Wacker Neuson 803 Dualpower Manuals

Manuals and User Guides for Wacker Neuson 803 Dualpower. We have 2 Wacker Neuson 803 Dualpower manuals available for free PDF download: Operator's Manual, Service Manual

Wacker Neuson 803 Dualpower Operator's Manual (228 pages)

Track Excavator

Brand: Wacker Neuson | Category: Excavators | Size: 64 MB

Table of Contents

3
- Introduction
  
  11
- Safety Instructions
  
  33
  - Safety Symbols Found in this Manual
    33
  - Warranty
    34
  - Disposal
    34
  - Designated Use
    34
  - Preparing to Use the Machine
    35
    
    Conditions for Use
    35
    
    Operator Training and Knowledge
    35
    
    Preparing for Use
    35
    
    Information on Visibility
    36
    
    Modifications and Spare Parts
    36
  - Operator and Technician Qualifications and Basic Responsibilities
    36
    
    Operator/Owner Responsibility
    36
    
    Repair Person Qualifications
    36
  - Safety Instructions Regarding Operation
    37
    
    Preparing for Use
    37
    
    Starting and Stopping
    37
    
    Carrying Passengers
    38
    
    Danger Zone Awareness
    38
    
    Job Site Awareness
    38
    
    Operating the Machine
    38
    
    Mechanical Integrity
    39
    
    Traveling
    39
  - Operator Protection System
    40
    
    ROPS Rollbar
    40
    
    TOPS Rollbar (up to Serial No. AF01416)
    40
    
    Traveling Without ROPS Rollbar
    40
    
    Traveling Without TOPS Rollbar (up to Serial No. AF01416)
    40
    
    Shatter Protection (Option)
    41
    
    Work Range and Restricted Visibility
    41
  - Applications with Lifting Gear
    42
    
    General Information
    42
    
    Operation with Lowered ROPS Rollbar
    42
    
    Operation with Lowered TOPS Rollbar (up to Serial No. AI00966)
    42
  - Attachments
    42
    
    General Information Regarding Attachments
    42
    
    Installation Notes
    43
  - Trailers
    43
  - Hammer Operation
    44
    
    Safety Instructions
    44
    
    Working with a Hammer
    44
  - Transport and Towing
    45
    
    Towing
    45
    
    Transporting
    45
  - Safety Guidelines for Maintenance
    45
    
    General Maintenance Notes
    45
    
    Personal Safety Measures
    46
    
    Preparing for Maintenance and Repair Work
    46
    
    Performing Maintenance and Repairs
    47
  - Special Hazards
    47
    
    Electrical Energy
    47
    
    Overhead Electric Lines
    48
    
    Underground Electric Lines
    48
    
    Gas, Dust, Steam, Smoke
    49
    
    Hydraulics
    49
    
    Msds
    49
    
    Noise
    49
    
    Tracks
    49
    
    Battery
    51
  - Safety Guidelines While Using Internal Combustion Engines
    51
    
    Running the Engine
    51
    
    Dual Power Option
    52
    
    Fueling the Engine
    52
- Operation
  
  55
  - Control Stand Overview (up to Serial No. AI00814)
    56
  - Control Stand Overview (from Serial No. AI00815)
    59
  - Display Elements (Overview)
    60
  - Putting into Operation
    61
    
    Putting into Operation for the First Time
    61
    
    Running-In Period
    61
    
    Safety Instructions
    61
    
    Check Lists
    62
    
    Start-Up Checklist
    62
    
    Operation Checklist
    63
    
    Parking" Checklist
    63
  - Machine Travel
    64
    
    Starter
    64
    
    Throttle
    64
    
    Indicator Lights and Warning Lights (Overview)
    65
    
    Traveling Signal (Option)
    65
    
    Procedure
    67
    
    Starting the Engine: General
    67
  - Starting at Low Temperatures
    68
    
    Engine and Machine Warm-Up
    68
    
    When the Engine Has Started
    68
    
    Jump-Starting the Engine (Supply Battery)
    69
    
    Operating Temperature Range
    70
    
    Special Instructions for Traveling on Public Roads
    70
    
    Starting Machine Travel
    70
    
    Travel Levers
    70
    
    Travel Position
    70
    
    ISO/SAE Changeover (Option)
    71
    
    Hydraulic Brake
    72
    
    Stabilizer Blade as a Parking Brake
    72
  - Machine Travel on Slopes
    73
  - Gradient Angle
    74
  - Lateral Angle of Inclination
    75
    
    Changing the Width of the Stabilizer Blade
    76
    
    Stabilizer Blade Operation
    76
    
    Telescopic Travel Gear
    78
    
    Upper Carriage Lock
    79
    
    Parking the Machine
    80
    
    Parking the Machine on Slopes
    80
    
    Light System
    81
    
    Power Outlet
    81
    
    Access to the Control Stand
    82
    
    Seat Adjustment
    82
    
    Telescopically Extended Travel Gear
    83
    
    Lowerable TOPS Rollbar (up to Serial No. AI00966) (Option)
    84
    
    Lowering the Rollbar
    84
    
    Raising the Rollbar
    85
    
    Lowerable ROPS Rollbar (up to Serial No. AI00966) (Option)
    86
    
    Lowering the Rollbar
    86
    
    Lowering the Rollbar
    87
    
    Raising the Rollbar
    87
    
    Lowerable ROPS Rollbar (from Serial No. AI00967) (Option)
    88
    
    Lowering the Rollbar
    88
    
    Raising the Rollbar
    89
    
    Seat Belt (Option)
    91
    
    Engine Cover
    95
    
    Battery Master Switch
    96
    
    Towing the Machine
    97
    
    Lifting the Machine
    98
    
    Loading and Transporting the Machine
    100
    
    Tying down the Machine
    101
    
    Shatter Protection (Option) (from Serial No. AI00967)
    102
    
    General Safety Instructions
    104
    
    Machine Operation
    104
    
    Control Lever Overview
    106
    
    Left-Hand Control Lever
    106
    
    Right-Hand Control Lever
    106
    
    Boom Swivel Controls
    107
    
    Boom Swivel Controls (up to Serial No. AI00975)
    107
    
    Boom Swivel Controls (from Serial No. AI00976)
    108
    
    Auxiliary Hydraulics
    109
    
    Auxiliary Hydraulics (up to Serial No. AI00975)
    109
    
    Auxiliary Hydraulics (from Serial No. AI00976)
    110
    
    Auxiliary Hydraulics (Double-Action Option) (up to Serial No. AI00975)
    111
    
    Auxiliary Hydraulics (Double-Action Option) (from Serial No. AI00976)
    112
    
    Emergency Lowering
    114
    
    Rotating the Upper Carriage
    115
    
    Upper Carriage Deceleration
    115
    
    Lock Lever
    116
    
    Lock Lever (from Serial No. AI00815)
    116
    
    Lock Lever (up to Serial No. AI00814)
    116
    
    Dual Power (Option)
    117
    
    Overview of Connections
    118
    
    Coupling
    119
    
    Checking the Hydraulic Oil Levels of the Power Unit and Excavator
    121
    
    Changeover from HPU to Diesel Operation
    122
    
    Changeover from Diesel to HPU Operation
    123
    
    Uncoupling
    124
    
    Charging the Excavator Battery
    125
    
    Charging the Battery with the Mains
    127
    
    Charging the Battery with the Power Unit
    127
    
    Dual-Power Operation with Rotating Beacon
    128
    
    Pressure Release on the Auxiliary Hydraulics
    129
    
    Re-Equipping Attachments
    129
    
    Releasing Pressure
    129
    
    Removing a Bucket
    130
    
    Specific Safety Instructions
    130
    
    Connections for Auxiliary Hydraulics
    131
    
    Installing a Bucket
    131
    
    Connections for Auxiliary Hydraulics (Stick Hose Routing Option)
    132
    
    Attachments
    133
    
    Inadmissible Work Procedures
    133
    
    Maintenance of Attachments
    133
    
    Working with the Standard Bucket
    133
    
    Excavator Work Position
    134
    
    Bucket Position When Digging
    135
    
    Excavating Trenches
    135
    
    Loading
    135
    
    Excavating Trenches Sideways
    136
    
    Grading
    136
    
    Grading
    137
    
    Stabilizer Blade at Rear
    138
    
    Working Alongside Trenches
    138
- Malfunctions
  
  139
  - Engine Trouble
    139
- Maintenance
  
  141
  - Fuel System
    142
    
    Specific Safety Instructions
    142
    
    Draining Fuel
    143
    
    Refueling
    143
    
    Stationary Fuel Pumps
    143
    
    Bleeding the Fuel System
    144
    
    Fuel Prefilter with Water Separator
    145
  - Engine Lubrication System
    146
    
    Adding Engine Oil
    147
    
    Checking the Oil Level
    147
  - Engine Cooling System
    148
    
    Specific Safety Instructions
    148
    
    Checking the Coolant Level/Adding Coolant
    150
    
    Cleaning the Radiator
    151
  - Air Filter
    152
    
    Air Filter (up to Serial No. AI00875)
    153
    
    Replacing Air Filter Elements
    153
    
    Air Filter (from Serial No. AI00876)
    154
    
    Replacing Air Filter Elements
    154
  - V-Belt
    155
    
    Checking V-Belt Tension
    155
    
    Retightening the V-Belt
    155
  - Hydraulic System
    156
    
    Important Information on the Hydraulic System
    156
    
    Adding Hydraulic Oil
    157
    
    Checking the Hydraulic Oil Level
    157
    
    Important Information on the Use of Biodegradable Oil
    158
    
    Checking Hydraulic Pressure Lines
    159
  - Overview of Lubrication Points
    160
    
    Parking the Machine
    161
    
    Swiveling Cylinder Lubrication Points
    161
    
    Lubricating the Live Ring (Ball Bearing)
    162
    
    Lubricating the Teeth of the Live Ring
    163
    
    Ball Sockets (ISO/SAE Changeover Option)
    164
  - Tracks
    165
    
    Checking Track Tension
    165
    
    Tightening the Tracks
    166
  - Traveling Drive
    167
  - Electrical System
    168
    
    Servicing and Maintenance at Regular Intervals
    168
    
    Specific Safety Instructions
    168
    
    Alternator
    169
    
    Instructions Concerning Specific Components
    169
    
    Battery
    170
  - General Maintenance
    171
    
    Cleaning
    171
    
    General Instructions for All Areas of the Machine
    171
    
    Control Stand
    172
    
    Engine Compartment
    172
    
    Exterior of the Machine
    172
    
    Pivots and Hinges
    173
    
    Threaded Fittings and Attachments
    173
  - Preparatory Work before Taking out of Service
    173
  - Maintenance if the Machine Is out of Service for a Longer Period of Time
    174
    
    Putting into Operation Again
    174
  - Fluids and Lubricants
    175
    
    Oil Change and Filter Replacement (Hydraulics)
    177
  - Maintenance Label
    183
    
    Explanation of Symbols on the Maintenance Label
    183
- Technical Data
  
  185
  - Engine
    185
  - Travel Gear and Swivel Unit
    186
  - Stabilizer Blade
    187
  - Operating Hydraulics
    187
  - Connection Values of Dual Power Option
    187
  - Electrical System
    187
    
    Fuses Behind the Right-Hand Trim
    188
    
    Relays Behind the Right-Hand Trim
    188
  - Fuses and Relays with Dual Power Option
    189
  - Noise Levels
    190
  - Vibration
    190
  - Weight
    193
  - Coolant Compound Table
    193
  - Dimensions Model 803 (up to Serial No. AI00966)
    194
  - Dimensions Model 803 with Rollbar (from Serial No. AI00967)
    195
  - Dimensions Model 803 Without Rollbar (from Serial No. AI00967)
    196
  - Lift Capacity Tables 803
    197
    
    Safety Instructions - Lift Capacity Table
    197
Table of Contents

202
- Foreword
  203
- Safety Alerts
  203
- A Word to the User/Operator
  204
- One-Call First
  204
- Follow a Safety Program
  205
- Prepare for Safe Operation
  208
- Start Safely
  212
- Operate Safely
  214
- Load and Unload the Machine Safely
  221
- Shut down Safely
  221
- Perform Maintenance Safely
  222
- Final Word to the User
  227

Wacker Neuson 803 Dualpower Service Manual (196 pages)

Track excavator

Brand: Wacker Neuson | Category: Excavators | Size: 9 MB

Table of Contents
3
SHB 803 en – Edition 2.4 * 803S20Ivz.fm
8
Operation

10
Technical Data Chassis

24
Maintenance

39
- Fluids and Lubricants
  40
- Maintenance Plan (Overview)
  50
- Service Package
  50
- Introduction
  50
- Safety-Relevant Parts
  50
- Fuel System
  51
  - Specific Safety Instructions
    51
  - Refueling
    51
  - Stationary Fuel Pumps
    52
- Diesel Fuel Specification
  52
- Bleeding the Fuel System
  53
- Fuel Prefilter with Water Separator
  53
- Replacing the Fuel Filter
  55
- Engine Lubrication System
  56
  - Checking the Oil Level
    56
  - Adding Engine Oil
    57
  - Changing Engine Oil
    58
  - Replacing the Engine-Oil Filter Cartridge
    59
- Cooling System
  60
- Air Filter (up to Serial No. AI00875)
  64
  - Replacing Air Filter Elements
    65
- Air Filter (from Serial No. AI00876)
  65
  - Replacing Air Filter Elements
    66
- V-Belt
  68
  - Checking V-Belt Tension
    68
  - Retensioning the V-Belt
    69
- Pressure Check
  70
  - General
    70
  - Pressure Check of Gear Pump P2
    70
  - Pressure Check of Gear Pump P1
    71
- Hydraulic System
  74
- Tracks
  79
  - Checking Track Tension
    79
  - Setting the Tracks
    80
- Lubrication Points on Boom (up to Serial Number AI00966)
  81
  - Lubrication Strip
    82
- Overview of Lubrication Points (from Serial No. AI00967)
  83
- Electrical System
  89
- General Maintenance
  92
Engine

98
- Overview of Engine 3TNV70-VNS (Tier IV Final up to 2012)
  98
- Fuel System
  99
- Checking and Adjusting Valve Clearance
  101
- Tightening Order for Cylinder Head Bolts
  102
- Checking the Injection Nozzles
  103
  - Pressure Check
    103
- Checking the Nozzle Jet
  103
- Injection Time
  104
  - Checking and Adjusting Injection Time
    104
  - Replacement of Fuel Injection Pump
    105
- Adjusting Engine Speed
  106
- Compression
  106
- Checking the Coolant Thermostat
  106
- Checking the Thermal Switch
  107
- Oil Pressure Switch
  107
- Checking the Coolant Circuit
  108
- Engine Trouble
  109
- Overview of Engine 3TNV74F-SNNS (Tier IV Final from 2012)
  111
- Fuel System
  113
- Cooling System
  114
- Altitude-Dependent Output Reduction
  115
- Checking and Adjusting Valve Clearance
  116
- Tightening Order for Cylinder Head Bolts
  118
  - Order for Removing the Cylinder-Head Bolts
    118
  - Order for Installing the Cylinder-Head Bolts
    118
- Checking the Injection Nozzles
  119
  - Pressure Check
    119
- Checking the Nozzle Jet
  120
- Injection Time
  120
  - Checking Injection Time
    120
  - Setting Injection Time
    122
- Removing and Installing the Injection Pump
  123
  - Removing the Injection Pump
    123
  - Fitting the Fuel Injection Pump
    124
- Measuring and Adjusting the Engine Speed
  126
- Compression
  126
- Checking the Coolant Thermostat
  127
- Checking the Temperature Sensor
  127
- Oil Pressure Switch
  128
- Checking the Coolant Circuit
  128
- Cleaning the Cooling Water Channels
  128
- Coolant and Fuel Hoses
  129
- Crankcase Vent
  129
- Replacing the Glow Plugs
  129
- Engine Trouble
  130
Hydraulic System

133
- Hydraulic Pump PGP505B0050CA1H2NJ7J5C-505A00 (Tier IV Final up to 2012)
  134
- Pump Unit: Exploded View
  135
- Hydraulic Pump PGP505B0040CA1H2NJ7J5C-505A0040XB1J5B1B1 (Tier IV Final from 2012)
  136
  - Pump Unit: Exploded View
    137
- Main Valve Block
  138
  - Connections
    138
  - Legend
    139
  - Main Valve Block Diagram
    140
  - Pressure Limiting Valves
    141
  - Pump Assignment
    142
- Traveling Drive
  143
  - Function
    144
- Swivel Unit
  146
  - Swivel Unit
    147
- Swivel Joint
  148
  - Sealing
    148
- Mechanical Control
  149
- Troubleshooting in the Hydraulic System
  154
- Plastic Trims
  154
Electrical System

161
- Ohm's Law (Current, Voltage, Resistance); Power
  162
- Measuring Equipment, Measuring Methods
  162
- Cable Color Coding
  163
- Relays
  163
  - Use, Mode of Function
    163
- Electrical System
  164
- Control Lever Push Button
  166
  - Working Light
    166
  - Dynamo
    167
  - Rectifier
    167
  - Starter
    167
Options

186
- Rollbar
  186
- ISO/SAE Changeover (Option)
  190
- Traveling Signal (Option)
  191
- Telematic
  192
  - Connections
    192
  - Functional Check/Diode
    192
- Zero-Emission Dual Power Drive
  193
  - Overview
    193

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Wacker Neuson 803 Dualpower Manuals

Wacker Neuson 803 Dualpower Operator's Manual (228 pages)

Table of Contents

Table of Contents

Introduction

Safety Instructions

Operation

Malfunctions

Maintenance

Technical Data

Table of Contents

Wacker Neuson 803 Dualpower Service Manual (196 pages)

Table of Contents

Operation

Technical Data Chassis

Maintenance

Engine

Hydraulic System

Electrical System

Options

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