Page 1 Operator's Manual Track Excavator 803 dual power This Operator's Manual includes the AEM Safety Manual CE-1009 Machine type E08-01 Edition Order no 1000287384 Language...
Page 2 – 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.
Page 3: Table Of Contents
Shatter protection (Option) ................2-9 Work range and restricted visibility ..............2-9 Applications with Lifting Gear ................2-10 General information ..................2-10 Operation with lowered TOPS rollbar (up to serial no. AI00966) ..... 2-10 OM 803 us - Ausgabe 3.7 * Ba803us3_7IVZ.fm...
Page 4 Engine and machine warm-up ................. 3-14 Jump-starting the engine (supply battery) ............3-15 Special instructions for traveling on public roads ..........3-16 Travel position ....................3-16 Starting machine travel ..................3-16 OM 803 us - Ausgabe 3.7 * * Ba803us3_7IVZ.fm...
Page 5 Upper carriage deceleration ................3-61 Lock lever ......................3-62 Lock lever (up to serial no. AI00814) ............... 3-62 Lock lever (from serial no. AI00815) ..............3-62 Dual Power (option) ....................3-63 Overview of connections ................. 3-64 OM 803 us - Ausgabe 3.7 * Ba803us3_7IVZ.fm...
Page 6 Air filter (up to serial no. AI00875) ..............5-13 Replacing air filter elements ................5-13 Air filter (from serial no. AI00876) ..............5-14 Replacing air filter elements ................5-14 V-belt ........................5-15 Checking V-belt tension ................... 5-15 OM 803 us - Ausgabe 3.7 * * Ba803us3_7IVZ.fm...
Page 7 Stabilizer blade ......................6-3 Operating hydraulics ....................6-3 Connection values of Dual Power option ..............6-3 Electrical system ...................... 6-3 Fuses behind the right-hand trim ............... 6-4 Relays behind the right-hand trim ..............6-4 OM 803 us - Ausgabe 3.7 * Ba803us3_7IVZ.fm...
Page 8 Weight ........................6-9 Dimensions model 803 (up to serial no. AI00966) ..........6-10 Dimensions model 803 with rollbar (from serial no. AI00967) ....... 6-11 Dimensions model 803 without rollbar (from serial no. AI00967) ......6-12 Lift capacity tables 803 ..................6-13 Safety instructions –...
Page 9 Preparing for maintenance and repair work ........2-14 Putting into operation ..............3-2 Check lists ..................3-8 Putting into operation for the first time ..........3-7 Safety instructions ................3-7 Refueling ....................5-3 Running-in period .................. 3-7 OM 803 us - Ausgabe 3.7 * Ba803us3_7SIX.fm...
Page 10 Coolant compound table ..............6-9 Dimensions ..............6-10 6-11 6-12 Electrical system ................6-3 Engine .....................6-1 Noise levels ..................6-6 Operating hydraulics ...............6-3 Vibration ..................6-6 Track maintenance ................5-25 Warranty ....................2-2 Working Freeing the machine ..............3-82 Recommendations ................3-82 OM 803 us - Ausgabe 3.7 * * Ba803us3_7SIX.fm...
Page 11: Introduction
• Subject to modifications and printing errors. Your Wacker Neuson dealer will be pleased to answer any further questions regarding the machine or the Operator’s Manual. Abbreviations/symbols •...
Page 12: Machine Overview (Up To Serial No. Ai00966)
Boom light Boom Stick Track Travel gear Stabilizer blade Handhold Lifting eye for loading/tying down the machine Engine cover Storage bin for Operator’s Manual Lock lever Fig. 1: Machine outside views OM 803 us – Edition 3.7 * * 803b110.fm...
Page 13: Machine Overview (From Serial No. Ai00967)
Travel gear Stabilizer blade Handhold Lifting eye for loading/tying down the machine Engine cover Storage bin for Operator’s Manual Lock lever ROPS rollbar (option) Shatter protection (option) Fig. 2: Machine outside views OM 803 us – Edition 3.7 * 803b110.fm...
Page 14: Brief Description
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- struction sites and elsewhere.
Page 15: Definition Of The Term "Protective Structure
Information! Check the rollbar and all protective structures once a day for damage. Information! Protective structures may only be installed or removed by a Wacker Neuson service center. Responsibility for machine equipped with protective structures The decision regarding the necessary protective structures (type and level I or II) must be made by the machine owner and depends on the specific work situation.
Page 16: Fields Of Application, Attachments
In order to avoid damage to the machine, only the attachments listed below have been certified. • Please 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...
Page 17: Regulations
Do not use the seat belt if the rollbar is lowered, or if the machine is not equipped with a rollbar. • Machine operation with the rollbar lowered is prohibited – see chapter Operation with lowered ROPS rollbar on page 2-9. OM 803 us – Edition 3.7 * 803b110.fm...
Page 18: Ec Declaration Of Conformity
(refer to the original declaration of conformity supplied with the machine). Applies to EU countries, and countries with legislation sim- ilar to that of the EU. Applies to all machines with CE marks that have not been modified without authorization since the product was placed on the market. OM 803 us – Edition 3.7 * * 803b110.fm...
Page 19: Type Labels And Component Numbers
The type label is located at the front right, on one side of the rollbar. Fig. 2: ROPS bar type label (symbolic representation) Engine number The type label is located on the cylinder-head cover (engine). Fig. 3: Diesel engine number (symbolic representation) OM 803 us – Edition 3.7 * 803b110.fm...
Page 20: Overview Of Adhesive Labels
Introduction 1.12 Overview of adhesive labels Number and position of adhesive labels can differ depending on country. 1-10 OM 803 us – Edition 3.7 * * 803b110.fm...
Page 21: Noise Levels
During operation with a zero-emission power unit, there must be no biodegradable hydrau- lic oil in the excavator or power unit. Position Under the engine cover on the hydraulic oil reservoir 1-11 OM 803 us – Edition 3.7 * 803b110.fm...
Page 22 On either side of the control stand Fig. 14: Lock lever Meaning This label shows the forward traveling direction. Position On either side of the undercarriage Fig. 15: Direction indicator 1-12 OM 803 us – Edition 3.7 * * 803b110.fm...
Page 23 Check before starting the machine the operating pattern that has been chosen. Wiring diagram Controls ISO controls (Europe) Operating Pattern A SAE controls (US) Operating Pattern B Fig. 19: ISO/SAE changeover Position On the control stand 1-13 OM 803 us – Edition 3.7 * 803b110.fm...
Page 24 On the front side of the engine cover Fig. 20: Maintenance plan Meaning Battery master switch Position On the front side of the engine cover Fig. 21: Battery master switch 1-14 OM 803 us – Edition 3.7 * * 803b110.fm...
Page 25: Overview Of Safety Labels
Introduction 1.13 Overview of safety labels Number and position of adhesive labels can differ depending on country. 1-15 OM 803 us – Edition 3.7 * 803b110.fm...
Page 26 Carefully and slowly open the cover only after the reservoir has cooled down, to release the pressure. Wear suitable protective clothing to open the cover. Position In the engine compartment Fig. 25: Hydraulic oil reservoir under pressure 1-16 OM 803 us – Edition 3.7 * * 803b110.fm...
Page 27 Always work on firm ground. Follow the instructions given in the Operator’s Manual. Position At the front on the engine cover (standard). On the left on the rollbar (option). Fig. 29: Warnings 1-17 OM 803 us – Edition 3.7 * 803b110.fm...
Page 28 Position At the front on the engine cover (standard). On the left on the rollbar (option). (up to serial no. AI00824) (from serial no. AI00825) Fig. 32: Warnings 1-18 OM 803 us – Edition 3.7 * * 803b110.fm...
Page 29 Before leaving the seat, raise the lock lever to prevent unintentional movements! Stay clear of the machine’s slewing range during operation. Position At the right on the control stand Fig. 37: Use the lock lever 1-19 OM 803 us – Edition 3.7 * 803b110.fm...
Page 30 Keep a safe distance from high-voltage lines. Always keep a safe distance from electrically conductive parts with the machine and the equipment. Position On the control stand Fig. 41: Electric shock hazard 1-20 OM 803 us – Edition 3.7 * * 803b110.fm...
Page 31 Meaning (option) Read the Operator’s Manual before connecting lines. Position At the rear left. Fig. 45: Dual Power connection 1-21 OM 803 us – Edition 3.7 * 803b110.fm...
Page 32 Introduction 1-22 OM 803 us – Edition 3.7 * * 803b110.fm...
Page 33: Safety Instructions
Failure to observe the instructions identified by this symbol can result in dam- age to the environment. The environment is at risk if environmentally hazard- ous material, such as waste oil, is not subject to proper use or disposal. OM 803 us – Edition 3.7 * 803b210us.fm...
Page 34: Warranty
1.7 “Fields of application, attachments” chapter. 2. No other applications are designated for the use of the machine. Wacker Neuson will not be liable for damage resulting from use other than mentioned above. The operator alone will bear the risk.
Page 35: Preparing To Use 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). OM 803 us – Edition 3.7 * 803b210us.fm...
Page 36: Information On Visibility
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.
Page 37: Safety Instructions Regarding Operation
• Fold up the lock lever base before releasing the seat belt in order to avoid unintentional operation. • Lower the attachments to the ground. OM 803 us – Edition 3.7 * 803b210us.fm...
Page 38: Job Site Awareness
Therefore, adjust the travel speed to your abilities and the surroundings. Carrying passengers • Do not lift, lower or transport people on the machine or in the attachment. • Never install a man basket or a working platform to the machine. OM 803 us – Edition 3.7 * * 803b210us.fm...
Page 39: Mechanical Integrity
• Empty the bucket and tilt it in until the bucket opening is in the upward horizontal position as a minimum before traveling on public roads. • Apart from the operator, no other persons are allowed to ride on the machine.operator OM 803 us – Edition 3.7 * 803b210us.fm...
Page 40: Operator Protection System
• No welding, straightening or bending. • Do not mount any brackets. • Repair work may be performed by a Wacker Neuson dealer only. • Always replace the complete rollbar if it is deformed, cracked or otherwise damaged. • If you are not sure, always contact a Wacker Neuson dealer.
Page 41: Shatter Protection (Option)
• Replace the complete protective structure if it is damaged, deformed and/or cracked. • If you are not sure, always contact a Wacker Neuson dealer. • Repair work may be performed by a Wacker Neuson dealer only. Important Do not use brushes, steel wool or other abrasive cleaners for cleaning the polycarbonate disc.
Page 42: Applications With Lifting Gear
• Before leaving the seat, always secure the machine against unintentional movement and unauthorized use. Lower the attachments to the ground. 2-10 OM 803 us – Edition 3.7 * * 803b210us.fm...
Page 43: Installation Notes
• Prior to fitting attachments to the stick, secure the control lever of the hydraulic control unit against unintentional movement. 2.11 Trailers Important Towing a trailer with this machine is prohibited. 2-11 OM 803 us – Edition 3.7 * 803b210us.fm...
Page 44: Hammer Operation
• Do not extend or retract the boom abruptly, otherwise the machine can tip over. • Stop work immediately if a hydraulic hose moves back and forth in an unusual manner. This could be a cause for a pressure accumulator defect. Contact your Wacker Neuson dealer and have the error repaired immediately.
Page 45: Transport And Towing
• Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immediately upon completion of the maintenance and repair work. 2-13 OM 803 us – Edition 3.7 * 803b210us.fm...
Page 46: Personal Safety Measures
• Prior to performing service, maintenance and repair work, always attach a warning label, such as “Repair work – do not start machine” to the starter lock or to the control elements as a precautionary measure. 2-14 OM 803 us – Edition 3.7 * * 803b210us.fm...
Page 47: Performing Maintenance And Repairs
Operator's Manual, including information on the replacement of parts/partial equipment. These activities may be performed only by a Wacker Neuson service center. • Disconnect the negative terminal of the battery if work needs to be performed on the electrical system.
Page 48: Underground Electric Lines
• Warn others against approaching and touching the machine. • Have the live wire de-energized. • Do not leave the machine until the line that has been touched or damaged has been safely de-energized. 2-16 OM 803 us – Edition 3.7 * * 803b210us.fm...
Page 49: Gas, Dust, Steam, Smoke
• Repair work on the tracks must be performed by technical personnel or by Wacker Neuson dealers only. • Damaged or malfunctioning tracks reduce the machine’s operational safety. Check the tracks regularly for: • Cracks, cuts or other damage. 2-17 OM 803 us – Edition 3.7 * 803b210us.fm...
Page 50 Safety instructions • Check track tension at regular intervals. 2-18 OM 803 us – Edition 3.7 * * 803b210us.fm...
Page 51: Battery
• 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. 2-19 OM 803 us – Edition 3.7 * 803b210us.fm...
Page 52: Fueling The Engine
• The power unit must be at the same level as the excavator. • Do not pull the power unit with the hydraulic hoses. • The operator must have permanent visual contact with the power unit. 2-20 OM 803 us – Edition 3.7 * * 803b210us.fm...
Page 53 • Do not squeeze hydraulic hoses. • Do not put hydraulic hoses over edges. • Do not put anything down on the hydraulic hoses. • Do not put the connecting cable over edges. 2-21 OM 803 us – Edition 3.7 * 803b210us.fm...
Page 54 Safety instructions 2-22 OM 803 us – Edition 3.7 * * 803b210us.fm...
Page 55: Operation
The symbols used in the description have the following meanings: • Identifies a list • Subdivision within lists or an activity. Follow the steps in the recommended order. Identifies an activity Description of the effects or results of an activity OM 803 us – Edition 3.7 * 803b320.fm...
Page 56: Control Stand Overview (Up To Serial No. Ai00814)
Operation 3.1 Control stand overview (up to serial no. AI00814) OM 803 us – Edition 3.7 * * 803b320.fm...
Page 57 For more information see page Operator seat..................................3-28 Upper carriage lock................................3-25 Engine cover lock ................................3-41 Starter ....................................3-10 Stabilizer blade/telescopic travel gear lever ......................3-22,3-24 Stabilizer blade/telescopic travel gear changeover lever....................3-24 Boom swivel pedal................................3-53 Engine cover Handhold OM 803 us – Edition 3.7 * 803b320.fm...
Page 58 For more information see page Auxiliary hydraulics pedal ..............................3-55 Footrest Lock lever...................................3-62 Throttle....................................3-10 Control lever (left) ................................3-52 Travel lever (left) ................................3-16 Travel lever (right)................................3-16 Control lever (right) ................................3-52 Display element ...................................3-6 OM 803 us – Edition 3.7 * * 803b320.fm...
Page 59: Control Stand Overview (From Serial No. Ai00815)
Auxiliary hydraulics pedal ..............................3-55 Footrest Lock lever ..................................3-62 Throttle....................................3-10 Control lever (left) ................................3-52 Travel lever (left)................................3-16 Travel lever (right)................................3-16 Control lever (right) ................................3-52 Display element ...................................3-6 Lever for switching over hammer/grab operation (option) ....................3-75 OM 803 us – Edition 3.7 * 803b320.fm...
Page 60: Display Elements (Overview)
Indicator light (red) – alternator charge function........................ 3-11 Indicator light (red) – engine oil pressure .......................... 3-11 Indicator light (red) – coolant temperature ........................3-12 Indicator light (yellow) – fuel gage............................. 3-12 Hour meter ..................................3-12 OM 803 us – Edition 3.7 * * 803b320.fm...
Page 61: Putting Into Operation
• Do not run the engine at high speed for extended periods. • Strictly observe the maintenance schedules in the appendix – see chapter 5.16 Mainte- nance plan (overview) on page 5-38. OM 803 us – Edition 3.7 * 803b320.fm...
Page 62: Check Lists
18 Anyone in the danger zone of the machine? 19 Indicator lights for engine oil pressure and alternator charge function illuminate. In case of dual-power operation: hydraulic oil levels of excavator and electro- hydraulic power unit OK?( 3-67) OM 803 us – Edition 3.7 * * 803b320.fm...
Page 63: Operation Checklist
Machine keys removed, especially if the machine cannot be supervised? ( 3-26) When parking on public roads: Machine adequately secured? When parking on slopes: Machine also secured with chocks under the tracks to prevent it from rolling away? ( 3-26) OM 803 us – Edition 3.7 * 803b320.fm...
Page 64: Machine Travel
Speed is set continuously with throttle 13. Position A: idling speed Position B: max. engine speed Fig. 50: Engine speed control (up to serial no. AI00814) Fig. 51: Engine speed control (from serial no. AI00815) 3-10 OM 803 us – Edition 3.7 * * 803b320.fm...
Page 65: Traveling Signal (Option)
• Do not rely on the traveling signal under any circumstances. • If the traveling signal does not sound, stop machine operation immediately and get in touch with a Wacker Neuson service center (observe the rele- vant national regulations). Indicator lights and warning lights (overview) Indicator light (red) –...
Page 66 Counts the operating hours when the engine or the electrohydraulic power unit is running if the machine is equipped with the Dual Power option. Information! The operating hours are only displayed if the starter is enabled. 3-12 OM 803 us – Edition 3.7 * * 803b320.fm...
Page 67: Starting The Engine: General
• Never preheat the engine more than 10 seconds After you have completed the starting preparations: Insert the starting key in the preheating start switch Turn the starting key to position 1 Fig. 52: Preheating start switch 3-13 OM 803 us – Edition 3.7 * 803b330.fm...
Page 68: Starting At Low Temperatures
During the warm-up phase, check for unusual noise, exhaust color, 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. 3-14 OM 803 us – Edition 3.7 * * 803b330.fm...
Page 69: Jump-Starting The Engine (Supply Battery)
12 V – remove the terminal, then the terminal) – this prevents sparking in the vicinity of the battery! Starting battery Fig. 54: Starting aid with battery jumper cables 34001b710 05 eps 3-15 OM 803 us – Edition 3.7 * 803b330.fm...
Page 70: Special Instructions For Traveling On Public Roads
Can cause serious injury or death. • Slowly and carefully actuate the travel levers/pedals The stabilizer blade side is the front side. Raise the attachment and the stabilizer blade. Fig. 56: Travel levers 3-16 OM 803 us – Edition 3.7 * * 803b330.fm...
Page 71: Iso/Sae Changeover (Option)
The sleeve is safely locked if it is firmly connected with the ball pin and if it is engaged in the lower position. Lower covers 1. Fig. 57: Control stand covers 3-17 OM 803 us – Edition 3.7 * 803b330.fm...
Page 72: Hydraulic Brake
Reduce travel speed with the travel levers, and not with the engine speed control of the diesel engine. Stabilizer blade as a parking brake The stabilizer blade is used as a parking brake. Press the stabilizer blade against the ground. 3-18 OM 803 us – Edition 3.7 * * 803b330.fm...
Page 73: Machine Travel On Slopes
Always travel straight ahead when traveling uphill or downhill. When changing position, do not exceed a maximum gradient angle of 15° and a maximum lateral angle of inclination of 10°. < 10° Fig. 60: Traveling on slopes 3-19 OM 803 us – Edition 3.7 * 803b330.fm...
Page 74: Gradient Angle
Raise the boom about 20 – 30 cm (8 – 12 in) off the ground and position it straight ahead at the center of the machine. Do not exceed a maximum sloping angle of 15°. < 15° 20 – 30 cm (8 – 12 in) Fig. 63: Traveling downhill 3-20 OM 803 us – Edition 3.7 * * 803b330.fm...
Page 75: Lateral Angle Of Inclination
Lateral angle of inclination On lateral inclinations over 10°, pile up material to create a level surface that can be used as a platform for the machine. > 10° Fig. 65: Platform 3-21 OM 803 us – Edition 3.7 * 803b330.fm...
Page 76: Stabilizer Blade Operation
(for example when traveling through a door frame). • Adjust the stabilizer blade and the telescopic travel gear to the same widths when operating the machine. 3-22 OM 803 us – Edition 3.7 * * 803b330.fm...
Page 77 Turn out the stabilizer blade extensions B on either side. Fig. 69: Changing the width of the stabilizer blade Insert pins A on either side. Fig. 70: Changing the width of the stabilizer blade 3-23 OM 803 us – Edition 3.7 * 803b330.fm...
Page 78: Telescopic Travel Gear
• Adjust the stabilizer blade and the telescopic travel gear to the same widths when operating the machine. Information! In order to achieve the best possible stability, lower the stabilizer blade, turn out the extensions (option) and extend the telescopic travel gear. 3-24 OM 803 us – Edition 3.7 * * 803b330.fm...
Page 79: Upper Carriage Lock
Locking the upper carriage Pull lever 2 from position A to position B Unlocking the upper carriage Push lever 2 from position B to position A 3-25 OM 803 us – Edition 3.7 * 803b330.fm...
Page 80: Parking The Machine
WARNING Accident hazard due to control lever operation! Can cause serious injury or death. • Raise the lock lever before leaving the seat. Fig. 75: Parking the machine on slopes 3-26 OM 803 us – Edition 3.7 * * 803b330.fm...
Page 81: Light System
• The 12 V outlet may only be used during diesel operation, since the battery is not charged during Dual-Power operation – see chapter Charging the excavator battery on page 3-71. Fig. 77: 12 V outlet 3-27 OM 803 us – Edition 3.7 * 803b330.fm...
Page 82: Seat Adjustment
• Stop the machine on firm, level and horizontal ground – see chapter Parking the machine on page 3-26 • Lower the boom • Stop the engine • Raise the lock lever • Remove the starting key 3-28 OM 803 us – Edition 3.7 * * 803b330.fm...
Page 83: Telescopically Extended Travel Gear
Use handhold A. Fig. 79: Footholds Use handhold A. Fig. 80: ROPS handles Telescopically extended travel gear Use handhold A. Fig. 81: Footholds and handles with a telescopically extended travel gear 3-29 OM 803 us – Edition 3.7 * 803b330.fm...
Page 84: Lowerable Tops Rollbar (Up To Serial No. Ai00966) (Option)
Curl the bucket Stop the engine Raise the lock lever Remove the starting key Information! In order to lower it, the rollbar must be held by one person on either side. 3-30 OM 803 us – Edition 3.7 * * 803b330.fm...
Page 85: Raising The Rollbar
Slowly and carefully raise the rollbar Re-insert the screws on either side A and secure them with new lock nuts A NOTICE Replace the lock nuts every time they are loosened. Fig. 84: Raising the rollbar 3-31 OM 803 us – Edition 3.7 * 803b330.fm...
Page 86: Lowerable Rops Rollbar (Up To Serial No. Ai00966) (Option)
Remove the lock nuts and screws A on either side Slowly and carefully lower the rollbar Insert the screws again on either side and secure them with the lock nuts 3-32 OM 803 us – Edition 3.7 * * 803b330.fm...
Page 87: Raising The Rollbar
In order to raise it, the rollbar must be held by one person on either side. Slowly and carefully raise the rollbar Fit pins B again on either side and secure them with the split pins 3-33 OM 803 us – Edition 3.7 * 803b330.fm...
Page 88: Lowerable Rops Rollbar (From Serial No. Ai00967) (Option)
Stop the machine on firm, level and horizontal ground Fully raise the boom Pull the stick toward the machine Curl the bucket Position the boom straight ahead Stop the engine Raise the lock lever 3-34 OM 803 us – Edition 3.7 * * 803b330.fm...
Page 89: Raising The Rollbar
Remove the starting key Information! In order to raise it, the rollbar must be held by one person on either side. Slowly and carefully lower the rollbar Fig. 88: Lowering the rollbar 3-35 OM 803 us – Edition 3.7 * 803b330.fm...
Page 90 Install the linch pins and bolts B on either side Fig. 89: Lowering the rollbar Rotating beacon bracket Bracket P for installing a rotating beacon is located on top of the rollbar. Fig. 90: Rotating beacon bracket 3-36 OM 803 us – Edition 3.7 * * 803b330.fm...
Page 91: Seat Belt (Option)
After an accident the belt strap is stretched and no longer serviceable. In an accident, the seat belt does not provide enough safety! • Replace the seat belt after an accident. • Have fastening points and seat fixture checked for bearing capacity. 3-37 OM 803 us – Edition 3.7 * 803b330.fm...
Page 92 • Hold buckle latch A at a right angle to the seat belt and pull the seat belt to the required length • To shorten the seat belt, just pull the free end E of the belt 30763b0005.eps Fig. 93: Longer/shorter seat belt adjustment 3-38 OM 803 us – Edition 3.7 * * 803b330.fm...
Page 93 After an accident the belt strap is stretched and no longer serviceable. In an accident, the seat belt does not provide enough safety! • Replace the seat belt after an accident. • Have fastening points and seat fixture checked for bearing capacity. 3-39 OM 803 us – Edition 3.7 * 803b330.fm...
Page 94 • Hold the retracting seat belt • Press button D on buckle B Latch A is released by spring pressure • Unfastening the retracting seat belt Fig. 95: Unfastening the retracting seat belt 3-40 OM 803 us – Edition 3.7 * * 803b330.fm...
Page 95: Engine Cover
Turn the starting key in lock 3 to the left (L) Fig. 96: Engine cover lock Engine cover locked Turn the starting key in lock 3 to the right (R) Engine cover unlocked 3-41 OM 803 us – Edition 3.7 * 803b330.fm...
Page 96: Battery Master Switch
Flip up the battery isolator switch A and remove from the B positive terminal. Establish the electric power supply: Set the battery isolator switch A to the positive terminal B and fold down. Fig. 100: Battery master switch 3-42 OM 803 us – Edition 3.7 * * 803b330.fm...
Page 97: Towing The Machine
• Start machine travel and tow away slowly. • Ensure that no one is between the vehicles during towing. • Have a recovery service or a Wacker Neuson service center tow the machine away if necessary – see chapter Transportation on page 2-10.
Page 98: Lifting The Machine
Do not attempt to lift the excavator with any type of crane including wheel load- ers unless the crane operator is qualified to lift loads in craning operations. The crane operator shall be knowledgable of OSHA 1910 craning regulations. 3-44 OM 803 us – Edition 3.7 * * 803b330.fm...
Page 99 Fig. 103: Crane lifting (with rollbar) Raise the rollbar after loading the machine. Required lengths L1 and L2 of the lifting gear: Length Dimension 1054 mm (42 in) 1718 mm (68 in) 3-45 OM 803 us – Edition 3.7 * 803b330.fm...
Page 100: Loading And Transporting The Machine
The manufacturer’s warranty shall not apply to accidents or damage caused by loading or transporting. • Secure the machine against unintentional movement – see chapter Parking the machine on page 3-26! 3-46 OM 803 us – Edition 3.7 * * 803b330.fm...
Page 101: Tying Down The Machine
Information! Only use OSHA-approved lifting devices. Use edge protectors to avoid damage both to the machine and to the belts, ropes or chains. Fig. 106: Tying down the excavator 3-47 OM 803 us – Edition 3.7 * 803b330.fm...
Page 102: Shatter Protection (Option) (From Serial No. Ai00967)
• Pay attention to the restricted work range (see fig. 109). • Machine operation is prohibited without a shatter protection. • For 803 machines up to serial number AI00966, operation with an attach- ment causing fragments to fly around is absolutely prohibited, because a shatter protection cannot be mounted.
Page 103 2014) Job site Height of working area: 120 cm (47 in). 0° The figures refer to work with a Wacker Neuson hydraulic hammer. Information! Working with another attachment can modify the height of the working area. 120 cm (47 in) Fig.
Page 104: Machine Operation
• Do not raise the bucket over the heads of persons, the seat or the cabs of trucks or other means of transport. Material can fall out, or the bucket can knock against the truck and cause serious/fatal injury and serious damage. 3-50 OM 803 us – Edition 3.7 * * 803b340.fm...
Page 105 • Use an external light source in case of poor illumination of the job site. If this is not enough to illuminate the job site sufficiently, stop machine operation and only take it up again if sufficient illumination can be ensured. 3-51 OM 803 us – Edition 3.7 * 803b340.fm...
Page 106: Control Lever Overview
Position Lever Function Forward Lowers the boom To the right Tilts out the bucket Backward Raises the boom To the left Tilts in the bucket Fig. 111: Right-hand control lever 3-52 OM 803 us – Edition 3.7 * * 803b340.fm...
Page 107: Boom Swivel Controls
The boom can be swiveled Fig. 113: Swivel controls Swiveling the boom to the left: Press the front half of the right-hand pedal Boom swivels to the left Fig. 114: Actuating the swiveling mechanism 3-53 OM 803 us – Edition 3.7 * 803b340.fm...
Page 108: Boom Swivel Controls (From Serial No. Ai00976)
Fig. 117: Keeping the swiveling mechanism in position Swiveling the boom to the left: Press the front half of the right-hand pedal Boom swivels to the left Fig. 118: Actuating the swiveling mechanism 3-54 OM 803 us – Edition 3.7 * * 803b340.fm...
Page 109: Auxiliary Hydraulics
Unfold the left-hand pedal 10 Auxiliary hydraulics can be actuated Fig. 120: Auxiliary hydraulics Actuating the auxiliary hydraulics: Press the left-hand pedal Oil flows through the auxiliary hydraulics line Fig. 121: Actuating the auxiliary hydraulics 3-55 OM 803 us – Edition 3.7 * 803b340.fm...
Page 110: Auxiliary Hydraulics (From Serial No. Ai00976)
Keep the left-hand pedal in position but do not press it Actuating the auxiliary hydraulics: Press the left-hand pedal Oil flows through the auxiliary hydraulics line Fig. 123: Actuating the auxiliary hydraulics 3-56 OM 803 us – Edition 3.7 * * 803b340.fm...
Page 111: Auxiliary Hydraulics (Double-Action Option) (Up To Serial No. Ai00975)
Oil flows forward through the left or right-hand pressure line. Information! Check the auxiliary hydraulics pedal for correct function. Unfold the left-hand pedal 10 Auxiliary hydraulics can be actuated Fig. 125: Auxiliary hydraulics 3-57 OM 803 us – Edition 3.7 * 803b340.fm...
Page 112: Auxiliary Hydraulics (Double-Action Option) (From Serial No. Ai00976)
Hammer/grab operation changeover is performed with lever 19. Position Lever Function Turn lever 19 upward Grab operation Turn lever 19 to the right Hammer operation Fig. 128: Hammer and grab operation changeover (from WNCE0801EPAL00210) 3-58 OM 803 us – Edition 3.7 * * 803b340.fm...
Page 113 Fig. 131: Keeping the auxiliary hydraulics in position Actuating the auxiliary hydraulics: The left-hand pedal can be pressed forward or backward Oil flows through the auxiliary hydraulics line Fig. 132: Actuating the auxiliary hydraulics 3-59 OM 803 us – Edition 3.7 * 803b340.fm...
Page 114: Emergency Lowering
Observe the following during emergency lowering: Lower lock lever A. Push the right-hand control lever B forward until the boom is fully lowered to the ground. Return control lever B to neutral. 3-60 OM 803 us – Edition 3.7 * * 803b340.fm...
Page 115: Rotating The Upper Carriage
The upper carriage’s rotation is sufficiently braked by moving control lever 14 on the left back to initial position. Moving the control lever in the opposite direction (counteraction) brakes the upper carriage with maximum hydraulic output. 3-61 OM 803 us – Edition 3.7 * 803b340.fm...
Page 116: Lock Lever
Set lever 12 to position A. The control levers are locked. Unlocking the lock lever Set lever 12 to position B. The control levers are unlocked. Fig. 137: Lock lever 3-62 OM 803 us – Edition 3.7 * * 803b340.fm...
Page 117: Dual Power (Option)
Dual Power (option) on page 2-17 NOTICE In order to avoid damage to the machine, Wacker Neuson recommends operating the 803 compact excavator in dual-power operation only with the HPU8 power unit. During operation with a zero-emission power unit, there must be no biode- gradable hydraulic oil in the excavator or power unit.
Page 118: Overview Of Connections
• The hydraulic hoses of the power unit must be connected to the excavator before starting the power unit. Fig. 138: Overview of connections (symbolic representation) Designation Split pin Pins Lance Hydraulic connections Clamping screw 3-64 OM 803 us – Edition 3.7 * * 803b340.fm...
Page 119: Coupling
Fasten a pin and the split pin on the power unit again. Fig. 141: Insert lance C in the holder on the excavator and secure it with pin B and split pin A. Fig. 142: 3-65 OM 803 us – Edition 3.7 * 803b340.fm...
Page 120 Use a suitable container to collect fluids and lubricants as they flow out and dispose of them in an environmentally friendly manner. Fig. 144: Screw clamping screw F and fasten the hydraulic hose on the lance as shown. Fig. 145: 3-66 OM 803 us – Edition 3.7 * * 803b340.fm...
Page 121: Checking The Hydraulic Oil Levels Of The Power Unit And Excavator
• Add hydraulic oil if no hydraulic oil can be seen in one of both sight glasses. • Do not start operation if no air can be seen in one of the sight glasses. Contact a Wacker Neuson service center. Fig. 146: Power unit Excavator Fig. 147: 3-67 OM 803 us – Edition 3.7 * 803b340.fm...
Page 122: Changeover From Hpu To Diesel Operation
Remove key A and store it in the document box. Fig. 150: Indication B must be in position 1. Fig. 151: Start the diesel engine: turn the starting key to position 3. Fig. 152: 3-68 OM 803 us – Edition 3.7 * * 803b340.fm...
Page 123: Changeover From Diesel To Hpu Operation
Remove key A and store it in the document box. Fig. 155: Indication B must be in position 2. Fig. 156: Switch on the HPU: press the green push button (G) 7.5 kW version 9 kW version Fig. 157: 3-69 OM 803 us – Edition 3.7 * 803b340.fm...
Page 124: Uncoupling
Uncouple the hydraulic hose connections D from the power unit. Environment! Use a suitable container to collect fluids and lubricants as they flow out and dispose of them in an environmentally friendly manner. Fig. 159: 3-70 OM 803 us – Edition 3.7 * * 803b340.fm...
Page 125: Charging The Excavator Battery
• The power unit must be stopped during charging. NOTICE Possible damage to battery charger due to installation/routing near rotating parts. • Do not place the battery charger cables near rotating parts. 3-71 OM 803 us – Edition 3.7 * 803b340.fm...
Page 126 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 is located in the storage compartment above the hydraulic-oil radiator of the power unit.
Page 127: Charging The Battery With The Power Unit
Dispose of old batteries in an environmentally friendly manner. Fig. 164: LED working light The Dual Power option includes an energy-saving LED working light that is switched on and off with switch A. Fig. 165: 3-73 OM 803 us – Edition 3.7 * 803b340.fm...
Page 128: Dual-Power Operation With Rotating Beacon
Connect rotating beacon A to the external power supply B. Connecting the rotating beacon to the accessories outlet of the power unit is prohibited. Information! Using a rotating beacon screwed onto the power unit is prohibited. Wacker Neuson recommends a commercially available magnetic or clampable rotating beacon. 3-74...
Page 129: Pressure Release On The Auxiliary Hydraulics
Re-equipping the attachments is described below for a bucket. If you are fitting or remov- ing attachments with their own hydraulic functions – grab or offset bucket, for example – you must follow the special information given in the Operator’s Manual of the attachment. 3-75 OM 803 us – Edition 3.7 * 803b340.fm...
Page 130: Specific Safety Instructions
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. 3-76 OM 803 us – Edition 3.7 * * 803b340.fm...
Page 131: Installing A Bucket
Release the pressure on the operating hydraulics – see chapter 3.19 Pressure release on the auxiliary hydraulics on page 3-75. The attachment couplings can be connected. Raise the lock lever. Remove the starting key. 3-77 OM 803 us – Edition 3.7 * 803b340.fm...
Page 132: Connections For Auxiliary Hydraulics (Stick Hose Routing Option)
Pressure release on the auxiliary hydraulics on page 3-75. The attachment couplings can be connected. Raise the lock lever. Remove the starting key. Fig. 169: Auxiliary hydraulics – hose routing on stick 3-78 OM 803 us – Edition 3.7 * * 803b340.fm...
Page 133: Attachments
Do not allow the bucket to penetrate into the ground and do not excavate by using the traveling force of the machine. Working this way can damage the machine or the attachments. Fig. 171: Working with the traveling force 3-79 OM 803 us – Edition 3.7 * 803b340.fm...
Page 134: Excavator Work Position
Ensure that the bucket does not hit the stabilizer blade as you retract attachments for traveling or transport. Fig. 175: Retracting attachments Excavator work position Place stabilizer blade A on the side you want to dig Fig. 176: Excavator work position 3-80 OM 803 us – Edition 3.7 * * 803b340.fm...
Page 135: Bucket Position When Digging
• Loading material onto transport vehicles is more efficient if the excavator is at the rear end of the transport vehicle and not at the side. Fig. 181: Loading 3-81 OM 803 us – Edition 3.7 * 803b340.fm...
Page 136: Grading
Lower the boom all the way Slowly dump out the bucket The machine is pushed backward Reverse slowly Repeat this procedure until the tracks reach firm ground Reverse the machine away 3-82 OM 803 us – Edition 3.7 * * 803b340.fm...
Page 137: Grading
Set the depth of the layer you want to remove with the stabilizer blade lever The machine must not be raised by lowering the stabilizer blade The clearance between the stabilizer blade and the ground should be about 1 cm 3-83 OM 803 us – Edition 3.7 * 803b340.fm...
Page 138: Working Alongside Trenches
• We recommend using the first work position (Fig. 186) described above and to ensure that piston rod A does not touch stabilizer blade B under any circumstances. Fig. 186: Deep excavation 3-84 OM 803 us – Edition 3.7 * * 803b340.fm...
Page 139: Malfunctions
Engine overheats. Temperature warning system Coolant level too low responds Cooling system leaks Malfunctioning fan, torn or loose V-belt 5-15 Resistance in cooling system too high, flow capacity too low Malfunctioning injection nozzle OM 803 us – Edition 3.7 * 803b410.fm...
Page 140 Fuel grade does not comply with specifications 5-35 Engine smoke White Wrong valve clearance Malfunctioning injection nozzle Malfunctioning cylinder-head gasket Dirty air filter 5-12 Black Wrong valve clearance Malfunctioning injection nozzle OM 803 us – Edition 3.7 * * 803b410.fm...
Page 141: Maintenance
Immediately repair or replace parts that are already damaged or not working properly before they are due for replacement. Information! Safety-relevant parts may only be repaired or replaced by a Wacker Neuson dealer or a Wacker Neuson service center. Parts...
Page 142: Fuel System
• Before refueling, stop the engine, raise the lock lever and remove the starting key! • Do not refuel in closed rooms! • Wipe away fuel spills immediately! • Keep the machine clean to reduce the fire hazard! OM 803 us – Edition 3.7 * * 803b510.fm...
Page 143: Refueling
Only refuel from stationary fuel pumps. Fuel from barrels or cans is usually dirty. Even the smallest particles of dirt can cause • Increased engine wear • Malfunctions in the fuel system • Reduced effectiveness of the fuel filters OM 803 us – Edition 3.7 * 803b510.fm...
Page 144: Bleeding The Fuel System
• Stop the engine • Raise the lock lever • Remove the starting key • Bleed the fuel system again as described above • Have this checked by authorized personnel if necessary OM 803 us – Edition 3.7 * * 803b510.fm...
Page 145: Fuel Prefilter With Water Separator
Screw threaded fitting D back on again Environment! Fig. 191: Fuel prefilter Collect the fuel/water mixture as it drains with a suitable container and dispose of it in an environmentally friendly manner. OM 803 us – Edition 3.7 * 803b510.fm...
Page 146: Engine Lubrication System
• The oil level must be between the MAX and MIN marks. • Use only the specified engine oil (refill with the same engine oil). • Have the oil changed only by a Wacker Neuson service center. Information! In order to avoid engine damage, add the engine oil slowly so it can go down without entering the intake system.
Page 147: Checking The Oil Level
• Push oil dipstick A back in as far as possible • Completely remove all oil spills • Close and lock the engine cover Fig. 193: Oil dipstick and oil filler cap OM 803 us – Edition 3.7 * 803b510.fm...
Page 148: Engine Cooling System
Do not add a different coolant to the one in the reservoir. • Only use the coolant recommended by Wacker Neuson – see chapter 6.10 Coolant compound table on page 6-9. OM 803 us – Edition 3.7 * * 803b510.fm...
Page 149 Check the coolant level again. Close and lock the engine cover Environment! Use a suitable container to collect the coolant as it drains and dispose of it in an environmentally friendly manner! OM 803 us – Edition 3.7 * 803b510.fm...
Page 150: Checking The Coolant Level/Adding Coolant
The coolant level must be between the LOW and FULL reservoir seams If necessary, add coolant and repeat the procedure until the coolant level remains con- stant Close and lock the engine cover 5-10 OM 803 us – Edition 3.7 * * 803b510.fm...
Page 151: Cleaning The Radiator
Remove the starting key and carry it with you Let the engine and the coolant cool down Fig. 195: Cleaning the radiator Open the engine cover Remove dust and other foreign bodies from the radiator fins with compressed air 5-11 OM 803 us – Edition 3.7 * 803b510.fm...
Page 152: Air Filter
• Replace air filter element D after 50 operating hours at the latest! Information! Ensure that dust valve G shows downward once it is installed! 5-12 OM 803 us – Edition 3.7 * * 803b520.fm...
Page 153: Air Filter (Up To Serial No. Ai00875)
Carefully insert the new air filter element D in housing section F Position housing section E (ensure that it is properly seated) Fig. 198: Removing the air filter element Close bow clips H 5-13 OM 803 us – Edition 3.7 * 803b520.fm...
Page 154: Air Filter (From Serial No. Ai00876)
Close bow clips D. Ensure that dust valve F shows downward once it is installed. After replacing the filters, press button J to reset the yellow piston B. Fig. 202: Inside filter 5-14 OM 803 us – Edition 3.7 * * 803b520.fm...
Page 155: 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, and retighten it if necessary. Retighten new V-belts after about 15 minutes of running time.
Page 156: Hydraulic System
– observe the sticker on the hydraulic oil reservoir. • Contact a Wacker Neuson service center if the filter of the hydraulic system is dirty. 5-16 OM 803 us – Edition 3.7 * * 803b520.fm...
Page 157: Checking The Hydraulic Oil Level
Close filler cap B. Information! Use a suitable container to collect fluids and lubricants as they flow out and dispose of them in an environmentally friendly manner. Fig. 206: Hydraulic oil reservoir 5-17 OM 803 us – Edition 3.7 * 803b520.fm...
Page 158: 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 recommended. In addition, ask the oil supplier for a written decla- ration of guarantee.
Page 159: Checking Hydraulic Pressure Lines
• Do not remove protective hoses from hydraulic hoses. • Leaks and damaged pressure lines must be immediately repaired or replaced by a Wacker Neuson service center or after-sales personnel. This not only increases the operating safety of the machine but also helps to protect the environment.
Page 160: Overview Of Lubrication Points
Maintenance 5.8 Overview of lubrication points 5-20 OM 803 us – Edition 3.7 * * 803b520.fm...
Page 161: Parking The Machine
The lubrication point is located on the right under the engine cover. Apply grease to lubrication point 10 with a grease gun. Remove ejected grease. Fig. 208: Engine cover lubrication point 5-21 OM 803 us – Edition 3.7 * 803b520.fm...
Page 162: Lubricating The Live Ring (Ball Bearing)
Repeat steps 2 – 7 three times until the upper carriage is back in its initial position. Rotate the upper carriage several times by 360°. Fig. 211: Rotate the upper carriage by 90° at a time 5-22 OM 803 us – Edition 3.7 * * 803b520.fm...
Page 163: Lubricating The Teeth Of The Live Ring
Repeat steps 2 – 7 three times until the upper carriage is back in its initial position. Rotate the upper carriage several times by 360°. Fig. 213: Rotate the upper carriage by 90° at a time 5-23 OM 803 us – Edition 3.7 * 803b520.fm...
Page 164: Ball Sockets (Iso/Sae Changeover Option)
The sleeve is safely locked if it is firmly connected with the ball pin and if it is engaged in the lower position. Lower covers 1. Fig. 215: Ball pins (SAE controls shown) 5-24 OM 803 us – Edition 3.7 * * 803b520.fm...
Page 165: Tracks
Adjust the correct track tension if the play between the track roller and the track is not 15 – 20 mm (0.6 – 0.8 in). 15 – 20 mm 0.6 – 0.8 in Fig. 218: Measuring distance 5-25 OM 803 us – Edition 3.7 * 803b530.fm...
Page 166: Tightening The Tracks
• Release grease only as described below. NOTICE Excessive tension of the tracks causes serious damage to the cylinder and the track. • Tighten the tracks only up to the prescribed measuring distance 5-26 OM 803 us – Edition 3.7 * * 803b530.fm...
Page 167: Traveling Drive
If it is not correct: Adjust again. Should the tracks still be slack after injecting more grease, replace the tracks or the seals in the cylinders. Contact a Wacker Neuson dealer in this case. Fig. 219: Tightening the tracks Reducing tension Place a suitable container underneath to collect the grease.
Page 168: Electrical System
– see chapter Fuses behind the right-hand trim on page 6-4 • Cable and grounding connections • Battery charge condition – see Battery on page 5-30 • Condition of battery terminals 5-28 OM 803 us – Edition 3.7 * * 803b530.fm...
Page 169: Instructions Concerning Specific Components
• Always disconnect the battery before performing welding work or connecting a quick battery charger! • Have malfunctioning charge indicator lights immediately replaced – see chapter Indicator light (red) – alternator charge function on page 3-11 5-29 OM 803 us – Edition 3.7 * 803b530.fm...
Page 170: Battery
Checking the battery requires it to be removed and must be performed by a Wacker Neu- son service center. Always follow the specific battery safety instructions! Information! Do not disconnect the battery while the engine is running! Fig. 221: Battery 5-30 OM 803 us – Edition 3.7 * * 803b530.fm...
Page 171: General Maintenance
• Air intake filters, etc. Cleaning with volatile and easily flammable anticorrosion agents and sprays: • Ensure adequate room ventilation • Do not use unprotected lights or open flames • Do not smoke 5-31 OM 803 us – Edition 3.7 * 803b530.fm...
Page 172: Control Stand
• and do not point the jet directly at electric sensors such as the oil pressure switch. The humidity penetrating any such sensors causes them to fail and possibly leads to engine damage! 5-32 OM 803 us – Edition 3.7 * * 803b530.fm...
Page 173: Threaded Fittings And Attachments
Bucket teeth and pin fastenings on the attachment Rollbar fastening screws Retighten loose connections immediately. Contact a Wacker Neuson service center if necessary. Pivots and hinges All mechanical pivot points on the machine (door hinges, joints, for example) and fittings (door arresters, for example) must be lubricated regularly, even if they are not listed in the lubrication plan.
Page 174: Maintenance If The Machine Is Out Of Service For A Longer Period Of Time
• Start the diesel engine. • Let the engine run at idling speed at least 15 minutes without load. • Check the oil levels in all units and add oil if necessary. 5-34 OM 803 us – Edition 3.7 * * 803b530.fm...
Page 175: Fluids And Lubricants
Dual Power option: During operation with the electrohydraulic power unit HPU8, there must be no biodegradable hydraulic oil in the excavator or the power unit. Both must be filled with HVLP 46. Contact a Wacker Neuson service center before using power units from other manufacturers.
Page 176 Engine oil grade Ambient temperature (°C) °C SAE 10W SAE 20W SAE 10W-30 SAE 10W-40 API: CG-4/CH-4/ CI-4 SAE 15W-40 ACEA: E3, E4, E5 SAE 20 SAE 30 SAE 40 °F 5-36 OM 803 us – Edition 3.7 * * 803b530.fm...
Page 177: Oil Change And Filter Replacement (Hydraulics)
Oil grades for the hydraulic system, depending on temperature Hydrau- lics oil Ambient temperature grade °C ISO VG32 HVLP ISO VG46 ISO VG68 °F According to DIN 51524 section 3 5-37 OM 803 us – Edition 3.7 * 803b530.fm...
Page 178 Maintenance Wacker Neuson service center Customer Every 2000 o/h Every 1000 o/h once a year Every 500 o/h Every 250 o/h Every 50 o/h Maintenance (once a day) 5-38 OM 803 us – Edition 3.7 * * 803b540.fm...
Page 179 Maintenance Wacker Neuson service center Customer Every 2000 o/h Every 1000 o/h once a year Every 500 o/h Every 250 o/h Every 50 o/h Maintenance (once a day) 5-39 OM 803 us – Edition 3.7 * * 803b540.fm...
Page 180 Maintenance Wacker Neuson service center Customer Every 2000 o/h Every 1000 o/h once a year Every 500 o/h Every 250 o/h Every 50 o/h Maintenance (once a day) 5-40 OM 803 us – Edition 3.7 * * 803b540.fm...
Page 181 Maintenance Wacker Neuson service center Customer Every 2000 o/h Every 1000 o/h once a year Every 500 o/h Every 250 o/h Every 50 o/h Maintenance (once a day) 5-41 OM 803 us – Edition 3.7 * * 803b540.fm...
Page 182 Maintenance 5-42 OM 803 us – Edition 3.7 * * 803b540.fm...
Page 183: Maintenance Label
Engine Check the V-belt tension Hydraulic system Check oil level Hydraulic system Change the hydraulic oil Hydraulic system Replace the hydraulic oil filter Travel gear Check track tension Radiator fins Clean 5-43 OM 803 us – Edition 3.7 * 803b560.fm...
Page 184 Maintenance 5-44 OM 803 us – Edition 3.7 * * 803b560.fm...
Page 185: Technical Data
1300 +/− 25 rpm Idling speed (1,300 +/− 25 rpm) Fuel injection system Indirect injection Starting aid Glow plug (preheating time 4 seconds) Exhaust values according to EPA – Tier IV final (up to 2012) OM 803 us – Edition 3.7 * 803b610.fm...
Page 186: Travel Gear And Swivel Unit
Track width 180 mm (7 in) No. of track rollers on either side Ground clearance 132 mm (5 in) Ground pressure 0.24 kg/cm² (3.4 lbs/in Upper carriage swivel speed 8 rpm OM 803 us – Edition 3.7 * * 803b610.fm...
Page 187: Stabilizer Blade
Max. 170 bar (2,466 psi) Oil flow Max. 20 l/min (5.3 gal/min) 6.7 Electrical system Electrical system Dynamo 12 V 20 A Starter 12 V 1.1 kW (1.5 hp) Battery 12 V 30 Ah OM 803 us – Edition 3.7 * 803b610.fm...
Page 188: Fuses Behind The Right-Hand Trim
Fig. 223: Fuses (from serial number WNCE0801TPAL0051) Relays behind the right-hand trim Relay no. Protected circuit Starting relay Cutoff solenoid time lag relay 1s Cutoff solenoid switching relay Fig. 224: Relays OM 803 us – Edition 3.7 * * 803b610.fm...
Page 189: Fuses And Relays With Dual Power Option
10 A WNCE0801TPAL0051) Relay no. Protected circuit Starting relay Cutoff solenoid time lag relay 1s Cutoff solenoid switching relay K116 (A) Battery control Fig. 226: Relay K8 Fig. 227: Relay K116 (side view) OM 803 us – Edition 3.7 * 803b610.fm...
Page 190: Noise Levels
• In case of an aggressive working method or difficult terrain, add the environmental factors to the average vibration level in order to obtain the estimated vibration level. OM 803 us – Edition 3.7 * * 803b610.fm...
Page 191 • Move attachments without any jerks. • Adapt your speed and the itinerary to minimize vibration: • Travel around obstacles and uneven ground. • Reduce your speed when traveling across rough terrain. OM 803 us – Edition 3.7 * 803b610.fm...
Page 192 Coucil on minimum health and safety requirements regarding exposure of workers to risks arising from physical agents (vibration). Your Wacker Neuson dealer provides information on other machine functions reducing vibration and on safe operation. OM 803 us – Edition 3.7 * * 803b610.fm...
Page 193: Weight
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 indications can vary by +/− 2 %. OM 803 us – Edition 3.7 * 803b610.fm...
Page 194: Dimensions Model 803 (Up To Serial No. Ai00966)
Technical data 6.12 Dimensions model 803 (up to serial no. AI00966) 730 (29 in) 198 (8 in) 500 (20 in) 897 (35 in) 340 (14 in) 1220 (48 in) 787 (31 in) 1294 (51 in) 700/860 (28/34 in) 747 (29 in)
Page 195: Dimensions Model 803 With Rollbar (From Serial No. Ai00967)
Technical data 6.13 Dimensions model 803 with rollbar (from serial no. AI00967) 1220 (48 in) 3092 (10'-2'') Fig. 229: Machine dimensions (model 803) Main data Model 803 Height 2261 mm (89 in) Upper carriage width 730 mm (29 in) Width with retracted/extended telescopic travel gear...
Page 196: Dimensions Model 803 Without Rollbar (From Serial No. Ai00967)
Technical data 6.14 Dimensions model 803 without rollbar (from serial no. AI00967) 1220 (48 in) 3092 (10'-2'') Fig. 230: Machine dimensions (model 803) Main data Model 803 Height 1436 mm (57 in) Upper carriage width 730 mm (29 in) Width with retracted/extended telescopic travel gear...
Page 197: Lift Capacity Tables 803
1,0 m 2,0 m (9'-10'') (39 in) (79 in) • Full fuel tank. Fig. 231: Lift capacity table (model 803) • Machine at operating temperature. • Operator weight 75 kg (165 lbs). 6-13 OM 803 us – Edition 3.7 * 803b610.fm...
Page 198 618 (1,363) −0.5 m (−20 in) 2.41 (7.91) 146 (323) 210 (462) 316 (696) 561 (1,236) −1.0 m (−39 in) 2.05 (6.73) 138 (304) 149 (328) 243 (536) 418 (922) 6-14 OM 803 us – Edition 3.7 * * 803b610.fm...
Page 199 226 (499) 431 (951) −0.5 m (−20 in) 2.41 (7.91) 115 (253) 148 (325) 222 (490) 433 (955) −1.0 m (−39 in) 2.05 (6.73) 138 (304) 149 (328) 225 (497) 418 (922) 6-15 OM 803 us – Edition 3.7 * 803b610.fm...
Page 200 Technical data 6-16 OM 803 us – Edition 3.7 * * 803b610.fm...
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 will not be implemented on these machines.
Page 202 Contents Acknowledgment ....... . 2 Foreword ........3 Safety Alerts .
Page 203: Foreword
Foreword This safety manual is intended to point out some of the basic safety situations that may be encountered during Read And the normal operation and maintenance of the machine Understand and to suggest possible ways of dealing with these Manuals Before Operating conditions.
Page 204: One-Call First
One-Call First Always inspect the jobsite for evidence of unmarked utilities and contact others if necessary. Plan The Work Call Before You Dig Be aware of the lead time for marking the work area. Dial 811 (USA only) This time may vary from state to state and county to county.
Page 205: Follow A Safety Program
Follow A Safety Program Be Alert! For Safe Operation Know where to get assistance. Know where to find and You must be a qualified and authorized operator for safe how to use a first aid kit and fire extinguisher/fire operation of this machine. You must clearly understand suppression system.
Page 206 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.
Page 207 Follow A Safety Program — Always look in the direction of machine or boom movement. Drive facing the travel direction whenever Understand possible. Worksite Signals — Make sure you understand the rules covering traffic at the worksite. Know what all signs, flags and markings mean.
Page 208: Prepare For Safe Operation
Prepare For Safe Operation Check And Use All Available Protective And — Warning lights — Windshield wipers and devices and washers Safety Devices — Alternate exits — Window defroster Keep all protective devices in place and tightly fastened. — Mirrors —...
Page 209 Prepare For Safe Operation — Check the fuel and hydraulic systems. Have leaks repaired and fill to proper level. Wear — Check all exposed hydraulic components for leaks, Eye Protection 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.
Page 210 Prepare For Safe Operation Quick-coupling Device Safety Before using a quick-coupling device you must know and Read And understand proper installation, maintenance and operation. Understand Manuals Before WARNING! Failure to read and follow manufacturer’s Operating instructions for the correct operation and mainte- nance of the quick-coupler can allow the attachment to come off and cause death or serious injury.
Page 211 Prepare For Safe Operation Check The Work Area Know the location and work plan for other machines on the worksite. Know—beforehand—as much about the worksite as Correct unsafe conditions. Avoid operating in problem possible. Locate all ground workers near the worksite areas that cannot be corrected.
Page 212: Start Safely
Prepare For Safe Operation Mount And Dismount Properly When you enter or leave the machine: Maintain — Maintain a three-point contact with the machine. Three-Point Contact – Face 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.
Page 213 Start Safely Know the exact starting procedures for this machine. WARNING! Never operate any type of engine without See the manufacturer’s manual(s) for starting proper ventilation—exhaust fumes can kill. 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.
Page 214: Operate Safely
Start Safely Test All Controls Operate the control(s) to ensure correct operation in forward, neutral and reverse. Follow the manufacturer’s recommended warm-up Test steering—right and left—while moving slowly. procedures and bring all machine systems to operating temperature. WARNING! Prevent possible injury from loss of control. Know and understand the selected control pattern Machines come equipped with various control and operating mode before operating.
Page 215 Operate Safely Traveling On The Worksite Know and understand the worksite traffic flow patterns Operate and obey signalmen, road signs and flagmen. Controls Smoothly And Slowly 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.
Page 216 Operate Safely Safety Precautions Never reach into the compact excavator and attempt to Check Clearance, operate the controls from outside the cab. Look Out For Others 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.
Page 217 Operate Safely Utilities – Overhead And Underground DANGER! Electrocution or serious injury will result Maintain from CONTACTING or APPROACHING power lines Minimum Approach Distance 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.
Page 218 Operate Safely Trenching Safety Precautions WARNING! Do not dig under the machine or blade. A resulting cave-in could cause death or serious injury. Follow the worksite plan for proper construction of the WARNING! Avoid possible death or serious injury from trench.
Page 219 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. Swing Load Uphill When On — Avoid swinging to the downhill side of a slope. A Slope Always keep the boom and attachment as low and close to the machine as possible.
Page 220 Operate Safely WARNING! Do not dig under the machine. A cave-in could result and the machine could fall into the Use Caution Near excavation, resulting in death or serious injury. Excavation Edge – Do Not Undercut Machine Avoid Silica Dust Cutting or drilling concrete or rock containing quartz may result in exposure to silica dust.
Page 221: Shut Down Safely
Shut Down Safely Machine Shutdown — Check for and clean out trash build-up, especially in the engine compartment, battery box, around Properly shutting down a compact excavator can help exhaust components, in confined spaces, under the prevent accidents when the machine is left unattended. machine and around rotating components.
Page 222: Perform Maintenance Safely
Perform Maintenance Safely Maintain Equipment 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 Protect Yourself Wear personal protective clothing and Personal Protective Equipment (PPE) issued to you or called for Be sure to maintain equipment according to by job conditions.
Page 223 Perform Maintenance Safely Prepare The Work Area — Remove only guards or covers that provide access to the area being serviced. Replace all guards and — Position the compact excavator in a level area out of covers when work is complete. the way of other working equipment.
Page 224 Perform Maintenance Safely Common Maintenance Safety Practices Store all flammable fluids and materials away from work areas in suitable containers, per local regulations. Fuel Hazards Cooling System Hazards IMPORTANT! Always use approved fuel containers and dispensing equipment. Liquid cooling systems build up pressure as the liquid gets hot, so use extreme caution before removing the Fuels are flammable, so observe these practices to radiator or tank cap.
Page 225 Perform Maintenance Safely Electrical System Hazards If electrolyte is ingested, seek MEDICAL ATTENTION IMMEDIATELY. NEVER give fluids that would induce Before working on the electrical system, disconnect the vomiting. battery cable(s). — Remove the battery negative (-) cable(s) first. — When reconnecting the battery, connect the battery negative (-) cable(s) last.
Page 226 Perform Maintenance Safely Track Maintenance And Adjustment Check the tracks daily because the stability of the Follow compact excavator can be dramatically affected by Maintenance Instructions damage to tracks. Check for: — Damage or wear — Correct tension according to manufacturer’s instructions Check For —...
Page 227: Final Word To The User
Final Word To The User You have just finished reading the AEM Compact safety will help to build good judgment in all situations. Excavator Safety Manual. It is impossible for this Our objective is to help you develop, establish and manual to cover every safety situation you may maintain good safety habits to make operating a encounter on a daily basis.
Page 228 Tel.: (262) 255-0500 Fax: (262) 255-0550 Tel.: (800) 770-0957 www.wackerneuson.com Wacker Neuson Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong. Tel: (852) 3605 5360, Fax: (852) 2758 0032...

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803 dual power

Wacker Neuson 803 Operator's Manual

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Introduction

Safety Instructions

Operation

Malfunctions

Maintenance

Technical Data

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