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  5. Operator's Manual

Wacker Neuson 803 dual power Operator's Manual

Manual is about: Track Excavator

Summary of 803 dual power

  • Page 1

    Operator's manual track excavator 803 803 dual power machine type e08-01 edition 3.7 order no 1000287384 language us 1 0 0 0 2 8 7 3 8 4 this operator's manual includes the aem safety manual ce-1009.

  • Page 2

    Dokumentationen documentations order no operator's manual 1000287384 service manual 1000164843 spare parts list 1000161641 copyright © 2016 wacker neuson baumaschinen gmbh, hörsching printed in michigan, usa all rights reserved, in particular the globally applicable copyright, right of reproduction ...

  • Page 3: Table of Contents

    Om 803 us - ausgabe 3.7 * ba803us3_7ivz.Fm 1-1 table of contents table of contents introduction 1 information on this operator’s manual ..................................................................... 1-1 machine overview (up to serial no. Ai00966) .................................................

  • Page 4: Table of Contents

    1-2 om 803 us - ausgabe 3.7 * * ba803us3_7ivz.Fm table of contents operation with lowered rops rollbar .............................................................. 2-10 attachments ........................................................................................................... 2-10 gene...

  • Page 5: Table of Contents

    Om 803 us - ausgabe 3.7 * ba803us3_7ivz.Fm 1-3 table of contents operating temperature range .......................................................................... 3-16 travel levers .................................................................................................... 3-16 iso/sae...

  • Page 6: Table of Contents

    1-4 om 803 us - ausgabe 3.7 * * ba803us3_7ivz.Fm table of contents coupling ........................................................................................................... 3-65 checking the hydraulic oil levels of the power unit and excavator .................. 3-67 changeover from hpu t...

  • Page 7: Table of Contents

    Om 803 us - ausgabe 3.7 * ba803us3_7ivz.Fm 1-5 table of contents retightening the v-belt .................................................................................... 5-15 hydraulic system ................................................................................................... 5-16...

  • Page 8: Table of Contents

    1-6 om 803 us - ausgabe 3.7 * * ba803us3_7ivz.Fm table of contents fuses and relays with dual power option .......................................................... 6-5 noise levels .............................................................................................................. 6-6 vi...

  • Page 9: Index

    Om 803 us - ausgabe 3.7 * ba803us3_7six.Fm 1-1 index a abbreviations .........................................................................................1-1 air filter .................................................................................................5-12 b biodegradable oil ........

  • Page 10: Index

    1-2 om 803 us - ausgabe 3.7 * * ba803us3_7six.Fm index s safety instructions .................................................................................2-1 general conduct .............................................................................2-3 identification .............................

  • Page 11: Introduction

    Om 803 us – edition 3.7 * 803b110.Fm 1-1 introduction 1 introduction 1.1 information on this operator’s manual the operator’s manual is stored in the storage bin at the rear of the seat. This operator’s manual contains important information on how to work safely, correctly and economically with the ...

  • Page 12: Introduction

    1-2 om 803 us – edition 3.7 * * 803b110.Fm introduction 1.2 machine overview (up to serial no. Ai00966) fig. 1: machine outside views 1 boom light 2 boom 3 stick 4 track 5 travel gear 6 stabilizer blade 7 handhold 8 lifting eye for loading/tying down the machine 9 engine cover 10 storage bin for ope...

  • Page 13: Introduction

    Om 803 us – edition 3.7 * 803b110.Fm 1-3 introduction 1.3 machine overview (from serial no. Ai00967) fig. 2: machine outside views 1 boom light 2 boom 3 stick 4 track 5 travel gear 6 stabilizer blade 7 handhold 8 lifting eye for loading/tying down the machine 9 engine cover 10 storage bin for operat...

  • Page 14: Introduction

    1-4 om 803 us – edition 3.7 * * 803b110.Fm introduction 1.4 brief description the model 803 excavator is a self-propelled work machine. Get informed on and follow the legal regulations of your country. This machine is a versatile and powerful helper for moving earth, gravel and debris on con- struct...

  • Page 15: Introduction

    Om 803 us – edition 3.7 * 803b110.Fm 1-5 introduction definition of the term “protective structure” protective structures are additional elements that protect the operator against hazards. These elements can be installed later on or as standard equipment. Explanation of abbreviations rops: roll over...

  • Page 16: Introduction

    1-6 om 803 us – edition 3.7 * * 803b110.Fm introduction 1.7 fields of application, attachments the attachments will decide in the first place how the excavator is used. Notice in order to avoid damage to the machine, only the attachments listed below have been certified. • please contact your wacker...

  • Page 17: Introduction

    Om 803 us – edition 3.7 * 803b110.Fm 1-7 introduction 1.8 regulations requirements to be met by the operator earth moving machines may be traveled and serviced only by persons who meet the fol- lowing requirements: • 18 years or older • physically and mentally suited for this work • persons have bee...

  • Page 18: Introduction

    1-8 om 803 us – edition 3.7 * * 803b110.Fm introduction 1.10 ec declaration of conformity the indications specified above correspond to the existing information at time of going to press. They have possibly changed in the mean- time (refer to the original declaration of conformity supplied with the ...

  • Page 19: Introduction

    Om 803 us – edition 3.7 * 803b110.Fm 1-9 introduction 1.11 type labels and component numbers information! Type, quantity and position of the labels depend on options, country and machine. Serial number the serial number is stamped on the machine chassis. It is also located on the type label. The typ...

  • Page 20: Introduction

    1-10 om 803 us – edition 3.7 * * 803b110.Fm introduction 1.12 overview of adhesive labels 1 1. Number and position of adhesive labels can differ depending on country..

  • Page 21: Introduction

    Om 803 us – edition 3.7 * 803b110.Fm 1-11 introduction the following states signs and symbols that do not contain explanatory text and that are not explained in the following chapters. Meaning machine is raised by the eye hooks – see chapter lifting the machine on page 3-44 position on either side o...

  • Page 22: Introduction

    1-12 om 803 us – edition 3.7 * * 803b110.Fm introduction meaning only refuel diesel fuel with a low sulfur content! – see chapter important information on the use of biodegradable oil on page 5-18 position on the fuel tank meaning (option) (up to serial number wnce0801epal00209) changeover from hamm...

  • Page 23: Introduction

    Om 803 us – edition 3.7 * 803b110.Fm 1-13 introduction meaning (up to serial no. Ai00814) this label describes the pedal and control lever functions. – see chapter 3.14 control lever overview on page 3-52 position on the control stand meaning (from serial no. Ai00815) this label describes the pedal ...

  • Page 24: Introduction

    1-14 om 803 us – edition 3.7 * * 803b110.Fm introduction meaning maintenance plan position on the front side of the engine cover meaning battery master switch position on the front side of the engine cover fig. 20: maintenance plan fig. 21: battery master switch.

  • Page 25: Introduction

    Om 803 us – edition 3.7 * 803b110.Fm 1-15 introduction 1.13 overview of safety labels 1 1. Number and position of adhesive labels can differ depending on country..

  • Page 26: Introduction

    1-16 om 803 us – edition 3.7 * * 803b110.Fm introduction meaning potential high pressure grease discharge from the track tension adjustment fitting. Always read the operator’s manual before working with the track tensioner. Position on either side of the travel gear. Meaning entanglement hazard. Sto...

  • Page 27: Introduction

    Om 803 us – edition 3.7 * 803b110.Fm 1-17 introduction meaning the reservoir is hot and under pressure. • allow the fluids to cool down! Carefully and slowly open the cover only after the reservoir has cooled down, to release the pressure. Wear suitable protective clothing and goggles to open the co...

  • Page 28: Introduction

    1-18 om 803 us – edition 3.7 * * 803b110.Fm introduction meaning (from serial no. Ai00825) crushing hazard. • only operate the machine from the operator’s seat. • machine operation is only allowed if the rollbar is raised and locked, and if the seat belt is fastened. • machine operation with the rol...

  • Page 29: Introduction

    Om 803 us – edition 3.7 * 803b110.Fm 1-19 introduction meaning collision hazard. Stay clear of the machine’s slewing range during operation. Position at the rear left meaning crushing hazard. Stay clear of the machine’s slewing range during operation. Position at the front left and right of the chas...

  • Page 30: Introduction

    1-20 om 803 us – edition 3.7 * * 803b110.Fm introduction meaning attention! Severe injury hazard. Explosion hazard. Do not use ether! This machine is equipped with an intake-air preheating system. Using ether can cause explosions or fire, which in turn can cause death or serious injury. Position in ...

  • Page 31: Introduction

    Om 803 us – edition 3.7 * 803b110.Fm 1-21 introduction meaning fuse assignment. Use only original fuses with the specified current rating! Position behind the right-hand trim meaning the coolant must have a thermal stability of –30 °c (–22 °f). – see chapter 6.10 coolant compound table on page 6-9 p...

  • Page 32: Introduction

    1-22 om 803 us – edition 3.7 * * 803b110.Fm introduction.

  • Page 33: Safety Instructions

    Om 803 us – edition 3.7 * 803b210us.Fm 2-1 safety instructions 2 safety instructions 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. Warnung danger danger indicates a h...

  • Page 34: Safety Instructions

    2-2 om 803 us – edition 3.7 * * 803b210us.Fm safety instructions 2.2 warranty warranty claims can be brought forward to your wacker neuson dealer only. Furthermore, the instructions in this operator's manual must be observed. 2.3 disposal all fluids, lubricants, material, etc., used on the machine a...

  • Page 35: Safety Instructions

    Om 803 us – edition 3.7 * 803b210us.Fm 2-3 safety instructions 2.5 preparing to use the machine conditions for use • the machine has been designed and built in accordance with state-of-the-art standards and the recognized safety regulations. Nevertheless, its use can constitute a risk to life and li...

  • Page 36: Safety Instructions

    2-4 om 803 us – edition 3.7 * * 803b210us.Fm safety instructions information on visibility • before putting the machine into operation, perform a visual check to ensure that there are neither persons nor objects or other sources of risk around the machine. • when using the machine, check the surroun...

  • Page 37: Safety Instructions

    Om 803 us – edition 3.7 * 803b210us.Fm 2-5 safety instructions 2.7 safety instructions regarding operation preparing for use • keep the machine clean. This reduces the risk of fire hazards (such as from combus- tible materials like rags), and reduces injury or operational accident hazard that can be...

  • Page 38: Safety Instructions

    2-6 om 803 us – edition 3.7 * * 803b210us.Fm safety instructions job site awareness • 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 bearing capacity • any necessary barriers s...

  • Page 39: Safety Instructions

    Om 803 us – edition 3.7 * 803b210us.Fm 2-7 safety instructions mechanical integrity • 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, s...

  • Page 40: Safety Instructions

    2-8 om 803 us – edition 3.7 * * 803b210us.Fm safety instructions 2.8 operator protection system tops rollbar (up to serial no. Af01416) rops rollbar the machine can be equipped with an optional lowerable tops or rops rollbar. Warnung danger personal injury hazard! In order to ensure the best possibl...

  • Page 41: Safety Instructions

    Om 803 us – edition 3.7 * 803b210us.Fm 2-9 safety instructions shatter protection (option) the optional shatter protection protects the operator against material falling from the front. Warnung danger piercing/penetration hazard by fragments from the front! Causes serious or deadly injuries. • a sha...

  • Page 42: Safety Instructions

    2-10 om 803 us – edition 3.7 * * 803b210us.Fm safety instructions 2.9 applications with lifting gear general information • craning applications are procedures involving raising, transporting and lowering point loads with the help of slings and load-securing devices (for example, ropes and chains). I...

  • Page 43: Safety Instructions

    Om 803 us – edition 3.7 * 803b210us.Fm 2-11 safety instructions • secure the attachments against unintentional movement. Installation notes • before uncoupling or coupling hydraulic lines (hydraulic quick couplers): • stop the engine • release the pressure in the hydraulic system. In order to do so,...

  • Page 44: Safety Instructions

    2-12 om 803 us – edition 3.7 * * 803b210us.Fm safety instructions 2.12 hammer operation • contact your wacker neuson dealer for information on the correct equipment. Safety instructions • if there is a risk of falling or projected objects, an operator safety shield must be installed. • during operat...

  • Page 45: Safety Instructions

    Om 803 us – edition 3.7 * 803b210us.Fm 2-13 safety instructions 2.13 transport and towing towing • the machine must be towed according to the procedures described within this operator's manual. • observe the prescribed transport position, admissible speed and itinerary. Transporting • the machine mu...

  • Page 46: Safety Instructions

    2-14 om 803 us – edition 3.7 * * 803b210us.Fm safety instructions personal safety measures • brief the technician and the operator before beginning special operations, repair work and maintenance. Appoint a person to supervise the activities. • observe the specific safety instructions in the mainten...

  • Page 47: Safety Instructions

    Om 803 us – edition 3.7 * 803b210us.Fm 2-15 safety instructions • 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 and repair work beneath a raised mach...

  • Page 48: Safety Instructions

    2-16 om 803 us – edition 3.7 * * 803b210us.Fm safety instructions • 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 incorpo- rated in the system to prevent damage from malfunction or short...

  • Page 49: Safety Instructions

    Om 803 us – edition 3.7 * 803b210us.Fm 2-17 safety instructions gas, dust, steam, smoke • operate the machine only on adequately ventilated premises. Before starting internal combustion engines or operating fuel-operated heating systems on enclosed premises, ensure that there is sufficient ventilati...

  • Page 50: Safety Instructions

    2-18 om 803 us – edition 3.7 * * 803b210us.Fm safety instructions • check track tension at regular intervals..

  • Page 51: Safety Instructions

    Om 803 us – edition 3.7 * 803b210us.Fm 2-19 safety instructions battery california proposition 65 warning battery posts, terminals and related accessories contain lead and lead compounds, chem- icals known to the state of california to cause cancer and reproductive harm. Wash hands after handling • ...

  • Page 52: Safety Instructions

    2-20 om 803 us – edition 3.7 * * 803b210us.Fm safety instructions • do not remove the radiator cap when engine is running or hot. The radiator fluid is hot and under pressure, and may cause severe burns. Fueling the engine when fueling the engine: • clean up any spilled fuel immediately. • refill th...

  • Page 53: Safety Instructions

    Om 803 us – edition 3.7 * 803b210us.Fm 2-21 safety instructions • do not travel across hydraulic hoses. • the protective hoses must be located on the exavator side of the hydraulic hose and must not be removed. • do not squeeze hydraulic hoses. • do not put hydraulic hoses over edges. • do not put a...

  • Page 54: Safety Instructions

    2-22 om 803 us – edition 3.7 * * 803b210us.Fm safety instructions.

  • Page 55: Operation

    Om 803 us – edition 3.7 * 803b320.Fm 3-1 operation 3 operation this chapter describes the controls, and contains information on the function and handling of the indicator lights and controls on the control stand. The pages stated in the table refer to the description of the controls. A combination o...

  • Page 56: Operation

    3-2 om 803 us – edition 3.7 * * 803b320.Fm operation 3.1 control stand overview (up to serial no. Ai00814) 1 3 9 8 2 7 6 4 5.

  • Page 57: Operation

    Om 803 us – edition 3.7 * 803b320.Fm 3-3 operation pos. Description for more information see page 1 operator seat .....................................................................................................................................................................3-28 2 upper carriage...

  • Page 58: Operation

    3-4 om 803 us – edition 3.7 * * 803b320.Fm operation 10 11 12 13 14 15 16 17 18 6 pos. Description for more information see page 10 auxiliary hydraulics pedal ................................................................................................................................................

  • Page 59: Operation

    Om 803 us – edition 3.7 * 803b320.Fm 3-5 operation 3.2 control stand overview (from serial no. Ai00815) 4 6 1 2 3 5 7 8 10 11 11 12 13 14 15 16 17 9 18 19 pos. Description for more information see page 1 operator seat .....................................................................................

  • Page 60: Operation

    3-6 om 803 us – edition 3.7 * * 803b320.Fm operation 3.3 display elements (overview) 20 24 22 21 23 pos. Description for more information see page 20 indicator light (red) – alternator charge function ......................................................................................................

  • Page 61: Operation

    Om 803 us – edition 3.7 * 803b320.Fm 3-7 operation 3.4 putting into operation information! Machine operation is only allowed when seated on the seat. Safety instructions • always use the climbing aids when climbing aboard the machine – see chapter 3.8 access to the control stand on page 3-28. • neve...

  • Page 62: Operation

    3-8 om 803 us – edition 3.7 * * 803b320.Fm operation check lists 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 du...

  • Page 63: Operation

    Om 803 us – edition 3.7 * 803b320.Fm 3-9 operation operation checklist after starting the engine, check and observe the following points: “parking” checklist check and observe the following points when parking the machine: no. Question ✔ 1 indicator light for engine and coolant temperature gone out?...

  • Page 64: Operation

    3-10 om 803 us – edition 3.7 * * 803b320.Fm operation 3.5 machine travel starter throttle speed is set continuously with throttle 13 . ➥ position a : idling speed ➥ position b : max. Engine speed 1 0 2 3 fig. 49: preheating start switch 4 position function power consumer 0 insert or remove the start...

  • Page 65: Operation

    Om 803 us – edition 3.7 * 803b320.Fm 3-11 operation traveling signal (option) a traveling signal sounds as soon as at least one of the tracks moves. Warning! Warning accident hazard during forward/backward machine travel. Serious crushing hazard causing death or serious injury. • do not allow anyone...

  • Page 66: Operation

    3-12 om 803 us – edition 3.7 * * 803b320.Fm operation indicator light (red) – coolant temperature danger never open the radiator and never drain coolant if the engine is warm since the cooling system is under high pressure – burn hazard! Can cause serious injury or death. • wait at least 10 minutes ...

  • Page 67: Operation

    Om 803 us – edition 3.7 * 803b330.Fm 3-13 operation before starting the engine: ☞ adjust your seating position – see seat adjustment on page 3-28 information! All controls must be within easy reach and you must be able to move them to the limit! Information! Operate the machine only on adequately ve...

  • Page 68: Operation

    3-14 om 803 us – edition 3.7 * * 803b330.Fm operation ☞ check whether all indicator lights are on ☞ have malfunctioning indicator lights immediately replaced ☞ turn the starting key to position 2 and hold it in this position for about 5 seconds ➥ engine is preheated ☞ turn and hold the starting key ...

  • Page 69: Operation

    Om 803 us – edition 3.7 * 803b330.Fm 3-15 operation jump-starting the engine (supply battery) safety instructions • never jump-start the engine if the battery of the machine is frozen – explosion hazard! ☞ dispose of a frozen battery! • the excavator must not touch the jump-starting vehicle when con...

  • Page 70: Operation

    3-16 om 803 us – edition 3.7 * * 803b330.Fm operation special instructions for traveling on public roads traveling on public roads is prohibited. Travel position • position the machine as shown. • position the boom at the center and raise it about 20 to 30 cm (8 – 12 in) off the ground. Information!...

  • Page 71: Operation

    Om 803 us – edition 3.7 * 803b330.Fm 3-17 operation the travel movements of the machine are controlled with the travel levers. Lock the upper carriage when traveling over longer distances. Forward or reverse travel speed depends on the position of the travel levers and on the engine speed. Informati...

  • Page 72: Operation

    3-18 om 803 us – edition 3.7 * * 803b330.Fm operation hydraulic brake the travel levers automatically return to their initial positions as soon as they are released. This creates sufficient hydraulic braking effect. When traveling downhill, the automatic hydraulic brake valves prevent the machine fr...

  • Page 73: Operation

    Om 803 us – edition 3.7 * 803b330.Fm 3-19 operation 3.7 machine travel on slopes warning! Warning accident hazard due to tipping over or slipping of machine! Can cause serious injury or death. • travel on slopes only on firm and level ground. • travel on slopes only with the telescopic travel gear e...

  • Page 74: Operation

    3-20 om 803 us – edition 3.7 * * 803b330.Fm operation information! Traveling diagonally on slopes is prohibited. Change position on level ground and then travel straight-ahead onto the slope. Traveling uphill during uphill travel, the control stand must face uphill. Set the stabilizer blade uphill. ...

  • Page 75: Operation

    Om 803 us – edition 3.7 * 803b330.Fm 3-21 operation lateral angle of inclination do not exceed a maximum lateral angle of inclination of 10°. On lateral inclinations over 10°, pile up material to create a level surface that can be used as a platform for the machine. Fig. 64: lateral angle of inclina...

  • Page 76: Operation

    3-22 om 803 us – edition 3.7 * * 803b330.Fm operation stabilizer blade operation warning! Warning injury hazard due to operation of stabilizer blade lever! Can cause serious injury or death. • raising the lock lever does not prevent the stabilizer blade from being lowered. • keep out of the danger z...

  • Page 77: Operation

    Om 803 us – edition 3.7 * 803b330.Fm 3-23 operation reducing the width of the stabilizer blade ☞ raise the stabilizer blade to about 1 – 2 cm (about 0.4 – 0.8 in). ☞ pull out pins a on either side. ☞ turn in the stabilizer blade extensions b on either side. ☞ insert pins a on either side. Increasing...

  • Page 78: Operation

    3-24 om 803 us – edition 3.7 * * 803b330.Fm operation telescopic travel gear warning! Warning injury hazard due to tipping over of machine! Can cause serious injury or death. • only perform work with an extended telescopic travel gear. • traveling with a retracted telescopic travel gear is only allo...

  • Page 79: Operation

    Om 803 us – edition 3.7 * 803b330.Fm 3-25 operation ☞ move lever 6 to the final right-hand position ☞ raise the machine evenly and horizontally by means of the boom and the stabilizer blade ☞ the telescopic travel gear is controlled via control lever 5 : information! Push or pull lever 5 until the t...

  • Page 80: Operation

    3-26 om 803 us – edition 3.7 * * 803b330.Fm operation parking the machine warning! Warning accident hazard due to incorrect parking! Can cause serious injury or death. • park the machine on level ground • press the boom and the stabilizer blade against the ground • secure the tracks accordingly (cho...

  • Page 81: Operation

    Om 803 us – edition 3.7 * 803b330.Fm 3-27 operation light system the working light is located on the right on the boom. The working light can be switched on with switch a as soon as the starting key is in position “1”. The switch has several positions and can be turned. Therefore continue turning sw...

  • Page 82: Operation

    3-28 om 803 us – edition 3.7 * * 803b330.Fm operation seat adjustment warning! Warning accident hazard when adjusting the operator seat during machine operation! Can cause serious injury or death. • adjust the correct seating position. • do not adjust the operator seat during operation. Horizontal a...

  • Page 83: Operation

    Om 803 us – edition 3.7 * 803b330.Fm 3-29 operation ☞ use handhold a . ☞ use handhold a . Telescopically extended travel gear ☞ use handhold a . A fig. 79: footholds fig. 80: rops handles a a fig. 81: footholds and handles with a telescopically extended travel gear.

  • Page 84: Operation

    3-30 om 803 us – edition 3.7 * * 803b330.Fm operation 3.9 lowerable tops rollbar (up to serial no. Ai00966) (option) warning! Warning accident hazard when operating the machine with a lowered rollbar! Can cause serious injury or death. • machine operation is only allowed if the rollbar is raised and...

  • Page 85: Operation

    Om 803 us – edition 3.7 * 803b330.Fm 3-31 operation ☞ remove the lock nuts and screws a on either side ☞ slowly and carefully lower the rollbar raising the rollbar ☞ stop the machine on firm, level and horizontal ground ☞ stop the engine ☞ raise the lock lever ☞ remove the starting key information! ...

  • Page 86: Operation

    3-32 om 803 us – edition 3.7 * * 803b330.Fm operation 3.10 lowerable rops rollbar (up to serial no. Ai00966) (option) warning! Warning accident hazard when operating the machine with a lowered rollbar! Can cause serious injury or death. • machine operation is only allowed if the rollbar is raised an...

  • Page 87: Operation

    Om 803 us – edition 3.7 * 803b330.Fm 3-33 operation notice replace the lock nuts every time they are loosened. Raising the rollbar ☞ stop the machine on firm, level and horizontal ground ☞ stop the engine ☞ raise the lock lever ☞ remove the starting key information! In order to raise it, the rollbar...

  • Page 88: Operation

    3-34 om 803 us – edition 3.7 * * 803b330.Fm operation 3.11 lowerable rops rollbar (from serial no. Ai00967) (option) warning! Warning accident hazard when operating the machine with a lowered rollbar! Can cause serious injury or death. • machine operation is only allowed if the rollbar is raised and...

  • Page 89: Operation

    Om 803 us – edition 3.7 * 803b330.Fm 3-35 operation ☞ remove the starting key information! In order to lower it, the rollbar must be held by one person on either side. ☞ remove the linch pins and bolts b on either side ☞ slowly and carefully lower the rollbar as far as it will go raising the rollbar...

  • Page 90: Operation

    3-36 om 803 us – edition 3.7 * * 803b330.Fm operation ☞ install the linch pins and bolts b on either side rotating beacon bracket bracket p for installing a rotating beacon is located on top of the rollbar. Fig. 89: lowering the rollbar b fig. 90: rotating beacon bracket p.

  • Page 91: Operation

    Om 803 us – edition 3.7 * 803b330.Fm 3-37 operation seat belt (option) seat belt (up to serial no. Ai01200) warning! Warning injury hazard when operating the machine without fastening the seat belt! Can cause serious injury or death. • operating the machine without fastening the seat belt is prohibi...

  • Page 92: Operation

    3-38 om 803 us – edition 3.7 * * 803b330.Fm operation seat belt c is for the operator’s safety. Fastening the seat belt: ☞ fasten the seat belt as follows before starting 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 ...

  • Page 93: Operation

    Om 803 us – edition 3.7 * 803b330.Fm 3-39 operation retracting seat belt (from serial no. Ai01201)) warning! Warning injury hazard when operating the machine without fastening the seat belt! Can cause serious injury or death. • operating the machine without fastening the seat belt is prohibited unde...

  • Page 94: Operation

    3-40 om 803 us – edition 3.7 * * 803b330.Fm operation the retracting seat belt c is for the operator’s safety. Fastening the retracting seat belt: ☞ fasten the retracting seat belt as follows before starting the machine: • hold belt on buckle latch a and run it slowly and steadily over the hips to b...

  • Page 95: Operation

    Om 803 us – edition 3.7 * 803b330.Fm 3-41 operation engine cover warning! Warning injury hazard due to rotating parts! Can cause serious injury or death. • open the engine cover only at engine standstill! • ensure that no one is injured by the open engine cover. • raise the lock lever • remove the s...

  • Page 96: Operation

    3-42 om 803 us – edition 3.7 * * 803b330.Fm operation opening the engine cover ☞ unlock and open the engine cover. ☞ let the engine cover engage in position a . • it is locked by letting curved rail b engage in position a . Close the engine cover ☞ unlock the engine cover. • it is unlocked by raisin...

  • Page 97: Operation

    Om 803 us – edition 3.7 * 803b330.Fm 3-43 operation towing the machine warning! Warning accident hazard due to towing! Can cause serious injury or death. • the machine may only be towed using suitable towing equipment (towing bar or cable) in connection with suitable towing facilities, such as a tow...

  • Page 98: Operation

    3-44 om 803 us – edition 3.7 * * 803b330.Fm operation lifting the machine warning! Warning accident hazard due to incorrect loading! Can cause serious injury or death. • ensure that no one is near the machine! • have loads fastened and crane operators guided by experienced persons only! The person g...

  • Page 99: Operation

    Om 803 us – edition 3.7 * 803b330.Fm 3-45 operation 1 fit an empty standard bucket and lock it safely. 2 empty the standard bucket or remove the attachment. 3 remove all dirt from the machine. 4 park the machine on firm, level and horizontal ground. 5 curl the standard bucket and lower it to transpo...

  • Page 100: Operation

    3-46 om 803 us – edition 3.7 * * 803b330.Fm operation loading and transporting the machine safety instructions • the transport vehicle must be of adequate size – refer to chapter 6 “technical data” for the machine’s dimensions and weights! • remove dirt (mud, snow, ice, for example) from the tracks ...

  • Page 101: Operation

    Om 803 us – edition 3.7 * 803b330.Fm 3-47 operation tying down the machine warning! Warning accident hazard due to incorrect loading or transportation! Can cause serious injury or death. • it is essential that you read the safety instructions at the beginning of this chapter and follow any other saf...

  • Page 102: Operation

    3-48 om 803 us – edition 3.7 * * 803b330.Fm operation 3.12 shatter protection (option) (from serial no. Ai00967) danger piercing/penetration hazard by objects from the front! Causes serious injury or death. • a shatter protection must be installed on a canopy version if an attachment (a hammer, for ...

  • Page 103: Operation

    Om 803 us – edition 3.7 * 803b330.Fm 3-49 operation installing (up to the 2nd quarter of 2014) 1 follow the safety instructions for assembly – see chapter parking the machine on page 3-26. 2 lower the boom to the ground. 3 stop the engine 4 raise the lock lever – see chapter lock lever (up to serial...

  • Page 104: Operation

    3-50 om 803 us – edition 3.7 * * 803b340.Fm operation 3 3.13 machine operation general safety instructions • machine operation is only allowed when seated on the seat – see chapter 2.6  safety instructions regarding operation  on page 2-6. • do not use the machine in areas with falling o...

  • Page 105: Operation

    Om 803 us – edition 3.7 * 803b340.Fm 3-51 operation • operation of the machine by unauthorized personnel is prohibited! • look out for high-voltage cables, underground cables, gas and water pipes during excavation work! • the hydraulic system of the machine is still pressurized even when the engine ...

  • Page 106: Operation

    3-52 om 803 us – edition 3.7 * * 803b340.Fm operation 3.14 control lever overview information! Moving a control lever quickly causes the corresponding function to be per- formed quickly. Moving a control lever slowly causes the corresponding func- tion to be performed slowly. Left-hand control lever...

  • Page 107: Operation

    Om 803 us – edition 3.7 * 803b340.Fm 3-53 operation 3.15 boom swivel controls warning! Warning injury hazard when operating the boom swivel mechanism! Can cause serious injury or death. • the boom swivel function cannot be locked. • press the pedal carefully, otherwise the boom is actuated earlier t...

  • Page 108: Operation

    3-54 om 803 us – edition 3.7 * * 803b340.Fm operation swiveling the boom to the right: ☞ press the rear half of the right-hand pedal ➥ boom swivels to the right boom swivel controls (from serial no. Ai00976) warning! Warning injury hazard when operating the boom swivel mechanism! Can cause serious i...

  • Page 109: Operation

    Om 803 us – edition 3.7 * 803b340.Fm 3-55 operation swiveling the boom to the right: ☞ press the rear half of the right-hand pedal ➥ boom swivels to the right 3.16 auxiliary hydraulics warning! Warning injury hazard due to auxiliary hydraulics operation! Can cause serious injury or death. • the auxi...

  • Page 110: Operation

    3-56 om 803 us – edition 3.7 * * 803b340.Fm operation auxiliary hydraulics (from serial no. Ai00976) warning! Warning injury hazard due to auxiliary hydraulics operation! Can cause serious injury or death. • the pedal is secured with a torsion spring. The pedal flips forward when it is released, but...

  • Page 111: Operation

    Om 803 us – edition 3.7 * 803b340.Fm 3-57 operation auxiliary hydraulics (double-action option) (up to serial no. Ai00975) warning! Warning injury hazard due to auxiliary hydraulics operation! Can cause serious injury or death. • in order to minimize the risk of unintentional operation, flip the ped...

  • Page 112: Operation

    3-58 om 803 us – edition 3.7 * * 803b340.Fm operation actuating the auxiliary hydraulics: ☞ the left-hand pedal can be pressed forward or backward ➥ oil flows through the auxiliary hydraulics line auxiliary hydraulics (double-action option) (from serial no. Ai00976) warning! Warning injury hazard du...

  • Page 113: Operation

    Om 803 us – edition 3.7 * 803b340.Fm 3-59 operation hammer operation enabled ➥ oil flows to the hammer through the pressure line and to the reservoir through the return line. Grab operation enabled • standard: press the pedal backward – the grab rotates to the left. • standard: press the pedal forwa...

  • Page 114: Operation

    3-60 om 803 us – edition 3.7 * * 803b340.Fm operation emergency lowering warning! Warning crushing hazard during boom lowering! Can cause serious injury or death. • ensure that no one is in the danger zone. Information! Lower the boom immediately after stopping the engine. Observe the following duri...

  • Page 115: Operation

    Om 803 us – edition 3.7 * 803b340.Fm 3-61 operation rotating the upper carriage specific safety instructions warning! Warning accident hazard due to possible farther rotation of the upper carriage in cold operating state! Can cause serious injury or death. • until the hydraulic fluid reaches operati...

  • Page 116: Operation

    3-62 om 803 us – edition 3.7 * * 803b340.Fm operation 3.17 lock lever warning! Warning crushing hazard due to unexpected movements of the machine or attachments! Can cause serious injury or death. • raise the lock lever before leaving the machine. • locking the lock lever makes it impossible to perf...

  • Page 117: Operation

    Om 803 us – edition 3.7 * 803b340.Fm 3-63 operation 3.18 dual power (option) dual power enables zero-emission working by means of an electrohydraulic power unit (wacker neuson hpu8) or conventional working with the diesel engine. If the machine is equipped with the dual power option, hydraulic hoses...

  • Page 118: Operation

    3-64 om 803 us – edition 3.7 * * 803b340.Fm operation overview of connections notice possible damage to the hydraulic system. • always couple and uncouple in the correct boom and stabilizer-blade posi- tion – see coupling on page 3-65. • before coupling or uncoupling hydraulic hoses, stop the power ...

  • Page 119: Operation

    Om 803 us – edition 3.7 * 803b340.Fm 3-65 operation coupling 1 put the excavator and the power unit on firm, level and horizontal ground. 2 position the upper carriage as shown. The stabilizer blade must be at the rear. 3 lower the stabilizer blade to the ground – see fig. 45 . 4 position the bucket...

  • Page 120: Operation

    3-66 om 803 us – edition 3.7 * * 803b340.Fm operation 13 connect the hydraulic hose connections d to the power unit. Caution injury hazard due to sharp-edged objects! Can cause injury. • wear protective gloves when coupling and uncoupling the hydraulic con- nections of the power unit. Information! P...

  • Page 121: Operation

    Om 803 us – edition 3.7 * 803b340.Fm 3-67 operation checking the hydraulic oil levels of the power unit and excavator check the hydraulic oil levels before starting the power unit. Notice possible damage to power unit or excavator. • check the hydraulic oil levels before starting and observe the fol...

  • Page 122: Operation

    3-68 om 803 us – edition 3.7 * * 803b340.Fm operation changeover from hpu to diesel operation notice possible damage to the excavator if the diesel engine is started in the hpu position. • stop the diesel engine and change over from hpu to diesel operation. Key a for changing over between hpu and di...

  • Page 123: Operation

    Om 803 us – edition 3.7 * 803b340.Fm 3-69 operation changeover from diesel to hpu operation key a for changing over between hpu and diesel operation is located in the document box behind the operator seat. 1 stop the diesel engine: turn the starting key to position 0 . 2 insert key a and turn it clo...

  • Page 124: Operation

    3-70 om 803 us – edition 3.7 * * 803b340.Fm operation uncoupling caution possible injury hazard due to sharp-edged objects! Can cause injury. • wear protective gloves when uncoupling the hydraulic connections of the power unit. Notice possible damage to power unit or excavator. • always couple and u...

  • Page 125: Operation

    Om 803 us – edition 3.7 * 803b340.Fm 3-71 operation charging the excavator battery the excavator battery is not charged because the diesel engine does not during excavator opera- tion with the zero-emission power unit. Charging the battery regularly is therefore necessary. Danger explosion hazard in...

  • Page 126: Operation

    3-72 om 803 us – edition 3.7 * * 803b340.Fm operation information! Only operate battery chargers with the same specifications as the one sup- plied with the power unit. Observe the operator’s manual of the battery charger. Contact a wacker neuson service center in case of doubt. The battery charger ...

  • Page 127: Operation

    Om 803 us – edition 3.7 * 803b340.Fm 3-73 operation charging the battery with the power unit turn protective cap c counterclockwise and remove it. Connect safety connector d of the battery charger with the accessories outlet e of the power unit. Charging the battery with the mains connect safety con...

  • Page 128: Operation

    3-74 om 803 us – edition 3.7 * * 803b340.Fm operation dual-power operation with rotating beacon the rotating beacon must be supplied with external power in countries or regions where a rotating beacon is mandatory during excavator operation. Connect rotating beacon a to the external power supply b ....

  • Page 129: Operation

    Om 803 us – edition 3.7 * 803b340.Fm 3-75 operation 3.19 pressure release on the auxiliary hydraulics notice before connecting or removing hydraulic lines from an attachment with hydraulic functions, ensure that the hydraulics are not under pressure! Ensure that no one is in the danger zone of the m...

  • Page 130: Operation

    3-76 om 803 us – edition 3.7 * * 803b340.Fm operation specific safety instructions • driving in pins with a plastic hammer can cause them to splinter, which can cause serious injury. ☞ always wear goggles, a hard hat, protective gloves, safety shoes and other suitable protective clothing. • do not s...

  • Page 131: Operation

    Om 803 us – edition 3.7 * 803b340.Fm 3-77 operation installing a bucket • install a bucket only if it is positioned on level ground with the flat side facing downward • apply grease to the pins and joints before inserting the pins • start the engine • straighten the stick so that bores d and e are f...

  • Page 132: Operation

    3-78 om 803 us – edition 3.7 * * 803b340.Fm operation connections for auxiliary hydraulics (stick hose routing option) auxiliary hydraulics can be connected as required. If the machine is equipped with the double-action auxiliary hydraulics option, only the flow direction of the hydraulic oil change...

  • Page 133: Operation

    Om 803 us – edition 3.7 * 803b340.Fm 3-79 operation attachments information! Please refer to the operator’s and maintenance manual of the attachment manufacturer for using and performing maintenance on attachments such as hammers, etc. Information! Check the auxiliary hydraulics pedal for correct fu...

  • Page 134: Operation

    3-80 om 803 us – edition 3.7 * * 803b340.Fm operation avoid impact during operation to avoid damage to the excavator bucket and machine components ☞ do not use the machine’s falling force for excavating, and do not use the bucket’s fall- ing force as a hoe, hammer or pile-driver. ➥ working this way ...

  • Page 135: Operation

    Om 803 us – edition 3.7 * 803b340.Fm 3-81 operation bucket position when digging ☞ move the bucket as shown in a . ➥ move the flat side of the bucket parallel to the ground. Information! Position b causes the bucket to penetrate into the ground. Work slows down, and the engine and the hydraulic pump...

  • Page 136: Operation

    3-82 om 803 us – edition 3.7 * * 803b340.Fm operation grading • use the stabilizer blade to fill in trenches and to grade (even out) surfaces. Information! Work on level ground. Grade (even out) with the stabilizer blade first in case of sloping ground. Excavating trenches sideways • the machine can...

  • Page 137: Operation

    Om 803 us – edition 3.7 * 803b340.Fm 3-83 operation 3.21 grading warning! Warning accident hazard when grading! Can cause serious injury or death. • ensure that no one is in the danger zone when working with the stabilizer blade grading ☞ lower the stabilizer blade to the ground – see chapter stabil...

  • Page 138: Operation

    3-84 om 803 us – edition 3.7 * * 803b340.Fm operation working alongside trenches notice possible boom damage 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 • ensure tha...

  • Page 139: Malfunctions

    Om 803 us – edition 3.7 * 803b410.Fm 4-1 malfunctions 4 malfunctions the information given in this chapter is provided for maintenance personnel, for fast and reliable detection of malfunctions and their appropriate repair. Repairs must only be performed by authorized personnel. 4.1 engine trouble p...

  • Page 140: Malfunctions

    4-2 om 803 us – edition 3.7 * * 803b410.Fm malfunctions insufficient engine output oil level too high 5-7 fuel grade does not comply with specifications 5-35 dirty air filter 5-12 wrong valve clearance injection line leaks malfunctioning injection nozzle engine does not run on all cylinders malfunct...

  • Page 141: Maintenance

    Om 803 us – edition 3.7 * 803b510.Fm 5-1 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 mandatory maintenance bear in mind the following points...

  • Page 142: Maintenance

    5-2 om 803 us – edition 3.7 * * 803b510.Fm maintenance 5.2 fuel system specific safety instructions warning! Warning burn hazard when refueling! Can cause serious injury or death. • fire, open flames and smoking is prohibited. • keep the maintenance area clean. • do not refuel in closed rooms. • do ...

  • Page 143: Maintenance

    Om 803 us – edition 3.7 * 803b510.Fm 5-3 maintenance refueling filler inlet a for the fuel tank is located in the engine compartment, on the left in traveling direc- tion. Environment! Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner! ...

  • Page 144: Maintenance

    5-4 om 803 us – edition 3.7 * * 803b510.Fm maintenance refueling from barrels if refueling from barrels cannot be avoided, note the following points (see fig. 189): • barrels must neither be rolled nor tilted before refueling • protect the suction pipe opening of the barrel pump with a fine-mesh scr...

  • Page 145: Maintenance

    Om 803 us – edition 3.7 * 803b510.Fm 5-5 maintenance fuel prefilter with water separator interrupt the 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 check the fuel prefilter as follows: ☞ if t...

  • Page 146: Maintenance

    5-6 om 803 us – edition 3.7 * * 803b510.Fm maintenance 5.3 engine lubrication system information! 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. Notice in order to avoid engine damage, use th...

  • Page 147: Maintenance

    Om 803 us – edition 3.7 * 803b510.Fm 5-7 maintenance checking the oil level • park the machine on level ground • stop the engine • raise the lock lever • remove the starting key • let the engine cool down • open the engine cover • clean the area around the oil dipstick with a lint-free cloth • oil d...

  • Page 148: Maintenance

    5-8 om 803 us – edition 3.7 * * 803b510.Fm maintenance 5.4 engine cooling system the radiator is located in the engine compartment, on the right-hand side of the engine, and cools the diesel engine. The coolant reservoir is also located in the engine compartment, behind the engine specific safety in...

  • Page 149: Maintenance

    Om 803 us – edition 3.7 * 803b510.Fm 5-9 maintenance • dirt on the radiator fins reduces the radiator’s heat dissipation capacity! To avoid this: ☞ clean the outside of the radiator at regular intervals. Use oil-free compressed air (2 bar max.) to clean. Maintain a certain distance from the radiator...

  • Page 150: Maintenance

    5-10 om 803 us – edition 3.7 * * 803b510.Fm maintenance checking the coolant level/adding coolant checking the coolant level • park the machine on level ground • stop the engine • raise the lock lever • remove the starting key and carry it with you • let the engine and the coolant cool down • open t...

  • Page 151: Maintenance

    Om 803 us – edition 3.7 * 803b510.Fm 5-11 maintenance information! Check the antifreeze every year before the cold season sets in cleaning the radiator information! Dirt on the radiator fins reduces the radiator’s heat dissipation capacity and can cause damage to the diesel engine! • check and if ne...

  • Page 152: Maintenance

    5-12 om 803 us – edition 3.7 * * 803b520.Fm maintenance 5.5 air filter notice the filter elements will be damaged if they are washed or brushed out! Bear in mind the following to avoid premature engine wear or damage: • do not clean the filter elements. • replace the air filter element according to ...

  • Page 153: Maintenance

    Om 803 us – edition 3.7 * 803b520.Fm 5-13 maintenance air filter (up to serial no. Ai00875) replace the air filter elements: • if the yellow piston b in dirt indicator a reaches the red service mark c . • every 1000 operating hours or once a year at the latest. General instructions for air filter ma...

  • Page 154: Maintenance

    5-14 om 803 us – edition 3.7 * * 803b520.Fm maintenance air filter (from serial no. Ai00876) replacing air filter elements replace the air filter elements: • if the yellow piston b in dirt indicator a reaches the red service mark c . • every 1000 operating hours or once a year at the latest. 1 park ...

  • Page 155: Maintenance

    Om 803 us – edition 3.7 * 803b520.Fm 5-15 maintenance 5.6 v-belt warning! Warning injury hazard when checking the v-belt tension! Can cause serious injury or death. • stop the engine before performing inspection work in the engine compartment • raise the lock lever • remove the starting key • discon...

  • Page 156: Maintenance

    5-16 om 803 us – edition 3.7 * * 803b520.Fm maintenance 5.7 hydraulic system important information on the hydraulic system danger burn hazard during maintenance on a hot engine and hydraulic system! Can cause serious injury or death. • wait at least 10 minutes after stopping the engine. • wear prote...

  • Page 157: Maintenance

    Om 803 us – edition 3.7 * 803b520.Fm 5-17 maintenance checking the hydraulic oil level 1 park the machine on firm, level and horizontal ground. 2 position the boom straight ahead at the center of the machine (see figure). 3 lower the boom and the stabilizer blade to the ground. 4 stop the engine. 5 ...

  • Page 158: Maintenance

    5-18 om 803 us – edition 3.7 * * 803b520.Fm maintenance important information on the use of biodegradable oil • use only the biodegradable hydraulic fluids that have been tested and released by wacker neuson. Always contact a wacker neuson dealer before using other products that have not been recomm...

  • Page 159: Maintenance

    Om 803 us – edition 3.7 * 803b520.Fm 5-19 maintenance checking hydraulic pressure lines specific safety instructions warning! Warning injury hazard when checking hydraulic pressure lines! Can cause serious injury or death. • wear protective gloves and safety glasses. • search for hydraulic leaks wit...

  • Page 160: Maintenance

    5-20 om 803 us – edition 3.7 * * 803b520.Fm maintenance 5.8 overview of lubrication points 1 1 2 2 3 3 4 4 8 8 7 9 10 10 12 11 5 5 6 6 13.

  • Page 161: Maintenance

    Om 803 us – edition 3.7 * 803b520.Fm 5-21 maintenance information! Keep the lubrication points clean and remove ejected grease. Parking the machine ☞ park the machine on level and horizontal ground. ☞ lower the boom and the attachment to the ground. ☞ lower the stabilizer blade to the ground. ☞ stop...

  • Page 162: Maintenance

    5-22 om 803 us – edition 3.7 * * 803b520.Fm maintenance ☞ a further lubrication point is located on the right on the swiveling console. ☞ apply grease to lubrication point 10 with a grease gun. ☞ remove ejected grease. Lubricating the live ring (ball bearing) danger crushing hazard! Do not rotate th...

  • Page 163: Maintenance

    Om 803 us – edition 3.7 * 803b520.Fm 5-23 maintenance lubricating the teeth of the live ring danger crushing hazard! Do not rotate the upper carriage during lubrication. Serious crushing hazard causing death or serious injury. • stop and park the machine – see chapter parking the machine on page 5-2...

  • Page 164: Maintenance

    5-24 om 803 us – edition 3.7 * * 803b520.Fm maintenance ball sockets (iso/sae changeover option) ☞ stop and park the machine. ☞ raise covers 1 . ☞ slide the knurled sleeve 13 upward, and hold, unhitch and grease it. The sleeve is safely locked if it is firmly connected with the ball pin and if it is...

  • Page 165: Maintenance

    Om 803 us – edition 3.7 * 803b530.Fm 5-25 maintenance 5.9 tracks track wear can vary according to work and ground conditions. Checking track tension danger crushing hazard when working under the machine! Causes serious injury or death. • ensure that no one is in the danger zone! • support the machin...

  • Page 166: Maintenance

    5-26 om 803 us – edition 3.7 * * 803b530.Fm maintenance tightening the tracks warning! Warning injury hazard due to grease escaping under pressure! Can cause serious injury or death. • wear protective gloves and safety glasses. • open the lubricating valve only very carefully and do not unscrew it m...

  • Page 167: Maintenance

    Om 803 us – edition 3.7 * 803b530.Fm 5-27 maintenance tightening the tracks ☞ inject grease with a grease gun through lubricating valve a . ☞ check the tension is correct by lowering the machine to the ground, starting the engine, letting it run at idling speed without any load and slowly moving the...

  • Page 168: Maintenance

    5-28 om 803 us – edition 3.7 * * 803b530.Fm maintenance 5.11 electrical system specific safety instructions • use only 12 v power sources. Higher voltages will damage the electrical components. • when connecting the battery leads, ensure that the poles +/ − are not inverted, otherwise sensitive elec...

  • Page 169: Maintenance

    Om 803 us – edition 3.7 * 803b530.Fm 5-29 maintenance instructions concerning specific components cables, lamps and fuses always observe the following instructions: • malfunctioning components of the electrical system must always be replaced by a wacker neuson service center. Lamps and fuses may be ...

  • Page 170: Maintenance

    5-30 om 803 us – edition 3.7 * * 803b530.Fm maintenance battery warning! Warning battery acid is highly caustic! Caustic injury hazard due to battery acid! Can cause serious injury or death. • always wear safety glasses and protective clothing with long sleeves. If acid is spilt: • thoroughly rinse ...

  • Page 171: Maintenance

    Om 803 us – edition 3.7 * 803b530.Fm 5-31 maintenance 5.12 general maintenance cleaning cleaning the machine is divided into 2 separate areas: • exterior of the machine • engine compartment the wrong choice of cleaning equipment and agents can impair the operating safety of the machine on the one ha...

  • Page 172: Maintenance

    5-32 om 803 us – edition 3.7 * * 803b530.Fm maintenance control stand notice never use high-pressure cleaners, steam jets or high-pressure water to clean the control stand. Water under high pressure can • penetrate into the electrical system and cause short circuits and • damage seals and disable th...

  • Page 173: Maintenance

    Om 803 us – edition 3.7 * 803b530.Fm 5-33 maintenance threaded fittings and attachments all threaded fittings must be checked regularly for tightness, even if they are not listed in the maintenance schedules. This applies in particular to: ☞ engine fastening screws ☞ fastening screws on the hydrauli...

  • Page 174: Maintenance

    5-34 om 803 us – edition 3.7 * * 803b530.Fm maintenance 5.14 maintenance if the machine is out of service for a longer period of time the following measures must be taken if the machine is out of service for more than 30 days. Putting into operation again • remove anticorrosion agent from the piston...

  • Page 175: Maintenance

    Om 803 us – edition 3.7 * 803b530.Fm 5-35 maintenance 5.15 fluids and lubricants component/application fluid/lubricant specification season/ temperature capacities 1 1. The capacities indicated are approximate values; the oil level check alone is relevant for the correct oil level capacities indicat...

  • Page 176: Maintenance

    5-36 om 803 us – edition 3.7 * * 803b530.Fm maintenance oil grades for the diesel engine, depending on temperature engine oil grade ambient temperature (°c) °c -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 sae 10w sae 20w sae 10w-30 api: cg-4/ch-4/ ci-4 acea: e3, e4, e5 sae 10w-40 sae 15w-40 sae 20 sae 30...

  • Page 177: Maintenance

    Om 803 us – edition 3.7 * 803b530.Fm 5-37 maintenance oil change and filter replacement (hydraulics) notice an additional oil change and filter replacement can be required depending on how the machine is used. Failure to observe these replacement intervals can cause damage to hydraulic components. •...

  • Page 178: Maintenance

    5-38 om 803 us – edition 3.7 * * 803b540.Fm maintenance 5.16 maintenance plan (overview) work description for servicing and maintenance on the attachment, p lease refer to the ope ration and maintenance manual of the attachment manufacturer. Maint enan ce plan/o perat ing ho urs ( o/h ) maintenance ...

  • Page 179: Maintenance

    Om 803 us – edition 3.7 * * 803b540.Fm 5-39 maintenance check the function of the pedals, they must flip back automatically (from serial no. Ai00976) • c lean, lubricate or repair the pedals, check the torsion springs ●● clean water ducts 7 ●● check radiator for engine and hydraulic oil for dirt. Cl...

  • Page 180: Maintenance

    5-40 om 803 us – edition 3.7 * * 803b540.Fm maintenance check battery electrolyte . A dd distilled water if necessary ●● ● check alternator, starter and electric connections, bearin g play and function ●● check preheating system and electric connections ●● pressure check of primar y pressure limitin...

  • Page 181: Maintenance

    Om 803 us – edition 3.7 * * 803b540.Fm 5-41 maintenance • stabilizer blade ●● • swiveling console ●● • swiveling cylinder ●● • boom ●● •s tic k ●● • attachments ●● • teeth of live ring ●● • live ring (ball be aring) ●● • ball sockets (iso/sae chan geover option) ● ● functional check ( ): check the f...

  • Page 182: Maintenance

    5-42 om 803 us – edition 3.7 * * 803b540.Fm maintenance 1. Drain engin e oi l the first time after 50 o/h, then every 250 o/h 2. Repl ac e the engine oil fi lter the firs t tim e after 50 o/h, th en ev ery 250 o/ h 3. Repl ac e the fuel filte r th e first tim e after 50 o/h, then ev er y 500 o/h 4. ...

  • Page 183: Maintenance

    Om 803 us – edition 3.7 * 803b560.Fm 5-43 maintenance 5.17 maintenance label explanation of symbols on the maintenance label symbol assembly explanation general visual check general grease instructions fuel system drain condensation water fuel system replace the fuel filter, clean the fuel prefilter...

  • Page 184: Maintenance

    5-44 om 803 us – edition 3.7 * * 803b560.Fm maintenance.

  • Page 185: Technical Data

    Om 803 us – edition 3.7 * 803b610.Fm 6-1 technical data 6 technical data 6.1 chassis sturdy steel sheet chassis, rubber-mounted engine 6.2 engine engine model 803 product yanmar diesel engine type 3tnv70-vns design water-cooled 4 stroke diesel engine number of cylinders 3 displacement 854 cm³ (52.1 ...

  • Page 186: Technical Data

    6-2 om 803 us – edition 3.7 * * 803b610.Fm technical data information! The machine has about 17 % less output at altitudes over 800 m (2625 ft) above see level. However, this does not affect operation. 6.3 travel gear and swivel unit engine model 803 product yanmar diesel engine type 3tnv74f-snns de...

  • Page 187: Technical Data

    Om 803 us – edition 3.7 * 803b610.Fm 6-3 technical data 6.4 stabilizer blade 6.5 operating hydraulics 6.6 connection values of dual power option 6.7 electrical system stabilizer blade model 803 width with stabilizer blade folded in/out 700/860 mm (27.6/34 in) height 198 mm (7.8 in) max. Lift over/un...

  • Page 188: Technical Data

    6-4 om 803 us – edition 3.7 * * 803b610.Fm technical data fuses behind the right-hand trim relays behind the right-hand trim f2 f3 f1 fig. 222: fuses (up to serial number wnce0801cpal0050) fuse no. Rated current (a) protected circuit f1 40 a main fuse: air-pressure sensor/output adap- tation (yanmar...

  • Page 189: Technical Data

    Om 803 us – edition 3.7 * 803b610.Fm 6-5 technical data fuses and relays with dual power option if the machine is equipped with the dual power option, the fuses and relays are located under the base plate. Fig. 225: fuses and relays with dual power option f1 f2 f3 f4 k9 k7 fuse no. Rated current (a)...

  • Page 190: Technical Data

    6-6 om 803 us – edition 3.7 * * 803b610.Fm technical data 6.8 noise levels information! Measurements performed on asphalted surface. 6.9 vibration vibration values indicated in m/s². Directive 2002/44/ec of european parliament and coucil on minimum health and safety requirements regarding exposure o...

  • Page 191: Technical Data

    Om 803 us – edition 3.7 * 803b610.Fm 6-7 technical data note: for further vibration indications, refer to the indications in iso/tr 25398 mechanical vibrations – directive on estimation of whole-body vibration when driving earth moving machines. This publication uses measuring values of internationa...

  • Page 192: Technical Data

    6-8 om 803 us – edition 3.7 * * 803b610.Fm technical data • reduce vibration to a minimum during long work cycles or when traveling over long distances: • use a machine with a suspension system (operator seat, for example). • enable the hydraulic oscillation damping if the machine is equipped with t...

  • Page 193: Technical Data

    Om 803 us – edition 3.7 * 803b610.Fm 6-9 technical data 6.10 coolant compound table 6.11 weight information! The actual machine weight depends on the selected options and must be read off the type label. Add the weight of all subsequently installed equipment to the weight of the machine. Weight indi...

  • Page 194: Technical Data

    6-10 om 803 us – edition 3.7 * * 803b610.Fm technical data 6.12 dimensions model 803 (up to serial no. Ai00966) 787 (31 in) 1294 (51 in) 1220 (48 in) 500 (20 in) 897 (35 in) 747 (29 in) 1906 (75 in) 323 (13 in) 1198 (47 in) fig. 228: machine dimensions (model 803) 198 (8 in) 15 07 ( 5 9 in ) 700/860...

  • Page 195: Technical Data

    Om 803 us – edition 3.7 * 803b610.Fm 6-11 technical data 6.13 dimensions model 803 with rollbar (from serial no. Ai00967) 730 (29 in) 180 (7 in) 1436 (57 in) 2261 (89 in) r747 (29 in) r1039(41 in) 1220 (48 in) 3092 (10'-2'') 1320 (52 in) 1766 (70 in) 2008 (79 in) 2853 (9'-4'') 178 (7 in) 194 (8 in) ...

  • Page 196: Technical Data

    6-12 om 803 us – edition 3.7 * * 803b610.Fm technical data 6.14 dimensions model 803 without rollbar (from serial no. Ai00967) main data model 803 height 1436 mm (57 in) upper carriage width 730 mm (29 in) width with retracted/extended telescopic travel gear 700/860 mm (28/34 in) width with stabiliz...

  • Page 197: Technical Data

    Om 803 us – edition 3.7 * 803b610.Fm 6-13 technical data 6.15 lift capacity tables 803 safety instructions – lift capacity table danger crushing hazard due to tipping over of machine. Causes serious crushing or injury resulting in death. • the authorized lift capacity specified in the table must nev...

  • Page 198: Technical Data

    6-14 om 803 us – edition 3.7 * * 803b610.Fm technical data longitudinal direction, stabilizer blade at front and raised longitudinal direction, stabilizer blade at front and lowered longitudinal direction, stabilizer blade at rear 2.5 m (98 in) 2.0 m (79 in) 1.5 m (59 in) 1.0 m (39 in) a max (m/ft) ...

  • Page 199: Technical Data

    Om 803 us – edition 3.7 * 803b610.Fm 6-15 technical data transverse direction, travel gear extended 2.5 m (98 in) 2.0 m (79 in) 1.5 m (59 in) 1.0 m (39 in) a max (m/ft) kg/lbs 2.4 m (94 in) 1.41 (4.61) 216 (477) -- -- -- -- 2.0 m (79 in) 2.03 (6.64) 167 (367) -- 170(376) -- -- 1.5 m (59 in) 2.40 (7....

  • Page 200: Technical Data

    6-16 om 803 us – edition 3.7 * * 803b610.Fm technical data.

  • Page 201

    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 that have already been delivered and that w...

  • Page 202

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  • Page 203: Foreword

    3 foreword 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 manuf...

  • Page 204: One-Call First

    5 one-call first 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 ...

  • Page 205: Follow A Safety Program

    7 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...

  • Page 206: Follow A Safety Program

    9 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 adm...

  • Page 207: Follow A Safety Program

    11 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, sir...

  • Page 208: Prepare For Safe Operation

    13 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 th...

  • Page 209: Prepare For Safe Operation

    15 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...

  • Page 210: Prepare For Safe Operation

    17 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 mainte- nance of the quick-couple...

  • Page 211: Prepare For Safe Operation

    19 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: — loc...

  • Page 212: Prepare For Safe Operation

    21 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 whe...

  • Page 213: Start Safely

    23 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, ...

  • Page 214: Start Safely

    25 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 operat...

  • Page 215: Operate Safely

    27 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 th...

  • Page 216: Operate Safely

    29 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 kno...

  • Page 217: Operate Safely

    31 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 ...

  • Page 218: Operate Safely

    33 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 ...

  • Page 219: Operate Safely

    35 — 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...

  • Page 220: Operate Safely

    37 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 permissi...

  • Page 221: Shut Down Safely

    39 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...

  • Page 222: Perform Maintenance Safely

    41 perform maintenance safely 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 ...

  • Page 223: Perform Maintenance Safely

    43 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 arou...

  • Page 224: Perform Maintenance Safely

    45 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. — ...

  • Page 225: Perform Maintenance Safely

    47 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, whic...

  • Page 226: Perform Maintenance Safely

    49 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 ...

  • Page 227: Final Word to The User

    51 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 ...

  • Page 228

    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 flughafenstr. 7 a-4063 hörsching phone: +43 (0) 7221 63000 fax: +43 (0) 7221 63000-2200 e-mail office.Linz@wack...