of the layer you want to remove with the stabilizer blade lever.
➥ Do not raise the machine by lowering the stabilizer blade.
The clearance between the stabilizer blade and the ground should be about 1 cm (0.4’’).
Fig. 118: Grading
3-64
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b340.fm
Troubleshooting
4 Troubleshooting
The information given in this chapter is provided for maintenance staff, for fast and reliable detection of malfunctions and their appropriate repair.
Repairs must be performed by authorized staff.
4.1
Engine trouble
Problem
Engine does not start or is not easy to start
Engine starts, but does not run smoothly or faultless
Engine overheats. Temperature warning system responds
Insufficient engine output
Possible causes
Wrong SAE grade of engine lubrication oil
Fuel grade does not comply with specifications
Defective or flat battery
Loose or oxidized cable connections in starter circuit
Defective starter, or pinion does not engage
Wrong valve tip clearance
Defective fuel injector
Defective cutoff solenoid
Defective fuse
Fuel grade does not comply with specifications
Dirty fuel filter
Wrong valve tip clearance
Injection line leaks
Defective fuel injector
Oil level too low
Oil level too high
Dirty air filter
Dirty cooler fins
Coolant level too low
Cooling system leaks
Defective fan, torn or loose V-belt
Resistance in cooling system too high, flow capacity too low
Defective fuel injector
Oil level too high
Fuel grade does not comply with specifications
Dirty fuel filter
Dirty air filter
Wrong valve tip clearance
Injection line leaks
Defective fuel injector
See
OM 25-3703 us – Edition 4.3.1 * 2503_3703b410.fm
4-1
Troubleshooting
Problem
Engine does not run on all cylinders
Insufficient or no engine oil pressure
Engine oil consumption too high
Engine smoke
Blue
White
Black
Possible causes
Injection line leaks
Defective fuel injector
Oil level too low
Machine inclination too high
Wrong SAE grade of engine lubrication oil
Oil level too high/wrong oil
Worn oil scraper ring
Machine inclination too high
Oil level too high/wrong oil
Machine inclination too high
Engine starting temperature too low
Fuel grade does not comply with specifications
Wrong valve clearance
Defective fuel injector
Defective cylinder-head gasket
Dirty air filter
Wrong valve clearance
Defective fuel injector
See
4-2
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b410.fm
Maintenance
5 Maintenance
5.1
Introduction
Operational readiness and the service life of machines are heavily dependent on maintenance.
It is therefore in the interest of the machine owner to perform the prescribed maintenance work.
Before performing service and maintenance work, always read, understand and follow the instructions given in:
• Chapter 2 “SAFETY INSTRUCTIONS” of this Operator's Manual
• The Operator's Manuals of the attachments.
Perform the prescribed inspections and rectify any disorders before putting the machine into operation.
Secure open (engine) covers appropriately. Do not open (engine) covers on slopes or in strong wind.
When using compressed air, dirt and debris can be blown into your face. Therefore, wear protective googles, masks, and clothing when using compressed air.
Daily service and maintenance work, and maintenance according to maintenance plan
“A”
must be performed by a specifically trained operator. All other maintenance work must be performed by trained and qualified staff only.
The maintenance plans indicate when the maintenance work mentioned below must be performed
– see Maintenance plan (overview)
OM 25-3703 us – Edition 4.3.1 * 2503_3703b510.fm
5-1
Maintenance
5.2
Fuel system
Refueling
A
Fig. 119: Fuel filler inlet
Warning!
Fire and fume inhalation hazards.
Do not refuel in closed rooms.
Never perform maintenance or repair work on the fuel system in the vicinity of open flames or sparks.
Never smoke when working on the fuel system or when refueling.
Before refueling, stop the engine and remove the starting key.
Wipe up any fuel spills immediately.
Remove spilled fuel from the machine components and surfaces before use to reduce the risk of fire.
The fuel fill inlet
A
) is located under the engine cover on the left rear side of the machine.
Environment!
Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner!
Important!
Do not run the fuel tank completely dry. Otherwise, air is drawn into the fuel system. This requires bleeding the fuel system
– see Bleeding the fuel system
Important!
Fill the tank with the correct fuel type at the end of each working day. This prevents condensation water from forming in the fuel tank overnight. Do not fill the tank completely but leave some space for the fuel to expand.
5-2
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b510.fm
Draining the fuel
A
Fig. 120: Fuel tank
Stationary fuel pumps wrong right
Fig. 121: Refueling from a barrel
Maintenance
Warning!
Fire hazard. Draining fuel may ignite if it comes into contact with hot engine parts or the muffler system.
Never bleed the fuel system if the engine is hot.
Environment!
Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner!
The fuel fill inlet
A
) is located under the engine cover on the left rear side of the
machine.
Proceed as follows:
☞
Open filler inlet
A.
☞ Drain the fuel with a suitable pump.
➥
Collect the fuel in a suitable container.
General
Only refuel from stationary fuel pumps. Fuel from barrels or cans is usually contaminated.
Even the smallest particles of dirt can cause:
• Increased engine wear.
• Malfunctions in the fuel system and.
• Reduced effectiveness of the fuel filters.
Refueling from barrels
If refueling from barrels cannot be avoided, note the following points (see fig. 121):
• Barrels must neither be rolled nor tilted before refueling.
• Protect the suction pipe opening of the barrel pump with a fine-mesh strainer.
• Immerse the suction pipe into the barrel until there is 15 cm (6") of clearance from the end of the pipe to the bottom of the barrel.
• Only fill the tank using refueling aids (funnels or filler pipes) with integral microfilter.
• Keep all refueling containers clean at all times.
OM 25-3703 us – Edition 4.3.1 * 2503_3703b510.fm
5-3
Maintenance
Diesel fuel specification
Bleeding the fuel system
Water separator
B
On
A
Fig. 122: Water separator
5-4
Off
C
Use only high-grade fuels
Grade
• 2-D ASTM D975 – 94
• 1-D ASTM D975 – 94
• EN 590 : 96
• ISO 8217 DMX
• BS 2869 – A1
• BS 2869 – A2
Use
USA
EU
International
England
Warning!
Fire and burn hazard. Draining fuel may ignite if it comes into contact with hot engine parts or the exhaust system. Hot fuel may cause burns.
Stop the engine before draining fuel.
Always wear protective equipment and safety glasses when working with fuel.
Never bleed the fuel system if the engine is hot.
Bleed the fuel system in the following cases:
• After removing and fitting the fuel filter, prefilter or the fuel lines back on again.
• After running the fuel tank empty.
• After running the engine again, after it has been out of service for a longer period of time.
☞
Bleed the fuel system as follows:
• Fill the fuel tank.
• Turn the starter key to the first position.
• Wait about 5 minutes while the fuel system bleeds itself automatically.
• Start the engine.
If the engine runs smoothly for a while, and then stops; or if it does not run smoothly:
• Stop the engine.
• Bleed the fuel system again as described above.
• Have this checked by authorized staff if necessary.
Interrupt fuel supply as follows:.
☞
Turn ball-type cock
B
to the
OFF
mark.
➥
Fuel supply is interrupted.
☞
Turn ball-type cock
B
to the
ON
mark.
Fuel supply is open again.
Check the water separator as follows:
☞
If the red indicator ring rises to position
C.
☞
Unscrew thread
A.
➥ The water drains.
➥
Wait until the indicator ring returns to the bottom of the water separator.
☞
Screw thread
A
back on again.
Environment!
Thread
A
is fitted with a hose. Collect the water as it drains with a suitable container and dispose of it in an environmentally friendly manner.
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b510.fm
Maintenance
5.3
Engine lubrication system
Checking the oil level
Fig. 123: Checking the oil level
Replacing engine oil
max min
A
NOTICE
Possible engine damage or power loss due to improper oil management. If the engine oil level is too low or if an oil change is overdue, this can cause engine damage or a loss of power.
Have the oil changed by an authorized workshop.
Refer to chapter 5.18 Maintenance plan (overview)
on page 5-35.
Important!
Check the oil level once a day.
We recommend checking it before starting the engine. After stopping a warm engine, wait at least 5 minutes before checking.
Checking the oil level
☞
Proceed as follows:
• Park the machine on level ground.
• Stop the engine!
• Fold the control lever base up.
• Let the engine cool down.
• Open the engine cover.
• Clean the area around the oil dipstick with a lint-free cloth.
• Oil dipstick
A
:
☞ Remove the dipstick.
☞
Wipe it with a lint-free cloth.
☞ Push it back in as far as possible.
☞
Withdraw it and read the oil level.
☞
Do not allow the engine oil level to fall below the MIN mark on the dipstick
.
NOTICE
Possibility of engine damage from too much oil or incorrect engine oil.
Do not add engine oil above the MAX mark of oil dipstick
A
(
).
Use only the specified engine oil.
Environment!
Use a suitable container to collect the engine oil as it drains and dispose of it in an environmentally friendly manner!
OM 25-3703 us – Edition 4.3.1 * 2503_3703b510.fm
5-5
Maintenance
A
OIL
Fig. 124: Oil dipstick and oil filler cap
B
Replacing engine oil
☞
Proceed as follows:
• Clean the area around oil filler cap
B
with a lint-free cloth.
• Open filler cap
B.
• Raise oil dipstick
A
slightly to allow any trapped air to escape.
• Add engine oil.
• Wait about 3 minutes until all the oil has run into the oil sump.
• Check the oil level
• Add oil if necessary and check the oil level again.
• Close filler cap
B.
• Push oil dipstick
A
back in as far as possible.
• Completely remove all oil spills from the engine.
5-6
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b510.fm
Maintenance
5.4
Engine and hydraulics cooling system
The hydraulic fluid cooler and engine coolant radiator are located in the engine compartment next to the engine. The cooling system maintains the optimum operating temperature in the hydraulic work and propulsion systems as well as the diesel engine.
The expansion tank for the coolant is also located in the engine compartment, in front of
Checking / filling up coolant
Improperly maintaining the cooling system can cause engine damage.
Dirt on the radiator fins reduces the cooler's heat dissipation capacity.
Clean the outside of the radiator at regular intervals. Use oil-free compressed air (2 bar (29 psi) max.) to clean. Maintain distance from the radiator to avoid damage to the radiator fins. Refer to the maintenance plans for the cleaning intervals.
In dusty or dirty work conditions, clean more frequently than indicated in the maintenance plans.
An insufficient coolant level reduces the heat dissipation capacity and can lead to engine damage:
Check the coolant level at regular intervals. Refer to the maintenance plans in the appendix for the intervals.
If coolant must be added frequently, check the cooling system for leaks and/or contact your dealer.
To avoid potential mechanical damage to the system, do not add cold water or coolant to the engine radiator unless the system components are cool.
After filling the expansion tank, make a test run with the engine and check the coolant level again after switching off the engine.
The use of the wrong coolant can destroy the engine and the cooler.
Add enough antifreeze compound to the coolant – but never more than
50 %. If possible use brand-name antifreeze compounds with anticorrosion additives.
Observe the coolant compound table
Do not use cooler cleaning compounds if an antifreeze compound has been added to the coolant – otherwise this causes sludge to form, which can damage the engine.
Follow the procedure below after filling the expansion tank:
Test run the engine.
Stop the engine.
Let the engine cool down.
Check the coolant level again.
Environment!
Use a suitable container to collect the coolant as it drains and dispose of it in an environmentally friendly manner!
OM 25-3703 us – Edition 4.3.1 * 2503_3703b510.fm
5-7
Maintenance
Specific safety instructions
Warning!
Burn hazard. The coolant in the system is hot under normal operating conditions and under approximately 1 bar (15 psi) pressure.
Never open the coolant tank or drain coolant if the engine is hot.
Wait at least 15 minutes after stopping the engine.
Wear protective glasses, gloves and clothing.
Open filler cap to the first notch and allow the pressure to escape.
Do not proceed with checking, maintaining or repairing the cooling system unless the components are comfortable to touch (less than 49°C (120°F).
Warning!
Hazardous material. Coolant mixtures are poisonous and flammable. Contact with skin and eyes should be avoided.
Wash skin immediately to remove coolant mixture from the skin to avoid irritation.
Wash eyes immediately if coolant comes in contact with the eye. Seek medical attention immediately.
Store coolant concentrate and mixtures in a secure space to prevent unauthorized contact.
Do not store or use coolant or coolant mixtures near open flames including smoking materials.
Dispose of used coolant through approved methods for recycling. Do not dispose of coolant or mixtures in sewers, toilets or dumping on the ground.
5-8
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b510.fm
Maintenance
5.5
Checking the coolant level
A
☞
Proceed as follows:
• Park the machine on level ground.
• Stop the engine!
• Fold the control lever base up.
• Remove the key and carry it with you.
• Let the engine and the coolant cool down.
• Open the engine cover.
• Check the coolant level on the transparent coolant tank
A
and on the radiator
B.
☞ If the coolant level is below the
LOW
seam or if there is no coolant at the radiator's filler inlet:
➥
Add coolant.
FULL
LOW
Important!
Check the coolant level once a day.
We recommend checking it before starting the engine.
Expansion tank for coolant
B
Fig. 125: Radiator
Adding coolant
After the engine has cooled down:
☞
Release overpressure in the radiator.
☞
Carefully open the cap to the first notch and fully release the pressure.
☞
Open filler cap B.
☞
Add coolant up to the lower edge of the filler inlet (radiator).
☞
Close filler cap B.
☞
Start the engine and let it warm up for about 5 – 10 minutes.
☞
Stop the engine.
☞
Remove the key and carry it with you.
☞
Let the engine cool down.
☞
Check the coolant level again.
➥ The coolant level must be between the
LOW and FULL
tank seams.
☞
If necessary, add coolant and repeat the procedure until the coolant level remains constant.
Important!
Check the antifreeze every year before the cold season sets in
OM 25-3703 us – Edition 4.3.1 * 2503_3703b510.fm
5-9
Maintenance
Draining coolant
Fig. 126: Pumping out coolant
A
Warning!
Burn hazard. Coolant is flammable and very hot.
Always wear appropriate protective equipment such as gloves.
Do not smoke while draining coolant.
Environment!
Use a suitable container to collect the coolant as it drains and dispose of it in an environmentally friendly manner!
Proceed as follows:
☞
Stop the engine.
☞ Let the coolant cool down.
☞
Open filler inlet
A
(
.)
☞ Drain the coolant with a suitable pump.
➥
Collect the coolant in a suitable container.
5-10
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b510.fm
5.6
Air filter
Maintenance
Fig. 127: Indicator for air filter contamination
NOTICE
Possible equipment damage. The filter cartridge will be damaged if it is washed or brushed out.
Keep in mind the following to avoid premature engine wear:
Do not clean the filter cartridge.
Replace the filter cartridge according to the maintenance plan.
Never reuse a damaged filter cartridge.
Ensure cleanliness when replacing the filter cartridge!
Replace the air filter element(s) as specified by the maintenance schedule or more often if indicator light
62
NOTICE
Filter cartridge degradation. Filter cartridges degrade prematurely in environments with acidic air, such as acid production facilities, steel and aluminium mills, chemical plants and other nonferrous-metal plants.
Replace the air filter after no more than 50 service hours.
General instructions for air filter maintenance:
• Store filters in their original packaging and in a dry place.
• Do not knock the filter against other objects as you install it.
• Check air filter attachments, air intake hoses and air filters for damage, and immediately repair or replace if necessary.
• Check the screws at the induction manifold and the clamps for tightness.
• Check the function of the dust valve, replace if necessary.
OM 25-3703 us – Edition 4.3.1 * 2503_3703b520.fm
5-11
Maintenance
Replacing the filter
E
G
Fig. 128: Removing the lower housing section
B
Fig. 129: Removing the filter element
F
Fig. 128: Replacing the inside filter
C
• Replace primary filter
B
as follows:
☞
Stop the engine.
☞
Remove the key and carry it with you.
☞
Let the engine cool down.
☞
Open the engine cover.
☞
Remove dirt and dust from the air filter and the area around the air filter.
☞
Rotate the filter end housing
E
(
) counter-clockwise to remove it.
☞
Remove lower housing section
E.
☞
Carefully remove primary filter
B
with slightly turning movements.
☞
Make sure
all dirt (dust) inside the upper and lower housing sections (
F
and
E
), including dust ejection valve
G,
has been removed.
☞
Clean the parts with a clean, lint-free cloth.
☞ Do not use compressed air.
☞
Check the air filter cartridges for damage.
☞
Install only a new or undamaged, serviceable primary filter element.
☞
Carefully insert the new primary filter
B
in the upper housing section
F.
☞
Position lower housing section
E
(make sure it is properly seated).
☞
Install the filter end housing
E
with the dust ejector valve
G
aimed downwards.
☞
To complete the installation, align the notches in the end and body housing and rotate the end housing clockwise until the joint is tightly seated.
• Replace secondary filter
C
as follows:
☞
Remove the primary filter to access the secondary filter. Use the previous instructions
for removing the primary filter ( Fig. 128 and Fig. 129
).
☞
Carefully remove
secondary
filter
C.
☞
Cover the air supply at the end of the filter with a clean lint-free cloth to prevent dust from entering the engine.
☞
Make sure
all dirt (dust) inside the upper and lower housing sections (
F
and
E
), including dust ejection valve
G,
has been removed.
☞ Clean the parts with a clean lint-free cloth.
☞ Do not use compressed air.
☞
Remove the cloth from the air supply.
☞
Check the air filter cartridges for damage.
☞
Install only a new or undamaged, serviceable secondary filter element.
☞
Carefully insert the new secondary filter
C
in the upper housing section
F.
☞
Carefully insert the primary filter
B
in the upper housing section
F.
☞
Position lower housing section
E
(make sure it is properly seated).
☞
Install the filter end housing
E
with the dust ejector valve aimed downwards.
☞
To complete the installation, align the notches in the end and body housing and rotate the end housing clockwise until the joint is tightly seated.
Important!
Make sure the dust valve
G
) is aimed downward after installation.
5-12
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b520.fm
Maintenance
5.7
V-belt
Checking V-belt tension
2
About 8 mm
Fig. 129: Checking V-belt tension
Warning!
Crushing, cutting, or burn hazards.
Stop the engine and permit a cool down time. Wait until the engine is comfortable to touch.
Only check, retighten, or replace the V-belt when the engine is stopped.
Disconnect the battery or the battery master switch before proceeding with work on the V-belt.
NOTICE
Cracked and stretched V-belts cause engine damage.
Have the V-belt replaced by a Wacker Neuson service center.
Check the V-belt once a day or every 10 service hours, and retighten if necessary!
Retighten new V-belts after about 15 minutes of running time.
1
• Check as follows:
☞ Stop the engine.
☞ Fold the control lever base up.
☞ Remove the key and carry it with you.
☞ Disconnect the battery or the battery master switch.
☞ Let the engine cool down.
☞ Open the engine cover.
☞ Carefully check V-belt
1
for damage, cracks or cuts.
☞ Replace the V-belt if it touches the base of the V-belt groove or the discs of the pulley.
• If the V-belt is damaged:
☞ Have the V-belt replaced by authorized staff.
☞ Press with your thumb about 100 N to check the deflection of the V-belt between the crankshaft disc and the fan wheel. A new V-belt should have a deflection of
6 to 8 mm (0.2’’ to 0.3’’) , a used V-belt (after about 5 minutes running time) should have a deflection of 7 to 9 mm ( 0.28’’ to 0.35’’)
2.
☞ Retighten the V-belt if necessary.
OM 25-3703 us – Edition 4.3.1 * 2503_3703b520.fm
5-13
Maintenance
Retightening the V-belt
A
5
4
Fig. 130: Retightening the V-belt
3
NOTICE
Possible engine damage. Overtightening the V-belt can damage the
V-belt, the V-belt guide, the alternator bearing and the water pump bearing.
Avoid contact of oil, grease or similar substances.
Check V-belt tension
– see Checking V-belt tension on page 5-13.
• Retighten as follows:
☞
Stop the engine.
☞ Fold the control lever base up.
☞
Remove the key and carry it with you.
☞ Disconnect the battery or the battery master switch.
☞
Let the engine cool down.
☞ Open the engine cover.
☞
Loosen fastening screws
3
and
4
(
) of alternator
5.
☞ Use a suitable tool to push alternator
5
in the direction of arrow
A
until reaching the
☞
Keep alternator
5
in this position, and at the same time retighten fastening screws
3
and
4
(
).
☞ Check V-belt tension again and adjust it if necessary.
☞
Connect the battery or the battery master switch.
☞ Close the engine cover.
5-14
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b520.fm
Maintenance
5.8
Hydraulic system
Specific safety instructions
Warning!
Pressurized hydraulic oil hazard. Hydraulic oil escaping under high pressure can catch fire, damage property, penetrate the skin and cause severe burns and injuries.
Do not operate the machine with leaking or damaged hydraulic system components.
Use a piece of cardboard to diagnose the source of hydraulic leaks.
Hydraulic oil can be hot and can cause serious burns if contact is made with skin. If contact occurs with hot oil, seek immediate medical attention and treatment for the burn.
Wear safety glasses/goggles to avoid eye contact. If oil contacts the eye flush immediately with clean water and seek emergency medical treatment.
Seek immediate medical attention if oil penetrates the skin. Oil can cause serious infections.sdfsdf
Do not overfill the hydraulic system with hydraulic oil.
Warning!
Release the pressure in all lines carrying hydraulic oil prior to any maintenance and repair work. To do this:
• Lower all hydraulically controlled attachments to the ground.
• Move all control levers of the hydraulic control valves several times.
• Fold the control lever base up.
• If the hydraulic oil in the sight glass is cloudy, this indicates that water or air has penetrated the hydraulic system. This can cause damage to the hydraulic pump!
☞ Contact your Wacker Neuson dealer immediately.
• Replace the hose or line if one of the problems mentioned below is detected.
☞ Damaged or leaky hydraulic seals.
☞
Worn or damaged hose covering or uncovered reinforcement branches.
☞ Bulging hose coverings in several positions.
☞
Entangled or crushed lines or fittings.
☞ Foreign bodies jammed or stuck in protective layers.
OM 25-3703 us – Edition 4.3.1 * 2503_3703b520.fm
5-15
Maintenance
Checking the hydraulic oil level
NOTICE
Possible equipment damage. Contaminated hydraulic oil, lack of hydraulic oil, or the wrong hydraulic oil can severely damage the hydraulic system.
Take care to avoid contamination when working!
To avoid dirt contamination, use the screened inlet when adding oil.
Only use authorized oils of the same type
on page 5-32
Always add hydraulic oil before the level gets too low
on page 5-18
If the hydraulic system is filled with biodegradable oil, then only use biodegradable oil of the same type for filling up – observe the label on the hydraulic oil tank!
Contact your Wacker Neuson dealer immediately if the hydraulic system filter is contaminated with metal shavings.
Environment!
Collect drained hydraulic oil and biodegradable oil in a suitable container!
Dispose of drained oil and used filters by an ecologically safe method.
Always contact the relevant authorities or commercial establishments in charge of oil disposal before disposing of biodegradable oil.
Warning!
Pressurized hydraulic oil hazard. Overfilling the hydraulic system with hydraulic oil can lead to high pressures and escaping hydraulic oil. This escaping hydraulic oil can cause severe injury.
Check the hydraulic oil level each time the machine is put into service or once a day.
5-16
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b520.fm
Fig. 131: Parking the excavator
B
MAX
MIN
Fig. 131: Oil level indicator on the hydraulic oil tank
Maintenance
1
☞
Proceed as follows:
• Park the machine on level ground.
• Retract the bucket and boom hydraulic cylinders, lower the boom and the bucket teeth to the ground.
• Lower the stabilizer blade to the ground.
• Set the boom straight (offset hydraulic cylinder).
• Stop the engine.
• Fold the control lever base up.
• Sight glass
B
is located in the rear left corner of the machine in the trim..
• Check the oil level on sight glass
B.
• The oil level must be about 1 cm (3/8“) over the center, between positions
MIN
and
MAX
➥ The
MIN
level is marked by the lower joint.
➥
The
MAX
level is marked by the upper joint.
If the oil level is lower
• Add hydraulic oil.
The oil level varies according to the machine's operating temperature:
Machine condition
• Before putting into operation
• Normal operation
Temperature
Between 10 and 30 °C -
(50 and 86°F)
Between 50 and 90 °C -
(122 and 194°F)
Oil level
LOW
FULL
mark
mark
Important!
Measure the oil level of the hydraulic system only after the machine reaches its operating temperature.
OM 25-3703 us – Edition 4.3.1 * 2503_3703b520.fm
5-17
Maintenance
Adding hydraulic oil
Fig. 132: Parking the excavator
C
Warning!
Pressurized hydraulic oil hazard. Removing the hydraulic filter plug can cause pressurized oil to escape. Escaping oil can cause serious injuries.
Permit the hydraulic oil to cool to a temperature that is comfortable to the touch.
Slightly loosen the breather plug on the hydraulic reservoir enough to relieve pressure in the tank.
Do not add hydraulic oil unless the engine is stopped. Otherwise, hydraulic oil will overflow at the filler opening on the hydraulic reservoir.
☞
Add oil as follows:
• Park the machine on level ground.
• Retract the bucket and boom hydraulic cylinders, lower the boom and the bucket teeth to the ground.
• Lower the stabilizer blade to the ground.
• Set the boom straight (offset hydraulic cylinder).
• Stop the engine.
• Fold the control lever base up.
• Let the engine cool down.
• Slowly open cap
C
of the hydraulic reservoir.
With the filter insert in place:
• Add hydraulic oil.
• Check the hydraulic oil level on sight glass
B.
• Add oil if necessary and check again.
• Close cap
C
of the hydraulic reservoir hand tight again.
Fig. 132: Hydraulic oil tank
5-18
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b520.fm
Maintenance
Important information for the use of biodegradable oil
• Use only the biodegradable hydraulic fluids which have been tested and approved by
Wacker Neuson Linz GmbH. Always contact Wacker Neuson Linz GmbH for the use of other products which have not been recommended. In addition, ask the oil supplier for a written declaration of guarantee. This guarantee is applicable to damage occurring on the hydraulic components, which can be proved to be due to the hydraulic fluid.
• Use only biodegradable oil of the same type for filling up. In order to avoid misunderstandings, a label providing clear information is located on the hydraulic oil tank (next to the filler inlet) regarding the type of oil currently used! Replace missing labels!
The combined use of two different biodegradable oils can affect the quality of one of the oil types. Therefore, make sure the remaining amount of initial hydraulic fluid in the hydraulic system does not exceed 8 % when changing biodegradable oil (manufacturer indications).
• Do not fill up with mineral oil – the content of mineral oil should not exceed 2 % in order to avoid foaming problems and to ensure biological degradability.
• When running the machine with biodegradable oil, the same oil and filter replacement intervals are valid as for mineral oil
• Always have the condensation water in the hydraulic oil tank drained by an authorized workshop before the cold season. The water content may not exceed 0.1 % by weight.
• The instructions in this Operator's Manual concerning environmental protection are also valid for the use of biodegradable oil.
• If additional hydraulic attachments are mounted or operated, use the same type of biodegradable oil for these attachments to avoid mixtures in the hydraulic system.
Subsequent change from mineral oil to biodegradable oil must be performed by a Wacker
Neuson service center.
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5-19
Maintenance
5.9
Pilot control filter
B
Fig. 133: Pilot valve
From serial number: AE01152
B
Fig. 133: Pilot valve
From serial number: AD02408
NOTICE
Possible equipment damage. Dirty oil can damage the piston valves within the pilot valves.
Check the pilot control filter every 1000 s/h and clean it if necessary.
Check the pilot valve as follows:
☞
Park the machine on level ground.
☞
Retract the bucket and boom hydraulic cylinders, lower the boom and the bucket to the ground.
☞
Lower the stabilizer blade to the ground.
☞
Straighten the boom.
☞
Stop the engine.
☞
Move the control levers in all directions repeatedly.
☞
Switch off the engine and remove the key.
☞
Fold up the control lever base.
☞
Let the engine cool down.
☞
Slowly open the breather filter.
➥ Release the pressure.
☞
Install the vacuum pump.
☞ Engage the pump before routing the hoses.
☞
Remove the joystick.
☞
Remove the pilot control hose from the joystick.
☞
Remove pilot control filter
B
from the joystick.
☞
Check pilot control filter screen
C
for dirt and clean it if necessary. Replace it by a new filter if it is damaged!.
☞
Assemble in the reverse order.
B
Fig. 133: Pilot valve
From serial number: AE01151
C
Fig. 133: Pilot control filter screen
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OM 25-3703 us – Edition 4.3.1 * * 2503_3703b520.fm
Maintenance
Checking hydraulic pressure lines
Specific safety instructions
Warning!
Pressurized hydraulic oil hazard. Hydraulic oil escaping under high pressure can catch fire, damage property, penetrate the skin and cause severe burns and injuries.
Do not operate the machine with leaking or damaged hydraulic system components.
Use a piece of cardboard to diagnose the source of hydraulic leaks.
Hydraulic oil can be hot and can cause serious burns if contact is made with skin. If contact occurs with hot oil, seek immediate medical attention and treatment for the burn.
Wear safety glasses/goggles to avoid eye contact. If oil contacts the eye flush immediately with clean water and seek emergency medical treatment.
Seek immediate medical attention if oil penetrates the skin. Oil can cause serious infections.
Retighten leaking threaded fittings and hose connections only when the system is not under pressure; i.e. release the pressure before working on pressurized lines.
Never weld or solder damaged or leaking pressure lines and threaded connections. Replace damaged parts with new ones.
Do not check for leaks with an incandescent light or open flame due to explosive fire risk from vaporized oil mist.
• Leaks and damaged pressure lines must be immediately repaired or replaced by an authorized workshop or after-sales staff.
This not only increases the operating safety of your machine but also helps to protect the environment
• Replace hydraulic hoses every 6 years from the date of manufacture, even if they do not seem to be damaged
In this respect, we recommend that you observe all the relevant safety standards for hydraulic lines, as well as the safety regulations regarding accident prevention and occupational health and safety in your country.
The article number is marked on the clamping section, and the date of manufacture is indicated on the hose of each hose connection.
OM 25-3703 us – Edition 4.3.1 * 2503_3703b520.fm
5-21
Maintenance
5.10 Tracks
Checking track tension
D
B
B
C
• Track wear can vary according to work and ground conditions.
☞
We recommend checking track wear and tension once a day.
☞ Park the machine on firm and level ground to check and perform maintenance.
Warning!
Crushing hazard. Do not work under the machine unless it has been raised and supported properly.
Raising the machine with the stabilizer and working attachments is not an acceptable stable platform to elevate the machine for work underneath the machine!
Check track tension as follows:
• The track has a mark
B
☞
Place the excavator so that mark
B
of the track is between the drive pinion
C
and the track tension roller
D
Fig. 134: Rubber track mark
Fig. 135: Raising the excavator
20 – 25 mm
☞
Park the machine on firm and level ground.
☞
Raise the excavator with the boom and the stick.
☞
Slowly and carefully actuate the control levers.
☞
Stop the engine.
☞
Remove the key and carry it with you.
☞
Fold the control lever base up.
☞
Support the raised machine with blocks and cribbing adequate to provide a stable position while working on the track system.
• Standard play between the sliding block's shoulder and the contact area of the second support roller of the drive pinion is 20 – 25 mm ( 0.79’’ - 0.98’’).
☞ Set the tension as follows if it is not in accordance with the rated value.
Fig. 136: Measuring distance
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OM 25-3703 us – Edition 4.3.1 * * 2503_3703b530.fm
Maintenance
Adjusting the track tension
Warning!
Projectile hazard.The grease fitting for track adjustment is subject to high pressure. The grease fitting can become a projectile if pressure caused by track tension is not properly relieved.
Do not remove the grease fitting.
Wear safety goggles, gloves and protective clothing to reduce skin exposure to grease. Wipe grease from skin and seek immediate attention if grease contacts eyes.
When relieving the pressure in the track tension system, do not turn the grease fitting farther than one counter-clockwise turn.
Do not loosen any part of the track tension system until the pressure has been released from the track tension system.
Keep your face away from the lubricating valve connection.
Do not use auxiliary force on the track or idler in an effort to force grease from the loosened fitting. Contact your Wacker Neuson dealer and wait for a qualified technician to determine the problem and how to solve it.
NOTICE
Possibility of equipment damage. Excessive tension of the tracks causes severe damage to the ram and the track.
Tighten the tracks only up to the prescribed measuring distance.
Tightening the tracks
Fig. 137: Tightening the tracks
Fig. 138: Draining grease
A
A
OM 25-3703 us – Edition 4.3.1 * 2503_3703b530.fm
☞
Inject grease with the pump through lubricating valve
A.
☞
Check the tension is correct by starting the engine, letting it run at idling speed and slowly moving the machine forwards and reverse and switching it off again.
☞
Check the tension of the track tracks again.
➥ If it is not correct:
☞
Adjust again.
☞
Contact your Wacker Neuson dealer if the procedure for tightening the tracks does not correct the track tension.
Reducing tension
• Drain the grease as described below. Do not drain it in any other way. Also bear in mind the safety instructions on this page.
☞
Slowly open the lubricating valve
A
by 1 turn to allow the grease to flow out.
☞ Place a suitable container underneath to collect the grease.
➥
The grease flows out of the groove of the lubricating valve.
☞
Retighten the lubricating valve
A.
☞
Check the tension is correct by starting the engine, letting it run at idling speed and slowly moving the machine forwards and reverse and switching it off again.
☞
Check the tension of the track tracks again .
➥
If it is not correct:
☞ Adjust again.
5-23
Maintenance
Environment!
Use a suitable container to collect the grease as it flows out and dispose of it in an environmentally friendly manner.
5.11 Track propulsion final drive
Warning!
Burn hazard. The traveling drive and the oil inside can remain hot and under pressure even after the engine has been switched off. This hot oil may leak from the traveling drive.
Wait until the engine has cooled down before performing maintenance work.
Checking the oil level and filling up oil
A
Fig. 139: Checking the oil level
Draining oil
Fig. 140: Draining oil
A
B
B
☞
Park the machine on firm and level ground.
☞
Place the machine so that filler plug
A
is at the top.
☞
Stop the engine.
☞
Let the engine cool down.
☞
Fold the control lever base up.
☞
Loosen and remove screws
A
and
B
with a suitable tool.
☞
A small quantity of oil must flow out of opening
B.
➥ If the oil does not flow out of opening
B
, fill up oil:
☞
Add oil through opening
A
,
➥ until a small quantity of oil flows out of opening
B.
☞
Screw screws
A
and
B
back in again.
☞
Move the machine a few meters or feet.
☞
Check the oil level again.
➥ If the oil level is not correct:
☞
Repeat the procedure.
☞
Park the machine on firm and level ground.
☞
Place the machine so that filler plug
B
is at the bottom.
☞
Stop the engine.
☞
Let the engine cool down.
☞
Fold the control lever base up.
☞
Loosen and remove screws
A
and
B
with a suitable tool.
➥
The oil now flows out of opening
B.
☞ Use a suitable container to collect the oil as it drains.
Environment!
Collect the oil with a suitable container and dispose of it in an environmentally friendly manner.
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OM 25-3703 us – Edition 4.3.1 * * 2503_3703b530.fm
Maintenance
5.12 Maintenance of attachments
Important!
Correct maintenance and service is absolutely necessary for smooth and continuous operation, and for an increased service life of the attachments. Please observe the lubrication and maintenance instructions in the Operator's Manuals of the attachments
5.13 Electric system
Warning!
Batteries can explode or cause chemical burns. A battery contains sulfuric acid and emits explosive gases when heavily discharged.
Do not smoke or use an open flame near the battery.
Do not handle the battery recklessly, causing acid to leak or spill.
Do not add circuits or electrical accessories that exceed the system capacity.
Do not connect a circuit without a correctly-rated fuse or circuit breaker.Possible equipment damage from improper battery connections.
When connecting the battery leads, make sure the poles +/– are not reversed, otherwise sensitive electric components will be damaged
Use only 12 V power sources. Higher voltages will damage the electric components.
Do not interrupt voltage-carrying circuits at the battery terminals because of the risk of sparking.
To prevent short circuits, never place tools or other conductive articles on the battery.
Disconnect the negative (
–
) battery terminal from the battery before starting repair work on the electric system.
Important!
Dispose of used batteries properly.
Service and maintenance work at regular intervals
Before driving the machine
☞
Check every time before driving the machine:
• Is the light system OK?
• Is the signalling and warning system OK?
Every week
☞
Check once a week:
– see chapter Fuse box in engine compartment
• Cable and earth connections
• Battery charge condition
• Condition of battery terminals
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5-25
Maintenance
Instructions concerning specific components
Cables, bulbs and fuses
Always observe the following instructions:
• Defective components of the electric system must always be replaced by an authorized expert.
• When performing maintenance work on the electric system, pay particular attention to ensuring good contact in leads and fuses.
• Blown fuses indicate overloading or short circuits. The electric system must therefore be checked before installing the new fuse.
• Only use fuses with the specified load capacity (amperage).
– see chapter Fuse box in engine compartment
Alternator
Always observe the following instructions:
• Only test run the engine with the battery connected.
• When connecting the battery, make sure the poles (+/–) are not reversed.
• Always disconnect the battery before performing welding work or connecting a quick battery charger.
• Replace defective charge indicator lights immediately
– see chapter 47 Indicator light
(red) – alternator charge function 3-12
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Battery
-
+
Fig. 141: Battery
A
Maintenance
Warning!
Battery acid hazard. The battery contains highly caustic sulphuric acid. This acid must not be allowed to come into contact with the skin, the eyes, clothing, or the machine.
When recharging and/or working near the battery, always wear goggles and protective clothing with long sleeves.
If acid is spilled, thoroughly rinse affected skin immediately with clean water and seek medical attention immediately.
Warning!
Battery explosion hazard. Lead acid batteries can generate a potentially explosive hydrogen and oxygen mixture. Batteries can explode or rupture during jump starting, particularly if the electrolyte is low or has been frozen.
Avoid open flames and sparks in the vicinity of the battery. Do not smoke.
Before jump-starting, take the battery to the dealer for appraisal by a qualified technician.
Replace a dead battery with a new one equivalent to the original.
Always disconnect the negative terminal (–) from the battery before starting repair work on the electric system.
Battery
A
is located under the cab, in front of the fuel tank. The battery is
“maintenance-free”. However have the battery checked at regular intervals to make sure the electrolyte level is between the MIN and MAX marks.
Checking the battery requires it to be removed and must be performed by an authorized workshop.
Always follow the specific battery safety instructions!
Important!
Do not disconnect the battery while the engine is running.
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5-27
Maintenance
5.14 General maintenance work
Cleaning
Cleaning the machine is divided into 3 separate areas:
• Inside the cab
• Exterior of the machine
• Engine compartment
To avoid personal injury and damage to the machine, always follow the recommendations for cleaning the machine.
General instructions for all areas of the machine
When using washing solvents
• Ensure adequate room ventilation.
• Wear suitable protective clothing.
• Do not use flammable liquids, such as petrol or diesel.
When using compressed air
• Work carefully.
• Wear goggles and protective clothing.
• Do not aim the compressed air at the skin or at other people.
• Do not use compressed air for cleaning your clothing.
When using a high-pressure cleaner or steam jet
• Electric components and damping material must be covered and not directly exposed to the jet.
• Cover the vent filter on the hydraulic oil tank and the filler caps for fuel, hydraulic oil etc.
• Protect the following components from moisture:
• Engine
• Electric components such as the alternator etc.
• Control devices and seals
• Air intake filters etc.
When using volatile and easily flammable anticorrosion agents and sprays:
• Ensure adequate room ventilation.
• Do not use unprotected lights or open flames.
• Do not smoke!
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Maintenance
Inside the cab
Exterior of the machine
Engine compartment
NOTICE
Possible equipment damage from high-pressure cleaning. Water under high pressure can penetrate the electric system and cause short circuits, damage seals, and disable the controls.
Never use high-pressure cleaners, steam jets, or high-pressure water to clean inside the cab.
We recommend using the following aids to clean the cab:
• Broom
• Vacuum cleaner
• Damp cloth
• Bristle brush
• Water with mild soap solution
Cleaning the seat belt:
• Clean the seat belt (which remains fitted in the machine) only with a mild soap solution; do not use chemical agents as they can destroy the fabric!
The following articles are generally suitable:
• High-pressure cleaner
• Steam jet
Warning!
Cutting, crushing, or burn hazards.
Stop the engine before cleaning.
NOTICE
Possibility of sensor damage. Water or steam jet cleaners can penetrate sensitive electronic components, leading to sensor failure and possible engine damage.
Allow the machine to cool completely before cleaning the engine with a water or steam jet.
Do not point the jet directly at electric sensors such as the oil pressure switch.
Threaded connections and fasteners
All screw connections must be checked regularly for tightness, even if they are not listed in the maintenance schedules.
☞
Engine fastening screws.
☞
Fastening screws on the hydraulic system.
☞
Line, bucket teeth and pin fastenings on the attachment.
Retighten loose connections immediately. Contact an authorized workshop if necessary.
Pivots and hinges
All mechanical pivot points on the machine (e.g. door hinges, joints) and fittings (e.g. door arresters) must be lubricated regularly, even if they are not listed in the lubrication plan.
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5-29
Maintenance
5.15 Lubrication points
Important!
Lubrication points with W = lubricate once a week (green caps).
Lubricate all other lubrication points daily (blue caps).
Lubricate the upper carriage bearing once a week.
Lubricate both lubrication points of the upper carriage tilting mechanism once a week
(3703 only).
Upper carriage Kippmatik tilting mechanism
Upper carriage bearing
Lubrication unit
Offset ram Live ring
5-30
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b530.fm
Maintenance
5.16 Maintenance if the machine is out of service for a longer period of time
NOTICE
Possibility of equipment damage from improper maintenance.
If the machine is out of operation, run it once a month without load. Remove the grease from the piston rods first!
Preparatory work before taking the machine out of service
☞
Carefully clean and dry the entire machine.
☞
Apply grease to all lubrication points.
☞
Change the engine oil.
☞
Apply grease to the piston rods of the hydraulic cylinders.
☞
Check and if necessary, fill up all oil levels such as in the gearbox and other units.
☞
Check and if necessary, fill up the hydraulic oil.
☞
Fill the fuel tank completely to avoid corrosion on the walls.
☞
Check the antifreeze in the coolant, change as required.
☞
Check the tire pressure for the prescribed value and protect the tires from direct sunlight.
☞
Remove the grounding strap from the battery, or remove the battery and store it in a safe place. Load the battery and perform battery maintenance at regular intervals.
☞
Cover the muffler pipe and the air intake opening of the air filter system.
Important!
Store the machine indoors if possible. If storing the machine outdoors cannot be avoided, place it on wooden boards and cover it with a tarpaulin.
Putting the machine into operation again
☞
Remove the grease from the piston rods.
☞
Install or connect the battery.
☞
Remove the covers from the
muffler
pipe and the air filter intake.
☞
Check the condition of the air filter cartridges and replace them if necessary.
☞
If the machine was out of service for over 6 months, change the oil in the gearbox and other units.
☞
Also replace hydraulic oil filters (return, suction and breather filters) if the machine has been out of service for over 6 months.
☞
Lubricate the machine according to the lubrication plan.
☞
Start the engine and let it run without load.
OM 25-3703 us – Edition 4.3.1 * 2503_3703b530.fm
5-31
Maintenance
5.17 Fluids and lubricants
Component / application
Diesel engine
Engine / machine fluid
Engine oil
2
SAE10W-40
Specification
Season / temperature
-20 °C (- 4°F)
+40 °C (104°F)
Travelling drive
Hydraulic oil tank
Gearbox oil
Hydraulic oil
3
6
Biodegradable oil
7
Roller and friction bearings
8
Q8 T 55, SAE85W-90
4
Q8 T 55, SAE80W-90
5
FINA PONTONIC GLS, SAE85W-90
HVLP46
200 Hydraulic
PANOLIN HLP Synth 46
FINA BIOHYDRAN SE 46
BP BIOHYD SE-46
404 Biodegradeable Hydraulic 32/46
FINA Energrease L21M
Mobilgrease CM-P
Year-round
Year-round
Year-round
Grease
Open gear
9
(live ring gears)
BP Energrease MP-MG2
Year-round
Grease nipples
Multipurpose grease
Battery terminals Acid-proof grease
11
10
FINA Energrease L21 M
Mobilgrease CM-P
FINA Marson L2
Mobilux EP2
2-D ASTM D975 – 94 (USA)
1-D ASTM D975 – 94 (USA)
EN 590 : 96 (EU)
ISO 8217 DMX (International)
BS 2869 – A1 (GB)
Year-round
Year-round
Fuel tank Diesel fuel
BS 2869 – A2 (GB)
Depending on outside temperatures
Summer or winter diesel fuel
Radiator Coolant
Soft water + antifreeze ASTM D4985
Distilled water + antifreeze ASTM
D4985
Water + antifreeze
Year-round
Washer system Cleaning agent
Year-round
1.
The capacities indicated are approximative values; the oil level check alone is relevant for the correct oil level
Capacities indicated are no system fills
2.
According to DIN 51502; API CD, CF, CF-4, CI-4, ACEA E3, E4, E5
3.
Hypoid gearbox oil based on basic mineral oil (SAE85W-90 according to DIN 51502), (API GL-4, GL5)
4.
The Q8 T55 SAE 85W-90 gearbox oil is no longer produced.
5.
The Q8 T55 SAE 80W-90 gearbox oil is used from 10/2006 onwards. Do not mix both gearbox oils!
6.
According to DIN 51524 section 3
7.
Biodegradable hydraulic oil based on saturated synthetic esters with an iodine value of < 10 g/mg, according to DIN 51524, section 3, HVLP, HEES
8.
KF2K-25 according to DIN 51502 multipurpose lithium grease with MoS² additive
9.
KP2N-20 according to DIN 51502 EP multipurpose calcium sulphonate complex grease
10. KF2K-25 according to DIN 51502 multipurpose lithium grease with MoS² additive
11. Standard acid-proof grease
Capacities
1
About 3.4 l
(0.89 gal)
About 0.6 l
(0.16 gal) each
53 l
(14 gal)
As required
As required
As required
As required
About 36 l
(9.5 gal)
About 4.5 l
(1.2 gal)
1.2 l (0.26 gal)
5-32
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b530.fm
Maintenance
Engine oil grade
API CD, CF, CF-4,
CI-4
ACEA E3, E4, E5
°C
°F
-20
-4
-15
5
Oil grades for the diesel engine, depending on temperature
-10 -5 0
Ambient temperature (C°)
5 10 15 20 25
SAE 10W
SAE 20W
SAE 10W-30
SAE 10W-40
SAE 15W-40
SAE 20
SAE 30
14 23
Additional oil change and filter replacement (hydraulics)
32 41 50 59 68
30 35 40
77
SAE 40
86 95 104
NOTICE
Possibility of hydraulic component damage. An additional oil change and filter replacement can be required depending on how the machine is used.
Observe the following intervals:
Application
Normal work (excavation work)
Percentage of hammer work
20 %
40 %
60 %
Over 80 %
Hydraulic oil
Every 1000 s/h
Every 800 s/h
Every 400 s/h
Every 300 s/h
Every 200 s/h
Hydraulic oil filter insert
Replace the first time after 50 s/h, then every 500 s/h
300 s/h
100 s/h
Important!
Please refer to the maintenance plan on page
for additional maintenance work.
OM 25-3703 us – Edition 4.3.1 * 2503_3703b530.fm
5-33
Maintenance
Authorized workshop
Customer
Every 1500 s/h
Every 1000 s/h once a year
Every 500 s/h
Every 250 s/h
50 s/h service
Maintenance work
(once a day)
5-34
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b540.fm
Authorized workshop
Customer
Every 1500 s/h
Every 1000 s/h once a year
Every 500 s/h
Every 250 s/h
50 s/h service
Maintenance work
(once a day)
Maintenance
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b540.fm
5-35
Maintenance
Authorized workshop
Customer
Every 1500 s/h
Every 1000 s/h once a year
Every 500 s/h
Every 250 s/h
50 s/h service
Maintenance work
(once a day)
5-36
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b540.fm
Specifications
6 Specifications
6.1
Model 2503
Engine
The measurements are Metric (Imperial).
Engine
Product
Type
Design
No. of cylinders
Displacement
Nominal bore and stroke
Output / speed
Max. interm. torque
Max. engine speed without load
Idling speed
Fuel injection system
Starting aid
Max. inclined position (engine no longer supplied with oil):
Muffler values according to
Hydraulic system
Model 2503
Tier II
Up to serial number
AH00610
Yanmar diesel engine
Tier III
From serial number
AH00611
Yanmar 3TNV 88-SNS Yanmar 3TNV88-BSNS
Water-cooled diesel engine
88 x 90 mm (3.46 x 3.54”)
19.4 kW (26.0 hp) / 2200 rpm 19,2 kW ( 27.75 hp) / 2200 rpm
107 Nm at 1200 rpm (79.14 lbf ft) 108,4 Nm at 1320 rpm ( 79.95 lbf ft)
2400 rpm
Preheater
30°
35° cont. max. 3min
EPA 2, EC 2
3 cylinders
1642 cm³ (100.2 in
3
)
The measurements are Metric (Imperial).
1100 rpm
Direct injection
Sheathed-element heater plugs
30°
35° cont. max. 3min
EPA 4, EC 3A
Hydraulics
Pump
Flow rate
Service pressure for work and drive hydraulics
Swivel unit service pressure
Hydraulic oil cooler
Hydraulic tank capacity (system fill)
Model 2503
Double variable displacement + gear pump
2x 28.8 + 19.2 l/min (2x 7.6 + 5.1 gpm)
240 bar (3481 psi)
200 bar (2901 psi)
Standard
45 Liter (11.9 gal)
Stabilizer blade
The measurements are Metric (Imperial).
Stabilizer blade
Width
Height
Max. lift over subgrade
Scraping depth
Model 2503
1370 mm ( 53.9’’)
340 mm ( 13.4’’)
390 mm ( 15.4’’)
415 mm ( 16.3’’)
OM 25-3703 us – Edition 4.3.1 * 2503_3703b610.fm
6-1
Specifications
Bucket (standard)
Work hydraulics
Undercarriage and swivel unit
The measurements are Metric (Imperial).
Bucket (standard)
Bucket width
Bucket capacity
The measurements are Metric (Imperial).
Work hydraulics
Max. service pressure
Main pressure restriction for boom/bucket/stick
Main pressure restriction for stabilizer blade
Main pressure restriction for pilot control pressure
Main pressure restriction for swivel drive (hydraulic motor pressure restriction)
Filter
Hydraulic tank capacity
Model 2503
500 mm ( 19.7’’)
75 l ( 19.8 gal)
Model 2503
240 bar (3481 psi)
240 bar (3481 psi)
210 bar (3046 psi)
35 bar ( 508 psi)
200 bar ( 2901 psi)
Reflux filter
27.2 l ( 7.19 gal)
Undercarriage/swivel unit
2 speed ranges
Climbing ability
Track width
No. of track rollers on either side
Ground clearance
Ground pressure
Upper carriage swivel speed
Model 2503
2.3/4.4 km/h
(1.4/2.7 mph)
30°/58 %
250 mm (10’’)
3
270 mm (11’’)
0.33 kg/cm² (4.7 psi)
9 rpm
6-2
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b610.fm
6.2
Model 3003
Engine
Hydraulic system
Stabilizer blade
Specifications
The measurements are Metric (Imperial).
Engine
Product
Type
Design
No. of cylinders
Displacement
Nominal bore and stroke
Output / speed
Max. interm. torque
Max. engine speed without load
Idling speed
Fuel injection system
Starting aid
Max. inclined position (engine no longer supplied with oil):
Muffler values according to
Model 3003
Tier II
Up to serial number: AD01820
Yanmar diesel engine
Yanmar 3TNV 88-NNS
Water-cooled diesel engine
3 cylinders
1642 cm³ (100.2 in
3
)
88 x 90 mm (3.46 x 3.54”)
31.6 kW (42.37 hp) / 2200 rpm
107,9 Nm at 1500 rpm ( 79.58 ft.lbs.)
2700 rpm
1100 rpm
Direct injection
Preheater
30°
35° cont. max. 3min
EPA 2, EC 2
The measurements are Metric (Imperial).
Hydraulics
Pump
Flow rate
Service pressure for work and drive hydraulics
Swivel unit service pressure
Hydraulic oil cooler
Hydraulic tank capacity (system fill)
Model 3003
Double axial piston pump + gear pump
2x 35,8+ 27,7 l/min (2x 9.46 + 7.32 gpm)
225 bar ( 3263.35 psi)
200 bar (2901 psi)
Standard
27 Liter ( 7 gal)
The measurements are Metric (Imperial).
Stabilizer blade
Width
Height
Max. lift over subgrade
Scraping depth
Model 3003
1480 mm (4’ 10’’)
370 mm (1’ 3’’)
400 mm (1’ 4’’)
450 mm (1’ 6’’)
OM 25-3703 us – Edition 4.3.1 * 2503_3703b610.fm
6-3
Specifications
Bucket (standard)
Work hydraulics
Undercarriage and swivel unit
The measurements are Metric (Imperial).
Bucket (standard)
Bucket width
Bucket capacity
The measurements are Metric (Imperial).
Work hydraulics
Max. service pressure
Main pressure restriction for boom/bucket/stick
Main pressure restriction for stabilizer blade
Main pressure restriction for pilot control pressure
Main pressure restriction for swivel drive (hydraulic motor pressure restriction)
Filter
Hydraulic tank capacity
Model 3003
500 mm ( 19.7’’)
88 l ( 23 gal)
Model 3003
225 bar ( 3263 psi)
225 bar ( 3263 psi)
210 bar ( 3045 psi)
35 bar ( 508 psi)
200 bar ( 2901 psi)
Reflux filter
27 l (7 gal)
Undercarriage/swivel unit
2 speed ranges
Climbing ability
Track width
No. of track rollers on either side
Ground clearance
Ground pressure
Upper carriage swivel speed
Model 3003
2.4/4.7 km/h
(1.5/2.9 mph)
30°/58 %
300 mm (11.8’’)
4
275 mm (11’’)
0.32 kg/cm² (4.6 psi)
10 rpm
6-4
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b610.fm
Specifications
6.3
Model 3503
Engine
Engine
Product
Type
Design
No. of cylinders
Displacement
Nominal bore and stroke
Output / speed
Max. interm. torque
Max. engine speed without load
Idling speed
Fuel injection system
Starting aid
Max. inclined position (engine no longer supplied with oil):
Muffler values according to
Hydraulic system
The measurements are Metric (Imperial).
Model 3503
Tier II
Up to serial number
AH00610
Tier III
From serial number
AH00611
Yanmar diesel engine
Yanmar 4TNV 88-WNS Yanmar 4TNV 88-BWNS
Water-cooled diesel engine
4 cylinders
2190 cm³ (133.6 in
3
)
88 x 90 mm (3.46 x 3.54")
23.7 kW (32.2 hp) / 2000 rpm
143 ( 105 ft.lbs.) /1200 rpm
2025 rpm
Preheater
30°
35° cont. max. 3 min
EPA 2, EC 2
1100 rpm
Direct injection
Sheathed-element heater plugs
30°
35° cont. max. 3 min
EPA 4, EC 3A
The measurements are Metric (Imperial).
Hydraulics
Pump
Flow rate
Service pressure for work and drive hydraulics
Swivel unit service pressure
Hydraulic oil cooler
Hydraulic tank capacity (system fill)
Model 3503
Double variable displacement pump + gear pump
2 x 44,5 + 25,1 l/min
(2 x 11.8 + 6.6 gpm) / 2025 min
-1
240 bar ( 3481 psi)
200 bar ( 2901 psi)
Standard
50 l ( 13.2 gal)
Stabilizer blade
The measurements are Metric (Imperial).
Stabilizer blade
Width
Height
Max. lift over subgrade
Scraping depth
Model 3503
1620 mm ( 63.78’’)
370 mm ( 14.57’’)
410 mm ( 16.14’’)
480 mm ( 18.9’’)
OM 25-3703 us – Edition 4.3.1 * 2503_3703b610.fm
6-5
Specifications
Bucket (standard)
Work hydraulics
Undercarriage and swivel unit
The measurements are Metric (Imperial).
Bucket (standard)
Bucket width
Bucket capacity
The measurements are Metric (Imperial).
Work hydraulics
Max. service pressure
Main pressure restriction for boom/bucket/stick
Main pressure restriction for stabilizer blade
Main pressure restriction for pilot control pressure
Main pressure restriction for swivel drive (hydraulic motor pressure restriction)
Filter
Hydraulic tank capacity
Model 3503
500 mm (19.7’’)
88 l (23.2 gal)
Model 3503
240 bar
(3481 psi)
240 bar
(3481 psi)
210 bar
( 3046 psi)
35 bar
( 508 psi)
200 bar
( 2901 psi)
Reflux filter
50 l
( 13.2 gal)
Undercarriage/swivel unit
2 speed ranges
Climbing ability
Track width
No. of track rollers on either side
Ground clearance
Ground pressure
Upper carriage swivel speed
Model 3503
2.8/5.5 km/h
(1.7/3.4 mph)
30°/58 %
300 mm (11.8’’)
4
280mm (11’’)
0.33 kg/cm² (4.7 psi)
9.2 rpm
6-6
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b610.fm
Specifications
6.4
Model 3703
Engine
Engine
Type
Design
No. of cylinders
Displacement
Nominal bore and stroke
Output / speed
Max. interm. torque
Max. engine speed without load
Idling speed
Fuel injection system
Starting aid
Max. inclined position (engine no longer supplied with oil):
Muffler values according to
Hydraulic system
The measurements are Metric (Imperial).
Model 3703
Tier II
Up to serial number
AH00610
Yanmar 4TNV 88-WNS
Tier III
From serial number
AH00611
Yanmar 4TNV 88-BWNS
Water-cooled diesel engine
4 cylinders
2190 cm³ (133.6 in
3
)
88 x 90 mm (3.46 x 3.54")
23,7 kW (31.8 hp) / 2000 min
-1
143 Nm (105 ft.lbs.) / 1200 min
-1
1100 rpm
Preheater
30°
35° cont. max. 3min
EPA 2, EC 2
2025 rpm
1000 rpm
Direct injection
Sheathed-element heater plugs
30°
35° cont. max. 3min
EPA 4, EC 3A
The measurements are Metric (Imperial).
Hydraulics
Pump
Flow rate
Service pressure for work and drive hydraulics
Swivel unit service pressure
Service pressure for auxiliary hydraulics
Hydraulic oil cooler
Hydraulic tank capacity (system fill)
Model 3703
Double variable displacement pump + gear pump
2 x 44,5 + 25,1 l/min
(2 x 11.8 + 6.6 gpm) / 2025 min
-1
240 bar (3481 psi)
200 bar ( 2901 psi)
240/210 bar (3481/3046 psi)
Standard
50 l (13.2 gal)
Stabilizer blade
The measurements are Metric (Imperial).
Stabilizer blade
Width
Height
Max. lift over subgrade
Scraping depth
Model 3703
1620 mm ( 63.78’’)
370 mm ( 14.57’’)
410 mm ( 16.14’’)
480 mm ( 18.9’’)
OM 25-3703 us – Edition 4.3.1 * 2503_3703b610.fm
6-7
Specifications
Bucket (standard)
Work hydraulics
Undercarriage and swivel unit
The measurements are Metric (Imperial).
Bucket (standard)
Bucket width
Bucket capacity
The measurements are Metric (Imperial).
Work hydraulics
Max. service pressure
Main pressure restriction for boom/bucket/stick
Main pressure restriction for stabilizer blade
Main pressure restriction for pilot control pressure
Main pressure restriction for swivel drive (hydraulic motor pressure restriction)
Filter
Hydraulic tank capacity
Model 3703
500 mm (19.7’’)
88 l (23.2 gal)
Model 3703
240 bar
(3481 psi)
240 bar
(3481 psi)
210 bar
( 3046 psi)
35 bar
( 508 psi)
200 bar
( 2901 psi)
Return filter
50 l
( 13.2 gal)
Undercarriage/swivel unit
2 speed ranges
Climbing ability
Track width
No. of track rollers on either side
Ground clearance
Ground pressure
Upper carriage swivel speed
Model 3703
2.8/5.5 km/h
(1.7/3.4 mph)
30°/58 %
300 mm (11.8’’)
4
280mm (11’’)
0.35 kg/cm² (5 psi)
9.2 rpm
6-8
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b610.fm
Specifications
6.5
Electric system
Fuse box in engine compartment
1
2
3
4
9
10
5
Fig. 142: Fuse box
6 7
8
11
Fuse no.
6
7
4
5
1
2
3
10
11
8
9
10
10
15
10
15
10
Rated current (A)
10
15
10
15
10
Protected circuit
Switch assignment, indicator lights, engine relays
Lights, boom, roof lights
12V/15 cab
Heating, horn
Valves
Window wiper, cab
Alternator excitation
Spare
Rotating beacon, radio, 12V outlet, antitheft protection
Socket
Spare
6.6
Noise levels
Sound power level
Sound power level (L
WA
)
Sound pressure level (L
PA at the driver's ear
)
2503
93 dB (A)
dB (A)
3003 3503 3703
95 dB (A) 95 dB (A) 95 dB (A)
Important!
Measurement of sound power level according to EC Directive 2000/14 EC.
Noise level at the driver's ear measured according to EC Directives 84/532/EEC,
89/514/EEC and 95/27/EEC.
Measurements performed on asphalted surface.
6.7
Vibration
Vibration
Effective acceleration value for the upper extremities of the body *
Effective acceleration value for the body *
< Trigger value
< Trigger value
* Measurements as per 2002/44/EC (excavating, driving and hammering with a Wacker Neuson hammer). Machine and attachment operation and maintenance as per Operator's Manual.
OM 25-3703 us – Edition 4.3.1 * 2503_3703b610.fm
6-9
Specifications
6.8
Coolant compound table
The measurements are Metric (Imperial).
Outside temperature
Up to °C ( °F)
4 (39)
-10 (14)
-20 (-4)
-25 (-13)
-30 (-22)
Water
% by volume
99
79
65
59
55
Coolant
Anticorrosion agent cm³/l
(in³/gal)
% by volume
10
(2.6)
1
Antifreeze agent
% by volume
–
20
34
40
44
6-10
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b610.fm
Specifications
6.9
Dimensions model 2503
The measurements are Metric (Imperial).
(7.9”)
(10’)
(4’
1”)
(14’ 6”)
(14’ 10”)
(4’ 7”)
(6’)
(15’ 1”)
(15’ 5”)
Fig. 143: Machine dimensions (model 2503)
OM 25-3703 us – Edition 4.3.1 * 2503_3703b610.fm
(4’
6”)
Main data
Service weight with cab/canopy
Height
Width
Transport length
Max. digging depth
Stick length (standard)
Stick length (long version)
Max. digging depth for long stick (+ 300 mm/11.8")
Max. vertical digging depth
Max. vertical digging depth (long stick)
Max. digging height
Max. digging height (long stick)
Max. dump height
Max. dump height (long stick)
Max. digging radius
Max. digging radius (long stick)
Max. reach at ground level
Max. reach at ground level (long stick)
Max. breakout force at bucket tooth
Max. tearout force (standard stick)
Max. tearout force (long stick)
Min. tail end slewing radius
Max. tail end lateral projection (90° rotation of upper carriage)
Max. boom displacement to bucket center (right-hand side)
Max. boom displacement to bucket center (left-hand side)
Model 2503
2620 / 2525 kg
(5776 / 5567 lbs)
2370 mm (7'9")
1370 mm (4'6")
4410 mm (14'6")
2620 mm (8'7")
1150 mm (3’9’’)
1350 mm (4’5“)
2825 mm (9'3")
1810 mm (5'11")
2000 mm (6'7")
4125 mm (13'6")
4250 mm (13'11")
2925 mm (9'7")
3080 mm (10'1")
4515 mm (14'10")
4693 mm (15'5")
4410 mm (14'6")
4602 mm (15'1")
20 kN (4496 ft.lbs.)
13 kN (2923 ft.lbs.)
11,7 kN (2630 ft.lbs.)
1240 mm (4'1")
555 mm (1’10“)
653 mm (2'2")
393 mm (1'3")
6-11
Specifications
6.10 Dimensions model 3003
The measurements are Metric (Imperial).
250 (9.9”)
3150 (10’ 4”)
(4’
2”)
4700 (15’ 5”)
4800 (15’ 9”)
1440
(4’ 9”)
1890
(6’ 2”)
6-12
4927 (16’ 2”)
5027 (16’ 6”)
Fig. 144: Machine dimensions (model 3003)
(4’
7”)
Main data
Service weight with cab/canopy
Height
Width
Transport length
Max. digging depth
Stick length (standard)
Stick length (long version)
Max. digging depth for long stick (+ 250 mm / 9.8")
Max. vertical digging depth
Max. vertical digging depth (long stick)
Max. digging height
Max. digging height (long stick)
Max. dump height
Max. dump height (long stick)
Max. digging radius
Max. digging radius (long stick)
Max. reach at ground level
Max. reach at ground level (long stick)
Max. breakout force at bucket tooth
Max. tearout force (standard stick)
Max. tearout force (long stick)
Min. tail end slewing radius
Max. tail end lateral projection (90° rotation of upper carriage)
Max. boom displacement to bucket center (right-hand side)
Max. boom displacement to bucket center (left-hand side)
Model 3003
3120 / 3025 kg
(6879 / 6669 lbs)
2400 mm (7'10")
1480 mm (4'10")
4695 mm (15'5")
2770 mm (9'1")
1200 mm (3’11’’)
1450 mm (4’9’’)
3025 mm (9'11")
1990 mm (6'6")
2224 mm (7’4“)
4470 mm (14'8")
4603 mm (15'1")
3150 mm (10'4")
3325 mm (10'11")
4800 mm (15'9")
5027 mm (16’6’’)
4700 mm (15'5")
4927 mm (16’2’’)
27.5 kN (6182 lbf)
16.2 kN (3642 lbf)
13.4 kN (3012 lbf)
1260 mm (4'2")
520 mm (1'8")
710 mm (2'4")
434 mm (1'5")
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b610.fm
Specifications
6.11 Dimensions model 3503
The measurements are Metric (Imperial).
3360 (11’)
5175 (16’11”)
5270 (17’3”)
1600
(5’3”)
2075
(6’10”)
R1400
(4’7”)
5456 (17’11”)
5546 (18’2”)
Fig. 145: Machine dimensions (model 3503)
Main data
Service weight with cab/canopy
Height
Width
Transport length
Max. digging depth
Stick length (standard)
Stick length (long version)
Max. digging depth for long stick (+ 300 mm / 11.8")
Max. vertical digging depth
Max. vertical digging depth (long stick)
Max. digging height
Max. digging height (long stick)
Max. dump height
Max. dump height (long stick)
Max. digging radius
Max. digging radius (long stick)
Max. reach at ground level
Max. reach at ground level (long stick)
Max. breakout force at bucket tooth
Max. tearout force (standard stick)
Max. tearout force (long stick)
Min. tail end slewing radius
Max. tail end lateral projection (90° rotation of upper carriage)
Max. boom displacement to bucket center (right-hand side)
Max. boom displacement to bucket center (left-hand side)
R1470 (4’10”)
Model 3503
3500 / 3405 kg (7716 / 7507 lbs)
2405 mm (7'11")
1620 mm (5'4")
5170 mm (16'11")
3230 mm (10’7’’)
1335 mm (4’5’’)
1635 mm (5’4’’)
3530 mm (11'7")
2220 mm (7’3“)
2500 mm( 8'2")
4910 mm (16'1")
5100 mm (16'9")
3620 mm (11'10")
3810 mm (12'6")
5270 mm (17'3")
5546 mm (18'2")
5175 mm (17'0")
5456 mm (17'11")
30.3 kN (6812 ft.lbs.)
20.6 kN (4631 ft.lbs.)
16.8 kN (3777 ft.lbs.)
1400 mm (4'7")
590 mm (1'11")
685 mm (2'3"9
415 mm (1'4")
OM 25-3703 us – Edition 4.3.1 * 2503_3703b610.fm
6-13
Specifications
6.12 Dimensions model 3703
The measurements are Metric (Imperial).
300 (11.8”)
3360 (11’)
5150 (16’11”)
5270 (17’3”)
R1400
(4’7”)
1600
(5’3”)
2075
(6’10”)
6-14
5432 (17’10”)
5546 (18’2”)
Fig. 146: Machine dimensions (model 3703)
R1470 (4’10”)
Main data
Service weight with cab/canopy
Height
Width
Transport length
Max. digging depth
Stick length (standard)
Stick length (long version)
Max. digging depth for long stick (+ 300 mm (11.8")
Max. vertical digging depth
Max. vertical digging depth (long stick)
Max. digging height
Max. digging height (long stick)
Max. dump height
Max. dump height (long stick)
Max. digging radius
Max. digging radius (long stick)
Max. reach at ground level
Max. reach at ground level (long stick)
Max. breakout force at bucket tooth
Max. tearout force (standard stick)
Max. tearout force (long stick)
Min. tail end slewing radius
Max. tail end lateral projection (90° rotation of upper carriage)
Max. boom displacement to bucket center (right-hand side)
Max. boom displacement to bucket center (left-hand side)
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b610.fm
Model 3703
3734 / 3639 kg
(8232 / 8023 lbs)
2520 mm (8'3")
1620 mm (5'4")
5170 mm (17'0")
3120 mm (10'3")
1335 mm (4’5’’)
1635 mm (5’4’’)
3417 mm (11'3")
2105 mm (6'11")
2385 mm (7'10")
5020 mm (16'6")
5220 mm (17'2")
3735 mm (12'3")
3935 mm (12'11")
5270 mm (17'3")
5546 mm (18'2")
5150 mm (16'11")
5432 mm (17'10")
30.4 kN (6834 ft.lbs.)
20.6 kN (4631 ft.lbs.)
16.8 kN (3777 ft.lbs.)
1400 mm (4'7")
590 mm (1'11")
686 mm (2'3")
416 mm (1'4")
Specifications
6.13 Lift capacity table 2503
All table indications in kg (lbs) and horizontal position on firm ground without bucket.
A
B
3.0 m
(9´8“)
2.0 m
(6´6“)
1.0 m
(3´3“)
0.0 m
(0´0“)
-1.0 m
(3´3“)
-2.0 m
(6´6“)
415*
(915*)
410*
(904*)
425*
(937*)
450*
(992*)
475*
(1047*)
445*
(981*)
415*
(915)
350
(772)
310
(683)
315
(694)
380
(838)
445*
(981*)
410*
(904*)
460*
(1014*)
505*
(1113*)
3.5 m
(11´5“)
380
(838)
365
(805)
355
(783)
3.0 m
(9´8“)
2.5 m
(8´2“)
2.0 m
(6´6“)
400*
(882*)
420*
(926*)
540*
(1190*)
635*
(1400*)
580*
(1279*)
400*
(882*)
420*
(926*)
460
(1014)
440
(970)
435
(959)
460*
(1014*)
670*
(1477*)
835*
(1841*)
790*
(1742*)
460*
(1014*)
595
(1312)
560
(1235)
560
(1235)
1000*
(2205*)
1210*
(2668*)
1030*
(2271*)
435*
(959*)
815
(1797)
770
(1698)
775
(1709)
435*
(959*)
* max
A
B
Admissible load on extended stick
Reach from live ring center
Load hook height
Lift capacity limited by hydraulics
With the stabilizer blade in driving direction
Fig. 147: Lift capacity table (model 2503)
Without the stabilizer blade, 90° to driving direction
If equipped with a bucket or other attachments, lift capacity or tilt load is reduced by bucket or attachment dead weight.
Calculation basis: according to ISO 10567
The track excavator's lift capacity is restricted by the settings of the pressure limiting valves and the hydraulic system's stabilizing features.
Neither 75 % of the static tilt load nor 87 % of the hydraulic lift capacity is exceeded.
OM 25-3703 us – Edition 4.3.1 * 2503_3703b610.fm
6-15
Specifications
6.14 Lift capacity table 3003
All table indications in kg (lbs) and horizontal position on firm ground without bucket.
A
B
3.0 m
(9´8“)
2.0 m
(6´6“)
1.0 m
(3´3“)
0.0 m
(0´0“)
-1.0 m
(3´3“)
-2.0 m
(6´6“)
760*
(1676*)
760*
(1676*)
790*
(1742*)
825*
(1819*)
860*
(1896*)
825*
(1819*)
455
(1003)
345
(761)
310
(683)
320
(705)
380
(838)
690
(1521)
770*
(1698)
900*
(1984)
1000*
(2205)
3.5 m
(11´5“)
430
(948)
405
(893)
390
(860)
3.0 m
(9´8“)
2.5 m
(8´2“)
2.0 m
(6´6“)
725*
(1598*)
825*
(1819*)
1055*
(2326*)
1225*
(2701*)
1145*
(2524*)
570
(1257)
550
(1213)
510
(1124)
480
(1058)
480
(1058)
700*
(1543*)
950*
(2094*)
1330*
(2932*)
1615*
(3560*)
1505*
(3318*)
700
(1543)
735
(1620)
660
(1455)
620
(1367)
620
(1367)
1990*
(4387*)
2300*
(5071*)
1975*
(4354*)
1075*
(2370*)
900
(1984)
865
(1907)
875
(1929)
915
(2017)
* max
A
B
Admissible load on extended stick
Reach from live ring center
Load hook height
Lift capacity limited by hydraulics
With the stabilizer blade in driving direction
Fig. 148: Lift capacity table (model 3003)
Without the stabilizer blade, 90° to driving direction
If equipped with a bucket or other attachments, lift capacity or tilt load is reduced by bucket or attachment dead weight.
Calculation basis: according to ISO 10567
The track excavator's lift capacity is restricted by the settings of the pressure limiting valves and the hydraulic system's stabilizing features.
Neither 75 % of the static tilt load nor 87 % of the hydraulic lift capacity is exceeded.
6-16
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b610.fm
Specifications
6.15 Lift capacity table 3503
All table indications in kg (lbs) and horizontal position on firm ground without bucket.
3.5 m
(11´5“)
2.5 m
(8´2“)
1.5 m
(4´9“)
A
B
3.0 m
(9´8“)
2.0 m
(6´6“)
1.0 m
(3´3“)
0.0 m
(0´0“)
-1.0 m
(3´3“)
-2.0 m
(6´6“)
800*
(1764*)
840*
(1852*)
890*
(1962*)
955*
(2105*)
1045*
(2304*)
1150*
(2533*)
545
(1202)
480
(1058)
415
(915)
420
(926)
475
(1047)
675
(1488)
900*
(1984*)
955*
(2105*)
4.5 m
(14´8“)
745*
(1642*)
870*
(1918*)
1100*
(2425*)
1300*
(2866*)
1310*
(2888*)
685
(1510)
660
(1455)
620
(1367)
595
(1312)
590
(1301)
1110*
(2447*)
1795*
(3957*)
2130*
(4696*)
2100*
(4630*)
1700*
(3748*)
1105
(2436)
1000
(2205)
930
(2050)
950
(2094)
975
(2150)
4200*
(9259*)
3300*
(7275*)
2295
(5060)
2345
(5170)
* max
A
B
Admissible load on extended stick
Reach from live ring center
Load hook height
Lift capacity limited by hydraulics
With the stabilizer blade in driving direction
Fig. 149: Lift capacity table (model 3503)
Without the stabilizer blade, 90° to driving direction
If equipped with a bucket or other attachments, lift capacity or tilt load is reduced by bucket or attachment dead weight.
Calculation basis: according to ISO 10567
The track excavator's lift capacity is restricted by the settings of the pressure limiting valves and the hydraulic system's stabilizing features.
Neither 75 % of the static tilt load nor 87 % of the hydraulic lift capacity is exceeded.
OM 25-3703 us – Edition 4.3.1 * 2503_3703b610.fm
6-17
Specifications
6.16 Lift capacity table 3703
All table indications in kg (lbs) and horizontal position on firm ground without bucket.
A
B
3.0 m
(9´8“)
2.0 m
(6´6“)
1.0 m
(3´3“)
0.0 m
(0´0“)
-1.0 m
(3´3“)
-2.0 m
(6´6“)
800*
(1764*)
845*
(1863*)
900*
(1984*)
955*
(2105*)
1050*
(2315*)
1150*
(2536*)
650
(1433)
350
(772)
340
(750)
340
(750)
395
(871)
575
(1268)
900*
(1984*)
955*
(2105*)
4.5 m
(14´8“)
340
(750)
340
(750)
3.5 m
(11´5“)
2.5 m
(8´2“)
1.5 m
(4´9“)
750*
(1653*)
900*
(1984*)
1125*
(2480*)
1300*
(2866*)
1300*
(2866*)
550*
(1213*)
530
(1168)
500
(1102)
460
(1014)
450
(992)
1210*
(2668*)
1850*
(4079*)
2150*
(4740*)
2080*
(4586*)
1650*
(3638*)
890
(1962)
800
(1764)
750
(1653)
750
(1653)
790
(1742)
4200*
(9259*)
3150*
(6945*)
1855
(4090)
1910
(4211)
* max
A
B
Admissible load on extended stick
Reach from live ring center
Load hook height
Lift capacity limited by hydraulics
With the stabilizer blade in driving direction
Fig. 150: Lift capacity table (model 3703)
Without the stabilizer blade, 90° to driving direction
If equipped with a bucket or other attachments, lift capacity or tilt load is reduced by bucket or attachment dead weight.
Calculation basis: according to ISO 10567
The track excavator's lift capacity is restricted by the settings of the pressure limiting valves and the hydraulic system's stabilizing features.
Neither 75 % of the static tilt load nor 87 % of the hydraulic lift capacity is exceeded.
6-18
OM 25-3703 us – Edition 4.3.1 * * 2503_3703b610.fm
:FDG8:K<O:8M8KFI
Contents
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A Word To The User/Operator . . . . . . . . . . . . . . . . . . . . . . 6
Follow A Safety Program . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Prepare For Safe Operation . . . . . . . . . . . . . . . . . . . . . . . 13
Shut Down Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Load And Unload The Machine Safely . . . . . . . . . . . . . . 40
Perform Maintenance Safely . . . . . . . . . . . . . . . . . . . . . . 41
Final Word To The User . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Acknowledgment
We wish to acknowledge the contributions of the members of AEM’s Compact Loader/Compact Excavator Council to the preparation of this Safety Manual.
2
NOTICE OF COPYRIGHT PROTECTION
Copyright, 2010, by the Association of Equipment Manufacturers. All rights reserved. This work may not be reproduced or disseminated in whole or in part by any means without the prior written permission of the Association of Equipment Manufacturers.
Copyright 2002-2010© AEM (Association of Equipment Manufacturers)
Revised 05/03, 09/10
This safety manual is intended to point out some of the basic safety situations that may be encountered during the normal operation and maintenance of the machine and to suggest possible ways of dealing with these conditions. This manual is
NOT
a substitute for the compact excavator manufacturer’s operator manual(s).
Additional precautions may be necessary, or some instructions may not apply, depending on equipment, attachments and conditions at the worksite or in the service area. The manufacturer has no direct control over equipment application, operation, inspection or maintenance. Therefore, it is
YOUR
responsibility to use safe work practices in these areas.
The information provided in this manual supplements the specific information about the machine that is contained in the manufacturer’s manual(s). Other information that may affect the safe operation of the machine may be contained on safety signs or in insurance requirements, employer’s safety and training programs, safety codes, local, state/provincial and federal laws, rules and regulations.
Foreword
Read And
Understand
Manuals Before
Operating
IMPORTANT!
Before you operate the compact excavator, make sure you have the manufacturer’s manual(s) for this machine and all attachments. If the manufacturer’s manuals are missing, obtain replacement manuals from your employer, equipment dealer or directly from the manufacturer. Keep this safety manual and the manufacturer’s manuals with the machine at all times. Read and understand all manuals.
Safety videos and other training resources are available from some manufacturers. Operators are encouraged to periodically review the safety video.
3
4
Safety Alerts
Symbol
This Safety Alert Symbol means:
“ATTENTION!
STAY ALERT! YOUR SAFETY IS INVOLVED!”
The Safety Alert Symbol identifies important safety messages on equipment, safety signs, in manuals or elsewhere. When you see this symbol, be alert to the possibility of death or personal injury. Carefully read the message that follows and inform other operators. Follow instructions in the safety message.
Signal Words
Signal words are distinctive words that will typically be found on safety signs on the compact excavator and other worksite equipment. These words may also be found in this manual and the manufacturer’s manuals.
These words are intended to alert the operator to a hazard and the degree of severity of the hazard.
DANGER
WARNING
CAUTION
NOTICE
DANGER
indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
indicates a property damage message.
One-Call First
Always inspect the jobsite for evidence of unmarked utilities and contact others if necessary.
Call Before You Dig
Dial 811 (USA only)
888-258-0808
(USA and Canada)
Plan The Work
Be aware of the lead time for marking the work area.
This time may vary from state to state and county to county. If you do not locate utilities, you may have an accident or suffer injuries, cause service interruptions, damage the environment or experience job delays.
Call
Before starting any digging project, contact the local
One-Call service by dialing 811 (USA only) to have underground utilities located. A One-Call referral number,
1-888-258-0808
, is also available for both
USA and Canada.
One-Call will notify participating utility companies that you intend to dig. You must also call utility companies that do not participate in the One-Call service.
Dig
Most utilities mark their underground facilities using
American Public Works Association (APWA) underground color codes. Verify marks before digging.
In the United States, OSHA Standard 29 CFR 1926.651 requires that the estimated location of underground utilities be determined before beginning an excavation.
When actual excavation approaches an estimated utility location, the exact location of the underground installation must be determined by a safe, acceptable and dependable method. Other OSHA regulations may also apply to the jobsite.
5
6
A Word To The User/Operator
It is
YOUR
responsibility to read and understand the safety manual and the manufacturer’s manuals before operating this machine. This safety manual takes you step by step through the working day.
Graphics have been provided to help you understand the text.
IMPORTANT: This manual covers safe practices for
Compact Excavators.
If the machine is equipped with special attachments, read the manufacturer’s operator and safety manuals pertaining to those attachments before using them.
Remember that
YOU
are the key to safety. Good safety practices not only protect you but also protect the people around you. Study this manual and the manufacturer’s manuals for the specific machine. Make them a working part of your safety program. Keep in mind that this safety manual is written only for compact excavators.
Contact the manufacturer of the equipment to answer any questions about safe operation that remain after studying the manufacturer’s manual(s) and this safety manual.
Read And
Understand All
Safety Signs
Practice all other usual and customary safe working precautions and remember:
SAFE OPERATION IS UP TO YOU!
YOU CAN PREVENT DEATH OR SERIOUS INJURY
CAUSED BY UNSAFE WORK PRACTICES!
Follow A Safety Program
Be Alert!
Know where to get assistance. Know where to find and how to use a first aid kit and fire extinguisher/fire suppression system.
Be Aware!
Take advantage of training programs offered.
Be Careful!
Human error is caused by many factors: carelessness, fatigue, overload, preoccupation, unfamiliarity of the operator with the machine or attachment, drugs, and alcohol to name a few. You can prevent death or serious injury caused by unsafe work practices.
For your safety and the safety of others, encourage fellow workers to act safely.
Never Operate
While Impaired By
Alcohol Or Drugs
For Safe Operation
You must be a qualified and authorized operator for safe operation of this machine. You must clearly understand the written instructions supplied by the manufacturer, be trained—including actual operation of the compact excavator—and know the safety rules and regulations for the worksite. It is a good safety practice to point out and explain safety signs and practices and ensure others understand the importance of following these instructions.
WARNING!
Drugs and alcohol affect an operator’s alertness and coordination and the operator’s ability to safely operate the equipment.
Never operate the compact excavator while impaired by use of alcohol or drugs. Never knowingly allow the operation of this machine when operator alertness or coordination is impaired.
An operator taking prescription or over-thecounter medication must consult a medical professional regarding any side effects of the medication that would hinder the ability to safely operate this equipment.
7
8
Follow A Safety Program
Protect Yourself
Wear personal protective clothing and Personal
Protective Equipment (PPE) issued to you or called for by job conditions.
You may need:
— Hard hat
— Safety boots with non-slip soles
— Safety glasses, goggles or face shield
— Heavy-duty gloves
— Hearing protection
— Reflective or high-visibility clothing
— Wet weather gear
— Respirator or filter mask
Wear whatever is needed to protect yourself—do not take chances.
WARNING!
Prevent death or serious injury from entanglement.
Do not wear loose clothing or accessories. Restrain long hair. Stay away from all rotating components when the engine is running.
Contact, wrapping or entanglement with rotating or moving parts could result in death or serious injury.
Avoid
Entanglement
Follow A Safety Program
Know The Rules
Most employers have rules governing operation and maintenance of equipment. Before you start work at a new location, check with your supervisor or the safety coordinator. Ask about the rules you will be expected to obey.
The Occupational Safety and Health Administration
(OSHA) enforces federal laws within the United States that apply to the safe operation, application and maintenance of equipment on a worksite. It is the employer’s responsibility to comply with these laws.
A federal representative may periodically inspect a worksite to see that these laws are being followed.
There may also be local, state/provincial, federal laws or international regulations that apply to this equipment and its use, along with specific worksite or employer rules. It is important that you know and comply with all applicable laws and rules, including those requiring operator training and certification.
s s s s s
Safety Rules
s s s s s
Know And
Understand
Rules Of
Operation
10
Follow A Safety Program
Some Rules You Must Work By
— Know the limitations and operating characteristics of the compact excavator. Do not overload it.
— Always wear the seat belt, if equipped. If the compact excavator is equipped with a foldable TOPS/ROPS, do not fasten the seat belt when the TOPS/ROPS is in the down position.
— Always have all shields and guards properly installed before operating the machine.
— Inspect the machine and all attachments before each use as specified by the manufacturer and your employer. Ensure the attachment is properly installed.
(See page 17,
Quick-coupling Device Safety
.)
— Only use parts and attachments that are approved by the original equipment manufacturer.
— Never modify or remove any part of the equipment
(except for service—then make sure it is replaced).
— Read and understand all safety signs installed on the machine.
— Know the location of other personnel and machines and make sure they are a safe distance from the machine.
— Know the worksite. Be aware of possible hazards that you may encounter.
lbs
?
kg
Know Machine
Limitations
And Operating
Characteristics
Inspect
The Machine Before
Each Workday
Be Aware Of
Worksite Hazards,
Keep Bystanders
Away
9
Follow A Safety Program
— Always look in the direction of machine or boom movement. Drive facing the travel direction whenever possible.
— Make sure you understand the rules covering traffic at the worksite. Know what all signs, flags and markings mean.
— Understand hand, flag, horn, whistle, siren and bell signals, if used at the worksite.
— Know when to use lights, turn signals, flashers and horns, if equipped.
— Do not allow riders.
— Keep hands and feet on controls when operating.
— Never lift or swing a load or attachment over anyone.
— Whenever you leave the machine, lower the excavator blade, bucket or other attachments to the ground. Stop the engine. Cycle the hydraulic controls, including auxiliary hydraulic control, to relieve trapped pressure. Engage control lock if equipped, and remove the ignition key. (See page 39,
Machine Shutdown
.)
— When transporting the compact excavator on a trailer, follow the manufacturer’s instructions for loading, tying down and unloading the compact excavator.
Understand
Worksite Signals
No Riders
Never Lift Or
Swing A Load Or
Attachment
Over Anyone
Engage
Control Lock
11
12
Follow A Safety Program
Know The Equipment
Read and understand the DANGER, WARNING, CAU-
TION and NOTICE safety signs and other informational signs found on the compact excavator and in the manufacturer’s operator manual. Ask your supervisor to explain any information you do not understand. Failure to obey safety instructions could result in death or serious injury.
Make sure all the manufacturer’s protective structures, guards, shields, screens and panels are in good repair, in place and securely fastened. Damaged, missing or weakened safety components can create a hazardous situation for you as the operator.
Never
remove or modify any safety components on the compact excavator. The excavator can be operated temporarily with a foldable TOPS/ROPS lowered for access through height-restricted openings. Do not fasten the seat belt when the TOPS/ROPS is in the down position.
Know the following about this compact excavator and all attachments.
— Function, purpose and use of controls
— The functions of all gauges, lights, dials, switches
— Slope and uneven terrain capabilities and proper operation – never operate on a slope with a foldable
TOPS/ROPS in the down position.
— Braking and steering characteristics
— Turning radius and clearances
— How to quickly stop equipment in an emergency
Read And
Understand All
Safety Signs
Read And
Understand
Manuals Before
Operating
Prepare For Safe Operation
Check And Use All Available Protective And
Safety Devices
Keep all protective devices in place and tightly fastened.
Make certain all guards, screens and panels, manufacturer’s operator manuals, and safety signs are installed on the machine and legible as supplied by the manufacturer. See that each item is securely in place and in operating condition.
The machine may be equipped with:
— A seat belt or other type of restraint
— Control locking device
— Safety signs
— Access and egress system (i.e., grab handles, handrails) and protective covers
— Travel alarm and back-up alarm
— Falling object guard structure (FOGS), falling object protective structure (FOPS), roll-over protective structure (ROPS)/tip-over protective structure (TOPS)
— Guards
— Special enclosures or accessories required for task or worksite conditions
— Operator protective structure (OPS) – side, front and rear shields, screens and doors
— Warning lights and devices
— Alternate exits
— Mirrors
— Fire extinguisher
— First aid kit
— Windshield wipers and washers
— Window defroster
— Operating lights
— Horn
Know which devices are required for protection during your specific operation and use them. The excavator can be operated temporarily with the TOPS/ROPS lowered for access through height restricted openings. Do not fasten the seat belt when the TOPS/ROPS is in the down position.
WARNING! NEVER remove or modify safety equipment.
Operating a machine without a protective structure (TOPS/ROPS, FOGS/FOPS or OPS) could result in death or serious injury. (See page 44,
Protective
Structure Safety
.)
Checklist
Follow A
Checklist
13
Prepare For Safe Operation
Check The Machine
14
Before you begin the workday, inspect the machine and have all systems in good operational condition. Do not operate the machine until all problems are corrected.
— Perform daily and periodic service procedures as instructed by the equipment manufacturer.
— Check that no safety switches or interlocks have been bypassed and that no warning tags have been placed on the machine.
— Check that safety signs, special instructions, lift capacity charts and operator manuals are legible and in the proper location.
— Check condition and operation of the seat belt and its mounts, if equipped.
— Make sure that the foldable TOPS/ROPS, if equipped, is properly secured in the raised position.
— Check condition and operation of the attachment quick-coupling device, if equipped. Perform daily cleaning and maintenance following the manufacturer’s instructions. (See page 17,
Quick-coupling Device Safety
.)
— Inspect steps, guardrails, platforms and handholds for damage or loose parts.
Maintain
Machine
Check Manuals
And
Safety Signs
Check Seat Belt
And Its Mounts
Check That
TOPS/ROPS Is Raised
And Properly
Secured
Prepare For Safe Operation
— Check the fuel and hydraulic systems. Have leaks repaired and fill to proper level.
— Check all exposed hydraulic components for leaks, routing problems or damage. Report worn or damaged components.
WARNING!
Diesel fuel and hydraulic fluid under pressure can penetrate the skin or eyes and cause serious injury, blindness or death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks, not your hand. Wear a face shield or safety goggles for eye protection.
If fluid is injected into the skin, it must be removed within a few hours by medical personnel familiar with this type of injury. (See page 46,
Hydraulic System Hazards
.)
— Check the cooling system.
WARNING!
Prevent possible injury from explosive release of hot fluids.
Allow the radiator to cool before checking the fluid level
. (See page 45,
Cooling System Hazards.
)
— Keep radiators and coolers clean and free of oil, grease, dirt, debris and moisture.
— Make sure all doors, guards and covers are in place and secured properly.
Wear
Eye Protection
High Pressure
Fluid Can Inject
Into The Body
Do Not
Loosen Cap
Until Cool
Check
The Radiator
And Engine
15
16
Prepare For Safe Operation
Check The Machine (continued)
— Check the tracks for broken or damaged pins, bushings, and other parts.
— Check the tracks for proper tension adjustment according to manufacturer’s instructions.
— Check the tracks for damage or wear. Replace badly worn or damaged tracks.
— Check the slew/swing brake for proper operation.
— Inspect working and other lights for proper operation.
— Inspect boom, arm and attachment for wear and damage.
— Make sure fire extinguishers are fully charged and in good working order.
Check Attachment And Coupler Installation
When changing buckets or installing attachments, follow the manufacturer’s instructions for proper maintenance and coupling. Make sure all connectors are securely fastened. Tighten all bolts, nuts and screws to torques recommended.
Check the attachment coupler and the attachment for wear and hydraulic leaks before coupling the attachment.
Before operating, ensure that quick-coupler pins or wedges are fully engaged and visibly locked to the attachment.
WARNING!
Avoid possible crushing injury.
Failure to properly secure the attachment to the machine coupler can allow the attachment to come off and could result in death or serious injury.
(See page 17,
Quick-coupling Device Safety
.)
Prepare For Safe Operation
Quick-coupling Device Safety
Before using a quick-coupling device you must know and understand proper installation, maintenance and operation.
WARNING! Failure to read and follow manufacturer’s instructions for the correct operation and maintenance of the quick-coupler can allow the attachment to come off and cause death or serious injury.
Protect yourself from injury:
— Install and maintain equipment, attachments and their operating systems according to manufacturers’ instructions.
— Securely latch attachments before work begins.
— Follow the manufacturer’s instructions for using positive locks on quick-coupling equipment.
— Make frequent visual inspections of quick-coupling systems—especially after changing attachments.
— Always check for interference limits of the coupler or tool with the carrier before operating.
Do not operate the machine if:
— there exists an incompatibility among components.
— there are broken, damaged or badly worn components.
— the lock/secure feature of the quick-coupler is impaired.
— the engaging lever or device is not fully engaged in a lock/secure condition.
Read And
Understand
Manuals Before
Operating
WARNING!
A quick-coupler that is not properly locked/secured could result in death or serious injury.
Perform all steps to lock/secure the device.
The steps to confirm that the device is properly locked/secured may include any or all of the following:
— Manually installing a locking pin, actuating a lever or other device.
— Movement of the attached work tool to confirm its engaged lock/secure condition.
— A visual check of the components as instructed by the quick-coupler manufacturer.
WARNING!
A quick-coupler that is disengaged when the attachment is in an unstable position could result in death or serious injury.
Place the attachment in a stable position, as instructed by the manufacturer, whenever coupling or uncoupling the attachment.
17
18
Prepare For Safe Operation
Clean Up
Clean windshields, mirrors and all lights. Use water and a clean cloth. Know and follow the manufacturer’s recommendations for using cleaning agents other than clean water on polycarbonate glazing.
Clean out the operator’s area. Steps and handholds must be clean and functional. Oil, grass, leaves, needles, snow, ice or mud in these areas can cause you to slip and fall.
Clean your boots before getting on the machine.
Clean out trash and debris buildup promptly, especially in the engine compartment, the battery box, around exhaust components, under the machine and around rotating components.
Remove all loose personal items or other objects from the operator’s compartment. Secure these items in a fixed tool box or remove them from the machine. Do not store any flammable material such as ether/cold-start fluid or oily rags in the operator’s compartment.
Maintain Vision –
Clean Up
Avoid Falls –
Clean Slippery
Surfaces
Avoid Fire –
Clean Out Debris
Put Away Tools
And Loose Items
Prepare For Safe Operation
Check The Work Area
Know—beforehand—as much about the worksite as possible. Locate all ground workers near the worksite and make sure clothing worn is easily seen. Be aware of weather conditions that can affect visibility, ground stability and traction.
Check for:
— Location of steep slopes, slide areas, drop-offs and overhangs
— Adequate traction on slopes
— Traffic locations and movement
— Thick dust, smoke and fog
— Soil conditions—look for signs of instability such as cracks or settlement
— Standing water and marshy areas
— Rocks and stumps
— Holes, obstructions, mud or ice
— Location of open trenches
— Exact location of any buried and/or overhead electrical, gas, telephone, water, sewer or other utility lines
Have the utility company mark, shut off or relocate the utility before you begin working.
Know the location and work plan for other machines on the worksite.
Correct unsafe conditions. Avoid operating in problem areas that cannot be corrected.
When operating the machine inside a building, know what clearances you will encounter—overhead, doorway, aisles, etc. Also, know the weight limitations of floors and ramps. Make sure there is sufficient ventilation for inside operation.
Walk Around
The Worksite
Be Seen –
Wear Visible
Clothing
19
20
Prepare For Safe Operation
Check The Work Area (continued)
Know the exact location of electrical, telephone, gas or other utility lines. (See page 5,
One-Call First
.)
DANGER!
Death or serious injury will result from touching or being near a machine that is in contact with or near an energized electrical source.
Never approach power lines with any part of the machine or load unless all local, state/provincial and federal (OSHA) required safety precautions have been taken.
Use extreme caution because high voltage sources can arc without contact.
When working near power lines, you must assume all lines are energized.
Maintain a safe distance from all utilities.
(See page 31,
Utilities—Overhead And Underground
.)
Use Caution When Fueling
IMPORTANT!
Always use approved fuel containers and dispensing equipment.
Fuels are flammable, so observe these practices to reduce the possibility of a serious accident.
— Shut off engine and ignition during refueling.
— Always ground the fuel nozzle against the filler neck to avoid sparks.
— Keep sparks and open flames away from fuel.
— Do not use a cell phone or two-way radio while fueling or handling fuel—they could cause sparks.
— Do not smoke while refueling or when handling fuel containers.
— Do not overfill the tank or spill fuel. Clean up spilled fuel immediately.
Locate All
Utilities, Maintain
A Safe Distance
Prepare For Safe Operation
Mount And Dismount Properly
When you enter or leave the machine:
— Maintain a three-point contact with the machine.
Three-point contact is defined as maintaining contact with at least one hand and two feet, or two hands and one foot, at all times.
— Face the machine when either mounting or dismounting.
— Use handholds, handrails, ladders or steps (as provided).
— The upperstructure and undercarriage must be oriented to align the access system.
— Never use control levers as handholds.
— Never step on foot controls when entering or leaving.
— Clean your boots and wipe your hands before mounting or dismounting.
— Never jump on or off the machine.
— Never attempt to mount or dismount a moving machine.
— Never mount or dismount while carrying tools or objects that prevent three-point contact.
Maintain
Three-Point Contact –
Face Machine
Do Not Jump Off
Machine
Do Not
Use Controls As
Handholds
21
22
Start Safely
Look Out For Others
Before starting, walk completely around the machine operating area. Make sure no one is under it, on it or close to it. Do not start the engine until everyone is clear of the operating area.
Starting The Engine
Do not start the engine or move any of the controls if there is a “DO NOT OPERATE” or similar warning tag attached to the start switch or controls. Check with your supervisor.
WARNING! Start the engine only from the operator’s seat. Never attempt to start the engine by shorting across starter terminals or reaching for the key from outside the cab.
This could result in the machine moving suddenly and unexpectedly and cause death or serious injury.
Walk-
Around
Inspection
Keep
Bystanders
Away
Start Only
From Operator’s
Position
Start Safely
Know the exact starting procedures for this machine.
See the manufacturer’s manual(s) for starting procedures.
— Clear the area of all persons.
— Sit in the operator’s seat and adjust the seat so you can operate all the controls properly.
— Familiarize yourself with warning devices, gauges and operating controls.
— Close or secure the cab door, if equipped.
— Fasten the seat belt, if equipped. If the compact excavator is equipped with a foldable TOPS/ROPS, do not fasten the seat belt when the TOPS/ROPS is in the down position.
— Put all controls, including those for auxiliary equipment, in the neutral/park position.
— Activate controls by releasing the control lock, if equipped.
— Start the engine following the instructions in the manufacturer’s manual(s).
If it is necessary to run the engine or operate the machine within an enclosed area, be sure there is adequate ventilation.
WARNING! Never operate any type of engine without proper ventilation—exhaust fumes can kill.
Know Starting
Procedure,
Read Manual
Fasten Seat Belt,
Use TOPS/ROPS
Ventilate
Work Area
23
Start Safely
Starting Aids
Do not
use ether/cold-start fluid if the engine is equipped with glow plugs or intake manifold preheater.
Ether/cold-start fluid is HIGHLY FLAMMABLE.
Before using it, always read the instructions on the ether/cold-start fluid container and the instructions in the manufacturer’s manual(s).
Do not
carry loose cans of starting fluid on the machine while operating.
If booster cables are used, follow the instructions in the manufacturer’s manual(s). The operator must be in the operator’s seat when boost-starting the engine so that the machine will be under control when the engine starts. Boost-starting is a two-person operation.
A battery explosion or a run-away machine could result from improper starting procedures.
Never boost-start a frozen battery. (See page 48,
Avoid
Battery Explosion
.)
After Starting The Engine
24
Observe gauges, instruments, and warning lights to ensure that they are functioning and their readings are within the operating range.
With the control levers or joysticks in neutral, test engine speed control.
Run An Operating Check
Do not use a machine that is not in proper operating condition. It is the
operator’s responsibility
to check the condition of all systems, and to run the check in a safe area.
WARNING!
Do not allow anyone to stand within the operating work radius of the machine and load.
Contact with moving parts of the compact excavator or load can cause death or serious injury.
Keep
Bystanders
Away
Start Safely
Test All Controls
Follow the manufacturer’s recommended warm-up procedures and bring all machine systems to operating temperature.
Machines come equipped with various control configurations, patterns and operating modes. Some have selectable or configurable controls that allow operation to suit personal preferences or specific applications. Make sure that you know which control pattern has been selected and understand how the machine will operate.
Make sure the engine is operating correctly. Operate each machine control to check all functions.
Check for possible interference between the attachment and the cab and operate appropriately.
Make sure the attachment quick-coupling device (if equipped) is operating properly, fully engaged and visibly locked. (See page 17,
Quick-coupling Device Safety
.)
Check the blade location before traveling. When the blade is in the rear, operate the steering levers in the opposite direction as when the blade is in the front.
See the machine manufacturer’s manual.
Operate the control(s) to ensure correct operation in forward, neutral and reverse.
Test steering—right and left—while moving slowly.
WARNING!
Prevent possible injury from loss of control.
Know and understand the selected control pattern and operating mode before operating.
Be certain you can control speed, direction, braking and boom motion before operating the machine.
Read And
Understand Manuals
Before Operating
Check
Instruments
And Controls
25
26
Operate Safely
Remember
— Stay in the operator’s seat, with the seat belt fastened, if equipped. If the compact excavator is equipped with a foldable TOPS/ROPS, do not fasten the seat belt when the TOPS/ROPS is in the down position.
— Understand the machine’s limitations. Be in control of the machine at all times.
— Assure yourself that the work area is clear of all bystanders and other machines. Stop the machine immediately if anyone approaches.
— If a failure that causes loss of control occurs, stop all machine motion as quickly as possible. Shut the machine down and remove the key. Correct or report the problem immediately.
Remember The Other Person
WARNING! Never allow an untrained or unqualified person to operate this machine.
Handled improperly, this machine could cause death or serious injury.
Do not allow anyone within the operating work radius of the compact excavator.
Fasten Seat Belt,
Use TOPS/ROPS
Look Before
Moving The Machine
Or Boom
Never use a bucket or other attachment as a work platform or personnel carrier.
WARNING!
Prevent possible injury from fall or runover.
The compact excavator is a one-person machine.
NEVER PERMIT RIDERS.
Always look around before you travel or move the boom. Look in the direction of machine movement.
Awareness on your part can prevent accidents.
Operate Safely
Traveling On The Worksite
Know and understand the worksite traffic flow patterns and obey signalmen, road signs and flagmen.
Check blade location before traveling. When blade is positioned to the rear, operate the steering levers in the opposite direction as when the blade is in the front.
The retractable track frame, if equipped, should be extended for traveling on the worksite. The track frame can be retracted to access narrow areas. Read and know manufacturer’s instructions before operation.
Know the maximum height and width of the machine.
Do not obstruct your vision when traveling. Always look in the direction of travel. Drive facing the travel direction when possible.
Operate the controls smoothly and slowly. Rapid and jerky movement of the controls can cause loss of both machine stability and control of the load.
When moving the machine, watch that enough clearance is available on both sides and above the boom and cab. Be especially careful to allow extra clearance on uneven ground.
Operate
Controls Smoothly
And Slowly
Know
Weight Limits
Check for hazards or obstructions before entering an underpass or other area with restricted clearance.
Check height and side clearances.
WARNING!
Avoid possible injury. The weight of the machine may cause the ground, dock, ramp or floor to give way, causing loss of control, fall or tipover.
Know weight limits and stay clear of the edges of excavations and drop-offs.
Failure to know and observe weight limits and use caution could result in death or serious injury.
27
Operate Safely
Traveling On The Worksite (continued)
Make sure all surfaces will support the weight of the machine.
Do not cross ditches, creeks or wet draws without an adequate fill or bridge crossing.
Match travel speed to the traffic, weather and ground conditions. Take it slow and easy when traveling. Travel cautiously over rough or slippery ground and on slopes.
Reduce speed when travelling over a rise.
Always give the right of way to loaded machines.
Maintain a safe distance from other machines.
If you encounter a blind corner, stop and then proceed with caution.
Avoid traveling over obstacles (logs, tree stumps, rough terrain, ditches, curbs, railroad tracks) whenever possible. If you must cross an obstacle, do so slowly and with caution.
28
Avoid steep slopes or unstable surfaces. If it is necessary to travel on a slope, follow manufacturer’s specific instructions. When on a slope, keep the boom centered and attachment as low and as close to the
Travel Slowly Over
Rough, Hazardous
Terrain
Drive Straight
Up And Down – NOT
ACROSS – Steep
Slopes
machine as possible. Proceed with extreme caution.
Do not drive
ACROSS
a steep slope under any circumstances. Drive straight up and down a slope.
Avoid turning on a slope. If it is necessary, use extreme caution and make the turn
WIDE and SLOW
with the boom centered and attachment as low and as close to the machine as possible.
Avoid sudden movement of the travel controls.
Operate Safely
Safety Precautions
Never reach into the compact excavator and attempt to operate the controls from outside the cab.
Before starting to excavate, set up safety barriers to the sides and rear area of the swing pattern to prevent anyone from walking into the working area.
Read and know manufacturer’s instructions before operation.
Make sure you are aware of personnel or machines that may be hidden in blind spots on the worksite, such as piles or stacks of material.
Make sure the machine has sufficient clearance from other machines or material on the worksite to prevent contact during machine or attachment movement.
WARNING!
Prevent death or serious injury.
Never lift, move or swing a load over any person or any machine cab.
Check Clearance,
Look Out For
Others
Do Not Lift
Or Swing A Load
Or Attachment
Over Anyone
Know and use the hand signals required for particular jobs. Know who has the responsibility for signaling. Take signals from one person only.
Do not operate during storms with high winds or lightning strikes. Do not mount or dismount during a period of lightning strikes. If you are on the machine, stay on it. Warn others to stay clear of the machine in case of a lightning strike.
29
30
Operate Safely
Load Lifting
Consult the rated lift capacity chart. Do not overload this machine. Know the exact lifting capacity of the machine as equipped. Make sure you have and know how to use a current lift capacity chart for the machine. Changing conditions such as slopes, wind, ice, mud, soft ground, type of load or the weight of attachments will affect the capacity and operating characteristics of the machine.
Consult your lift chart. Lifting and handling loads over the end of the machine, rather than over either side, will improve the lifting performance of the machine.
The retractable track frame, if equipped, should be fully extended for increased lifting performance.
Attach loads only to the manufacturer’s designated lifting points, if equipped.
If equipped, keep blade lowered for increased lifting performance. If ground is soft, place pads or timbers under the blade.
Operate the controls smoothly and slowly. Rapid and jerky movement of the controls can cause loss of both machine stability and control of the load.
Operate
Controls Smoothly
And Slowly
When lifting, be sure the load is properly balanced.
Move slowly so the load does not sway or swing around. Use a tag line for control.
If tracks or blade leave the ground, slowly lower the load to return the machine to the ground. Do not drop the load suddenly, because this can lead to loss of control.
Do not exceed rated lift capacity. Excessive load can cause tipping or loss of control.
Carry the load/attachment low and as close to the machine as possible. You must allow for movement in all directions. Be careful to maintain clearance of the attachment and load from the cab.
Keep all guards in place and windows closed or locked open. Keep cab doors closed or otherwise secured, if equipped.
Never leave the operator’s seat with a load suspended.
(See page 39,
Machine Shutdown.
)
Operate Safely
Utilities – Overhead And Underground
DANGER! Electrocution or serious injury will result from CONTACTING or APPROACHING power lines or apparatus. Maintain Minimum Approach Distance.
(See chart.)
DANGER!
Death or serious injury will result from touching or being near a machine that is in contact with or near an energized electrical source.
Never approach power lines with any part of the machine or load unless all local, state/provincial and federal (OSHA) required safety precautions have been taken.
Use extreme caution because high voltage sources can arc without contact.
REQUIRED CLEARANCE FOR OPERATION
NEAR HIGH VOLTAGE POWER LINES
Normal Voltage, kV
(Phase to Phase)
Over 50 to 200
Over 200 to 350
Over 350 to 500
Over 500 to 750
Over 750 to 1,000
Distance [Note (1)] ft (m)
10
15
20
25
35
45
(3.0)
(4.6)
(6.1)
(7.6)
(10.7)
(13.7) precipitation may require increased clearances.
Maintain
Minimum Approach
Distance
Stay Clear
Of Energized
Equipment
Check overhead clearances. If possible, have power to the lines de-energized and visibly grounded. If not possible, request a signal person for guidance to maintain at least the Minimum Approach Distance. (See chart.)
If the machine or load contacts an energized line, stay in the machine and attempt to break contact. Warn others to stay away from the machine. If machine catches fire and you are forced to leave, jump clear of the machine with both feet together and hop or shuffle away.
DO NOT
touch machine and ground at the same time.
31
32
Operate Safely
Locate All Underground Utilities
Confirm that One-Call has been contacted. Confirm that any utilities not subscribing to One-Call have been contacted. Confirm that the site has been marked or cleared. (See page 5,
One-Call First
.)
Obtain all information pertaining to the locate request, including the One-Call confirmation code or ticket number. If the facility owner has provided a locate sketch, obtain a copy. Review any engineering drawings provided by utilities. This information should be retained.
Personally verify One-Call utility marks. There are variations from state to state.
Take a copy of the locate sketch to the job site. Confirm all of the locates. Review the site for signs of unmarked utilities. These signs may include pedestals, pole risers, meters, trench lines, manhole covers, sewer drain outlets, etc. Review not only the immediate area, but also the perimeter of the area for utility markers.
Additionally, the area should be swept by an experienced operator using a device to locate utilities and large metal objects.
Any inconsistencies with line locations or any inaccurate locates must be resolved.
When excavating near underground services, expose the service by hand-digging or by using soft excavation, such as vacuum excavation, if permitted by local utilities.
When gas lines are present on the site, do not smoke or do anything to cause a spark in the vicinity of a gas line.
Make plans to restrict working area access—with cones and tape, barriers, warning signs, fences, etc.—until the job is complete.
Make certain that you are in compliance with all local, state/provincial, national and other requirements and regulations, including those regarding open excavations, or “potholes.”
Locate All
Utilities, Maintain
A Safe Distance
Operate Safely
Trenching Safety Precautions
Follow the worksite plan for proper construction of the trench. Check with your supervisor if you are unsure of correct trench construction or if operating conditions change.
Stay alert to changes in soil conditions. Trench collapse is hazardous to all workers in the area and could cause the machine to slide into the trench.
Keep heavy loads and equipment as far from the trench as possible.
Keep spoil and stored materials such as pipe at least two feet from the edge of the trench.
Keep personnel away from the equipment and attachments.
Never swing a load or attachment over anyone.
Do not undercut the machine.
WARNING! Do not dig under the machine or blade.
A resulting cave-in could cause death or serious injury.
WARNING!
Avoid possible death or serious injury from trench wall collapse.
Before backfilling, see the manufacturer’s manual for any specific instructions.
Do not get too close to the edge of the cut.
The weight of the machine plus the fill could cause the trench wall to collapse.
Keep
Personnel Away
From Equipment
And Attachments
33
Operate Safely
Slope And Uneven Terrain Operation
34
Compact excavator stability and load capacity are greatly reduced on slopes. Ensure the operation can be done safely. Prevent overturns and maintain stability control:
— Use machines equipped with TOPS/ROPS and a seat belt. Make sure folding TOPS/ROPS is raised and locked in place—always use the seat belt.
— The retractable track frame, if equipped, should be extended for operating on slopes or uneven terrain.
Read and know manufacturer’s instructions before operation.
— Review the manufacturer’s manual for specific instructions and limitations, including those for proper operation of alternate/emergency exits.
— Avoid extremely steep slope operation.
— Keep machine movements slow and smooth.
— Level the working area and machine as much as possible.
— Avoid working with the tracks across a slope.
This will reduce stability and increase the tendency of the machine to slide. Position the machine with the tracks running up and down the slope—blade downhill and lowered.
— Avoid slippery ground conditions.
Always Check
Manuals For Specific
Instructions
Fasten Seat Belt,
Use TOPS/ROPS
Level The
Work Area
If Possible
Operate Safely
— Travel straight up and down the slope with the attachment low and close to the machine. Do not move the boom while travelling.
— Avoid swinging to the downhill side of a slope.
Always keep the boom and attachment as low and close to the machine as possible.
If the machine begins to tip, roll or slide, stay in the machine with the seat belt securely fastened. Lower the attachment immediately. Hold on firmly and brace your feet on the floor. Lean away from the point of impact.
When operating the compact excavator on a slope, swing to the uphill side to dump load, if possible. If downhill dumping is necessary, swing only as far as required to dump the bucket. Use extreme caution.
Always drop spoil a sufficient distance from a trench to prevent cave-ins.
If possible, avoid working with the tracks across a slope.
Before moving the machine, raise the blade sufficiently to clear the ground, and then drive the machine forward or backward as required. Lower the blade to level the machine.
Swing Load
Uphill When On
A Slope
35
Operate Safely
36
Hazardous Conditions
When working in hazardous areas, be extremely alert.
Always consult the manufacturer’s operator manual for specific instructions.
Extreme caution is required when working near the edge of an excavation. Keep the machine a safe distance away from the edge. Avoid undercutting.
WARNING!
Never undercut a high bank.
The edges could collapse or a slide could occur, resulting in death or serious injury.
Work the jobsite in a manner that avoids creating overhangs or the need to be on top of banks or slopes.
Never operate the machine close to the edge of an overhang or stockpile.
Extreme caution should be used when working along the top of banks and slopes. Keep as far back from the edge as possible. Level the area if possible. Keep the machine tracks perpendicular to the edge so that if part of the edge collapses, the machine can be moved back.
Immediately move the machine back at any indication the edge may be unstable.
Use Caution –
Stay Safely Away
From Bank Or
Excavation Edge
Never Undercut
A High Bank
Operate
Perpendicular To
Banks – Stay Back
From The Edge
Operate Safely
WARNING! Do not dig under the machine.
A cave-in could result and the machine could fall into the excavation, resulting in death or serious injury.
Avoid Silica Dust
Cutting or drilling concrete or rock containing quartz may result in exposure to silica dust.
Do not exceed
Permissible Exposure Limits (PEL) to silica dust as determined by OSHA or other worksite rules and regulations.
Use a respirator, water spray or other means to control dust. Silica dust can cause lung disease and is known to cause cancer.
Operation In Flammable/Explosive Atmosphere
WARNING!
Avoid possible death or serious injury.
Never operate an excavator in these areas. Use of these excavators in explosive atmospheres can result in fires and explosions, causing death or serious injury.
Use Caution Near
Excavation Edge –
Do Not Undercut
Machine
Avoid
Silica Dust
Do Not Operate In
Explosive/Flammable
Atmosphere
38
p
Operate Safely
Towing
Many compact excavators may not be towed. Refer to the manufacturer’s manual(s) for specific towing instructions.
Never straddle a tow line or stand near a tow line under tension.
Parking
Park the machine in a designated area out of traffic, preferably on level ground. (See page 39,
Machine
Shutdown
.)
If freezing conditions are expected, the tracks should be first cleared of mud and dirt and the machine parked on planks or suitable debris.
Public roads are not suitable for parking. If the machine is disabled or you must park on a public road, barricade and mark the machine according to local and worksite regulations.
Consult
Manufacturer’s
Manual Before
Towing
37
Shut Down Safely
Machine Shutdown
Properly shutting down a compact excavator can help prevent accidents when the machine is left unattended.
Shut down the excavator following the specific procedures in the manufacturer’s operator manual.
A typical list includes:
— Stop the machine.
— Make sure the area around the machine is clear of personnel.
— Slew the machine to align the upperstructure with the undercarriage, if possible.
— Return controls to neutral, including the auxiliary hydraulic controls.
— Lower the attachment and blade to the ground with slight down-pressure.
— Idle engine for a short cool-down period.
— Stop the engine.
— Cycle all hydraulic controls to relieve system pressure.
— Engage the control locking device, if equipped.
— Remove ignition key.
— Block the tracks if on a slope or incline.
— Check for and clean out trash build-up, especially in the engine compartment, battery box, around exhaust components, in confined spaces, under the machine and around rotating components.
Safe Dismounting
Never dismount from moving equipment. Observe proper shutdown practices before dismounting. Check for slippery steps and handholds.
Dismount carefully using three-point contact facing the machine. (See page 21,
Mount And Dismount Properly
.)
Lower
Attachment
Shut Off Engine,
Remove Key, Engage
Control Lock
39
Load And Unload The Machine Safely
Loading And Unloading For Transport
All machines are not loaded in the same way, and the procedures given in the manufacturer’s manual(s) should always be followed.
40
Some precautions apply to all machines:
— Keep bystanders away.
— Wear the seat belt, if equipped.
— If the compact excavator is equipped with a foldable
TOPS/ROPS, make sure it is properly secured in the raised position.
— Place transport vehicle on a firm, level surface.
— Block or support the rear of the trailer.
— Secure the parking brake and block transport vehicle so it cannot move.
— Use ramps with slip-resistant surfaces, adequate size and strength, low angle (15 degrees or less) and proper height.
— Keep trailer bed and ramps clear of mud, oil, ice, snow, leaves and other debris.
— Position the attachment to the front of the machine.
— Drive forward up the ramps, raising the blade high enough for clearance.
— Cover or remove any SMV (Slow-Moving Vehicle) emblem.
— Secure the cab door, attachment and accessories in the transport position.
— Engage upperstructure slew lock, if equipped.
— Chain and block the excavator securely for transport.
Refer to the manufacturer’s operator manual for tie-down procedures.
Measure the transport height and width of the loaded machine to avoid overhead and width obstructions.
Make sure clearance flags, all lights and warning signs are in place and visible.
Read
Operator Manual
Keep
Bystanders
Away
Maintain Equipment
Perform Maintenance Safely
IMPORTANT!
Do not
modify equipment or add components not approved by the manufacturer. Use parts, lubricants and service techniques recommended by the manufacturer.
Maintain
Equipment
Be sure to maintain equipment according to manufacturer’s instructions. Regularly check the operation of the protective and safety devices.
Do not
perform any work on the compact excavator unless you are authorized and qualified to do so.
If you have been authorized to maintain the equipment,
read the operator, maintenance and service manuals.
Study the instructions, check the lubrication charts and examine all the instruction messages on the machine.
Maintenance can be dangerous unless performed properly. Be sure you have the necessary skill, information, tools and equipment to do the job correctly.
If adjustments must be made with the engine running, always work as a 2-person team with one person sitting in the operator’s seat while the other works on the machine.
Protect Yourself
Wear personal protective clothing and Personal
Protective Equipment (PPE) issued to you or called for by job conditions.
You may need:
— Hard hat
— Safety boots with non-slip soles
— Safety glasses, goggles or face shield
— Apron and heavy-duty gloves
— Hearing protection
— Welding helmet or goggles
— Respirator or filter mask
Wear whatever is needed to protect yourself—do not take chances.
41
Perform Maintenance Safely
42
WARNING!
Prevent death or serious injury from entanglement.
Do not wear loose clothing or accessories. Restrain long hair. Stay away from all rotating components when the engine is running.
Contact with or entanglement in rotating or moving parts could result in death or serious injury.
Wear a rubber apron and rubber gloves when working with corrosives. Wear gloves and safety shoes when handling wooden blocks, wire rope or sharp-edged metal.
Always use safety glasses, goggles or a face shield.
They provide eye protection from fluids under pressure, during grinding and while servicing batteries. Protection is also needed from flying debris, liquids and loose material produced by equipment, tools and pressurized air/water/oil/fuel.
Wear a face shield when you disassemble spring-loaded components or work with battery acids. Wear a welding helmet or goggles with a shaded filter when you weld or cut with a torch.
Do not sand, grind, flame-cut, braze or weld without an approved respirator or appropriate ventilation. If welding is required on the machine, refer to the manufacturer’s manuals or consult the equipment dealer for proper procedures. Make sure all flammable material is cleared from the area.
Keep pockets free of all objects that could fall out and drop into machinery.
Handle tools and heavy parts sensibly, with regard for yourself and other persons. Lower items—do not drop them.
Avoid
Rotating Parts
Avoid
Pinch Points
Perform Maintenance Safely
Prepare The Work Area
— Position the compact excavator in a level area out of the way of other working equipment.
— Make sure there is adequate light, ventilation and clearance.
— Remove oil, grease, ice and snow or water to eliminate any slippery surfaces.
— Clean around the machine and work area to minimize contamination. Clean up oil or fuel spills promptly and dispose of the material properly.
Prepare The Machine
— Attach a “DO NOT OPERATE” warning tag to the control levers and remove the ignition key if the machine should not be started.
— Block the tracks.
— Release all hydraulic, water and air pressure. Lower, lock or block all hydraulically supported components.
WARNING!
Disconnecting or loosening any hydraulic component or a part failure can cause unsupported equipment to drop.
Do not go under or near raised equipment unless supported by a manufacturerapproved support device(s).
Death or serious injury could result from falling equipment.
— Remove only guards or covers that provide access to the area being serviced. Replace all guards and covers when work is complete.
DO
N
OT
RAT
E
DO NOT
OPERATE
Use
Warning Tags
Remove
Key And Read
Maintenance
Manual
Use
Approved
Support Device
43
44
Perform Maintenance Safely
Use Approved Ventilation
If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.
WARNING!
Prevent possible injury.
Never work on machinery with the engine running unless instructed by the manufacturer’s manuals for specific service.
WARNING! Never operate any type of engine without approved ventilation
—EXHAUST FUMES CAN KILL.
Ventilate
Work Area
Use Jacks And Hoists Carefully
If you must work beneath raised equipment, use solid wood blocks, jack-stands or other rigid and stable supports. Never use concrete blocks. When using jacks or hoists, always be sure they are adequately supported and of adequate capacity.
Make sure the hoists or jacks you use are in good repair.
Never use jacks with cracked, bent or twisted parts.
Never use frayed, twisted or pinched cables. Never use bent, worn or distorted hooks.
Protective Structure Safety
Do not remove or modify a protective structure
(TOPS/ROPS, FOGS/FOPS OPS) except for service.
Reinstall with manufacturer-approved fasteners before further machine operation.
Replace a damaged protective structure. Refer to the manufacturer’s manual for specific instructions and inspection requirements.
Perform Maintenance Safely
Common Maintenance Safety Practices
Fuel Hazards
IMPORTANT!
Always use approved fuel containers and dispensing equipment.
Fuels are flammable, so observe these practices to reduce the possibility of a serious accident.
— Shut off engine and ignition before refueling.
— Always ground the fuel nozzle against the filler neck to avoid sparks.
— Keep sparks and open flames away from fuel.
— Do not use a cell phone or two-way radio while fueling or handling fuel—they could cause sparks.
— Do not smoke while refueling or when handling fuel containers.
— Do not cut or weld on or near fuel lines, tanks or containers.
— Do not overfill the tank or spill fuel. Clean up spilled fuel immediately.
Always use a nonflammable solvent when you clean parts. Do not use gasoline, diesel fuel or other flammable fluids.
Store all flammable fluids and materials away from work areas in suitable containers, per local regulations.
Cooling System Hazards
Liquid cooling systems build up pressure as the liquid gets hot, so
use extreme caution
before removing the radiator or tank cap. Be sure to:
— Stop the engine and wait for the system to cool.
— Wear protective clothing and safety glasses.
— Turn the radiator or tank cap slowly to the first stop to allow the pressure to escape before removing the cap completely.
Do Not
Loosen Cap
Until Cool
45
46
Perform Maintenance Safely
Hydraulic System Hazards
The hydraulic system is under pressure whenever the engine is running and may hold pressure even after the engine is shut off. Cycle all hydraulic controls, including auxiliary controls, after the engine is shut down to relieve trapped pressure in the lines.
During inspection of the hydraulic system:
— Wait for fluid to cool before disconnecting the lines.
Hot hydraulic fluid can cause SEVERE BURNS.
—
Do not
use your hand to check for leaks.
— Wear appropriate eye protection. Hydraulic fluid can cause permanent eye injury.
WARNING!
Diesel fuel and hydraulic fluid under pressure can penetrate the skin or eyes and cause serious injury, blindness or death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks, not your hand. Wear a face shield or safety goggles for eye protection.
If fluid is injected into the skin, it must be removed within a few hours by medical personnel familiar with this type of injury.
When venting or filling the hydraulic system, loosen the filler cap slowly and remove it gradually.
Never
reset any relief valve in the hydraulic system to a pressure higher than recommended by the manufacturer.
Follow manufacturer’s instructions when taking oil samples.
Do not permit an open flame around the hydraulic system.
Wear
Eye Protection
High Pressure
Fluid Can Inject
Into The Body
Do Not Exceed
Factory Pressure
Settings
Perform Maintenance Safely
Electrical System Hazards
Before working on the electrical system, disconnect the battery cable(s).
— Remove the battery negative (-) cable(s) first.
— When reconnecting the battery, connect the battery negative (-) cable(s) last.
Battery electrolyte contains acid, which is a POISON and can cause SEVERE CHEMICAL BURNS.
If electrolyte is ingested,
seek MEDICAL ATTENTION
IMMEDIATELY. NEVER give fluids that would induce vomiting.
Wear
Face Protection
Avoid Injury
— Wear a face shield to prevent electrolyte contact with your eyes.
— Wear chemical-resistant gloves and clothing to keep electrolyte off your skin and regular clothing.
WARNING!
Electrolyte will damage eyes or skin on contact.
Always wear a face shield to avoid getting electrolyte in eyes.
If electrolyte contacts eyes, flush immediately with clean water and get medical attention.
Wear rubber gloves and protective clothing to keep electrolyte off skin.
If electrolyte contacts exposed skin or clothing, wash off immediately with clean water.
Wear
Protective
Clothing
47
48
Perform Maintenance Safely
Avoid Battery Explosion
WARNING!
Avoid possible death or serious injury from explosion. Lead-acid batteries produce extremely explosive gases, especially when being charged.
Keep arcs, sparks, flames and lighted tobacco away.
—
Do not
smoke near batteries.
— Check battery cables for worn or damaged insulation.
— Keep arcs, sparks and open flames away from batteries.
— Provide adequate ventilation.
Never
check the battery by placing a metal object across the battery posts; the resulting spark could cause an explosion.
WARNING!
Avoid possible death or serious injury from battery explosion.
Do not charge a battery or booststart the engine if the battery is frozen.
Warm to 60°F
(15.5°C) or the battery may explode.
Safety rules during battery boost-starting:
— Follow the instructions for proper “battery booststarting” as specified in the manufacturer’s manual.
— Be sure the machines are not touching.
— Observe the polarity of the batteries and connections.
— Make the final cable connection to the engine or the ground point farthest from the battery and away from fuel lines. Never make the final connection at the starter or dead battery—sparks may ignite the explosive gases present at the battery.
— When disconnecting cables after boost-starting, remove the cables in reverse order of connection
(i.e., final connection first).
Avoid Sparks
And Open Flames
Near Batteries
Observe
Polarity – Make
Final Connection At
Ground Point
Perform Maintenance Safely
Track Maintenance And Adjustment
Check the tracks daily because the stability of the compact excavator can be dramatically affected by damage to tracks.
Check for:
— Damage or wear
— Correct tension according to manufacturer’s instructions
— Proper lubrication of track rollers and idlers—refer to the manufacturer’s manuals.
Track tension is important for good performance, reducing excessive track wear and preventing the tracks from coming off. Track and roller wear varies with working conditions and soil conditions. Special tools and procedures may be needed to check or adjust track tension. Follow manufacturer’s specific service procedure(s) when removing and installing tracks.
Follow
Maintenance
Instructions
Check For
Track Damage
WARNING!
Track tensioning systems have compressed springs or pressurized fluid (oil or grease). Improperly releasing track tension forces can result in death or serious injury.
Always follow the manufacturer’s warnings and instructions for track adjustment and other maintenance and servicing procedures.
WARNING!
Avoid possible death or serious injury.
Never strike or pound on track tension springs.
They may be under very high compression and could shatter explosively.
49
50
Perform Maintenance Safely
Complete Service And Repairs Before Machine
Is Released
Tighten all bolts, fittings and connections to torques specified by the manufacturer.
Clean or replace all damaged, missing or painted-over signs, plates and decals that cannot be read.
Inspect and install all guards, covers and shields after servicing. Replace or repair any damaged parts. Refill and recharge pressure systems only with manufacturerapproved or recommended fluids.
Check readiness of fire extinguishers, if so equipped.
Do not paint over or otherwise interfere with fire detectors or fire extinguisher access points.
Follow the instructions in the manufacturer’s manual(s) for proper service of any fire suppression equipment on the machine.
Air conditioning service is limited to approved service personnel. Refer to the manufacturer’s manual(s).
Verify
Service Work
When
Completed
Start the engine and check for leaks. (See page 46,
Hydraulic System Hazards
.) Operate all controls to make sure the machine is functioning properly. Test the machine if necessary. After testing, shut down and check the work you performed. Are there any missing cotter pins, washers, locknuts, etc.? Recheck all fluid levels before releasing the compact excavator for operation.
All parts should be inspected during repair and replaced if worn, cracked or damaged. Excessively worn or damaged parts can fail and cause death or injury.
Final Word To The User
You have just finished reading the AEM Compact
Excavator Safety Manual. It is impossible for this manual to cover every safety situation you may encounter on a daily basis. Knowledge of these safety precautions and your application to the basic rules of safety will help to build good judgment in all situations.
Our objective is to help you develop, establish and maintain good safety habits to make operating a
Compact Excavator easier and safer for you.
51
FORM CE-1009
Printed in U.S.A.
Wacker Neuson Linz GmbH keep abreast of the latest technical developments and constantly improve their products. For this reason, we may from time to time need to make changes to diagrams and descriptions in this documentation which do not reflect products which have already been delivered and which will not be implemented on these machines.
Technical data, dimensions and weights are given as an indication only. Responsibility for errors or omissions not accepted.
No reproduction or translation of this publication, in whole or part, without the written consent of Wacker Neuson Linz GmbH.
All rights under the provision of the Copyright Act are reserved.
Wacker Neuson Linz GmbH
Flughafenstraße 7
A-4063 Hörsching
Austria
Wacker Neuson Corporation
P. O. Box 9007
Menomonee Falls, WI 53052-9007
Telephone: (262) 255-0500
Fax: (262) 255-0550
Telephone: (800) 770-0957 www.wackerneuson.com
Wacker Neuson Linz GmbH
Flughafenstraße 7
A-4063 Hörsching
Telephone +43 (0) 7221 63000
Fax +43 (0) 7221 63000 - 2200
E-mail: [email protected]
www.wackerneuson.com
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Key Features
- Powerful engine
- Spacious cab
- Excellent visibility
- Robust design
- Durable construction
- Versatile attachments
- Track drive
- Hydraulic operation
