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Wacker Neuson 803 Dualpower, Operator'S Manual

The Wacker Neuson 803 Dualpower is a compact and versatile construction machine designed for maximum performance. Enhance your productivity with our comprehensive Service Manual, providing step-by-step instructions and troubleshooting tips. Download the manual for free at manualshive.com, empowering you to confidently operate and maintain your equipment.

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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

Problem

Possible causes

See

Engine does not start or is not easy to start

Wrong SAE grade of engine lubrication oil

5-35

Fuel grade does not comply with specifications

5-35

Malfunctioning or empty battery

5-30

Loose or oxidized cable connections in starter circuit

Malfunctioning starter, or pinion does not engage

Wrong valve clearance

Malfunctioning injection nozzle

Malfunctioning cutoff solenoid

Malfunctioning fuse

Engine starts, but does not run smoothly or faultless

Fuel grade does not comply with specifications

5-35

Dirty fuel filter

Wrong valve clearance

Air in fuel system

Injection line leaks

Malfunctioning injection nozzle

Engine overheats. Temperature warning system 
responds

Oil level too low

5-7

Oil level too high

5-7

Dirty air filter

5-12

Dirty oil radiator fins

5-8

Coolant level too low

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

Summary of Contents for 803 Dualpower

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: ...ns in particular of the copyright protection will be subject to civil and criminal prosecution Wacker Neuson Linz GmbH keep abreast of the latest technical developments and constantly improve their products For this reason we may from time to time need to make changes to diagrams and descriptions in this documentation which do not reflect products which have already been delivered and which will n...

Page 3: ...2 1 Warranty 2 2 Disposal 2 2 Designated Use 2 2 Preparing To Use The Machine 2 3 Conditions for use 2 3 Operator training and knowledge 2 3 Preparing for use 2 3 Information on visibility 2 4 Modifications and spare parts 2 4 Operator and Technician Qualifications and Basic Responsibilities 2 4 Operator Owner responsibility 2 4 Repair person qualifications 2 4 Safety Instructions Regarding Operat...

Page 4: ... 2 19 Safety Guidelines while using Internal Combustion Engines 2 19 Running the engine 2 19 Fueling the engine 2 20 Dual Power option 2 20 Operation 3 Control stand overview up to serial no AI00814 3 2 Control stand overview from serial no AI00815 3 5 Display elements overview 3 6 Putting into operation 3 7 Safety instructions 3 7 Putting into operation for the first time 3 7 Running in period 3 ...

Page 5: ...67 option 3 34 Lowering the rollbar 3 34 Raising the rollbar 3 35 Seat belt option 3 37 Engine cover 3 41 Battery master switch 3 42 Towing the machine 3 43 Lifting the machine 3 44 Loading and transporting the machine 3 46 Tying down the machine 3 47 Shatter protection option from serial no AI00967 3 48 Machine operation 3 50 General safety instructions 3 50 Control lever overview 3 52 Left hand ...

Page 6: ... Working with the standard bucket 3 79 Inadmissible work procedures 3 79 Excavator work position 3 80 Bucket position when digging 3 81 Excavating trenches 3 81 Loading 3 81 Grading 3 82 Excavating trenches sideways 3 82 Grading 3 83 Grading 3 83 Working alongside trenches 3 84 Stabilizer blade at rear 3 84 Malfunctions 4 Engine trouble 4 1 Maintenance 5 Introduction 5 1 Fuel system 5 2 Specific s...

Page 7: ...t regular intervals 5 28 Instructions concerning specific components 5 29 Alternator 5 29 Battery 5 30 General maintenance 5 31 Cleaning 5 31 General instructions for all areas of the machine 5 31 Control stand 5 32 Exterior of the machine 5 32 Engine compartment 5 32 Threaded fittings and attachments 5 33 Pivots and hinges 5 33 Preparatory work before taking out of service 5 33 Maintenance if the...

Page 8: ...evels 6 6 Vibration 6 6 Coolant compound table 6 9 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 lift capacity table 6 13 ...

Page 9: ...r filter 5 13 5 14 Biodegradable oil 5 18 Bleeding the fuel system 5 4 Checking the coolant level 5 10 Checking the engine oil level 5 7 Checking the hydraulic oil level 5 17 Cleaning 5 31 Electrical system 5 28 Engine and hydraulics cooling system 5 8 Engine lubrication system 5 6 Fuel system 5 2 General maintenance 5 31 Hydraulic pressure lines 5 19 Hydraulic system 5 16 Instructions concerning ...

Page 10: ...height adjustment 3 38 3 40 Shatter protection 2 9 3 48 Starting aid 3 15 T Technical data 6 1 Chassis 6 1 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 W Warranty 2 2 Working Freeing the machine 3 82 Recommendations 3 82 ...

Page 11: ... accidents Operational safety and readiness of the machine do not only depend on your skill but also on maintenance and servicing of the machine This is why regular maintenance and ser vice work is absolutely necessary Extensive maintenance and repair work must always be performed by a Wacker Neuson service center Use only original spare parts for repairs This ensures operational safety and readin...

Page 12: ...erial 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 Operator s Manual 11 Lock lever 7 5 7 3 2 1 4 8 10 2 6 8 9 3 11 5 4 6 8 ...

Page 13: ...utside 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 Operator s Manual 11 Lock lever 12 ROPS rollbar option 13 Shatter protection option 5 3 1 4 8 2 6 8 9 2 10 3 11 5 4 6 8 12 7 11 7 13 13 ...

Page 14: ...ge Tracked travel gear Stabilizer blade Live ring Upper carriage Water cooled diesel engine Hydraulic and electrical components Boom Information The machine can be equipped with the Telematic option for transmitting operating data location etc via satellite Traveling drive The diesel engine permanently drives two gear pumps the oil flow of which is sent to the hydraulic motor currently actuated Op...

Page 15: ...tective structures Incorrect work on the cabin and protective structures causes serious injury or death No drilling cutting or grinding on protective structures Welding straightening or bending work on protective structures is prohibited Have damaged protective structures immediately replaced Information Check the rollbar and all protective structures once a day for damage Information Protective s...

Page 16: ...y to the operator or personnel Always compare the weight of the attachment and its maximum payload with the indica tions in the lift capacity table Never exceed the maximum payload stated in the lift capac ity table 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 Use attachment ...

Page 17: ...eir qualifications to the contractor Persons are expected to perform work reliably They have been appointed by the contractor for traveling and servicing the earth moving machine Get informed on and follow the legal regulations of your country 1 9 TOPS rollbar up to serial no AI00966 ROPS NOTICE Always fasten the seat belt if the rollbar is raised NOTICE Do not use the seat belt if the rollbar is ...

Page 18: ...stelle Fachausschuss Bauwesen Landsberger Str 309 80687 Munich Germany Distinguishing EU number 0515 Notified body involved in procedure TÜV SÜD Industrie Service GmbH Westendstr 199 D 80686 Munich Directives and standards We hereby declare that this product corresponds to the relevant regulations of the following Directives and standards 2006 42 EC 2005 88 EC 2000 14 EC DIN EN ISO 12100 1 DIN EN ...

Page 19: ...mation example Machine designation HYDRAULIC EXCAVATOR Model Model year CEE no Output Serial no Max payload GWR Operating weight Front GAWR Transport weight Rear GAWR Version Other information see chapter 6 Technical data on page 6 1 ROPS bar type label The type label is located at the front right on one side of the rollbar Engine number The type label is located on the cylinder head cover engine ...

Page 20: ...1 10 OM 803 us Edition 3 7 803b110 fm Introduction 1 12 Overview of adhesive labels1 1 Number and position of adhesive labels can differ depending on country ...

Page 21: ...uced by the machine LWA sound power level Other information see chapter 6 8 Noise levels on page 6 6 Position On the front side of the engine cover Meaning The reservoir contains hydraulic oil Position On the hydraulic oil reservoir Meaning option The reservoir contains biodegradable hydraulic oil This label is notched on the side depending on the biodegradable hydraulic oil used 1 BP Biohyd SE S ...

Page 22: ...om hammer to grab operation Position On the control stand Meaning up to serial no AI00814 This label shows how to lock the control levers Position On the left hand side of the control element console Meaning from serial no AI00815 This label shows how to lock the control levers Position On either side of the control stand Meaning This label shows the forward traveling direction Position On either ...

Page 23: ...chapter 3 14 Control lever overview on page 3 52 Position On the control stand Meaning Indicates the control operations that do not comply with the ISO standard if the SAE con trols are selected Position On the control stand Meaning Check before starting the machine the operating pattern that has been chosen Position On the control stand Fig 16 Controls Fig 17 Controls Fig 18 SAE controls Fig 19 I...

Page 24: ...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: ...OM 803 us Edition 3 7 803b110 fm 1 15 Introduction 1 13 Overview of safety labels1 1 Number and position of adhesive labels can differ depending on country ...

Page 26: ...e engine compartment if the fan is still running Meaning Entanglement hazard You can be pinched or entangled in the engine V belt when the engine is running Stay clear of the engine compartment with the engine running Perform work in the engine compartment at engine standstill only Burn hazard Hot surface Do not touch Contents are under pressure Allow the reservoir to cool down Carefully and slowl...

Page 27: ...tor s Manual Position At the front on the engine cover standard On the left on the rollbar option Meaning up to serial no AI00824 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 rollbar lowered is prohibited Operate within stability limits of machine t...

Page 28: ...ing up to serial no AI00681 Lower the boom and the stabilizer blade to the ground as you leave the machine remove the starting key and place chocks on the left and right under the tracks Position At the front on the engine cover Meaning Crushing hazard due to unintentional machine operation Before performing maintenance and repair work stop the engine raise the lock lever and remove the starting k...

Page 29: ...ded fittings hydraulic cylinders couplings etc Position On either side of the boom Meaning Crushing hazard Stay clear of the machine s work range during operation Position On either side of the boom Meaning from serial number AF01941 Attention Severe injury hazard Operate the machine only when seated on the seat Before leaving the seat raise the lock lever to prevent unintentional movements Stay c...

Page 30: ...ve effect Do not drill holes or perform welding on this structure Have the machine serviced and repaired only by a Wacker Neuson service center Position On the ROPS bar Meaning Explosion hazard Connecting jump leads incorrectly can cause explosions and personal injury with possible death Always wear safety glasses and protective clothing Follow the specific battery safety instructions Position Nea...

Page 31: ...option Remove the shatter protection if the machine is transported on an open platform Position On the shatter protection at the upper left in traveling direction Information If an additional cross brace is installed from the 3rd quarter of 2014 the shat ter protection does not have to be removed before transporting the machine on an open platform Meaning option Read the Operator s Manual before c...

Page 32: ...1 22 OM 803 us Edition 3 7 803b110 fm Introduction ...

Page 33: ...nsequences of the hazard Obey all safety messages that follow this symbol to avoid possible injury or death WARNUNG CAUTION CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate injury Potential consequences of the hazard Obey all safety messages that follow this symbol to avoid possible minor or moderate injury NOTICE NOTICE indicates a situation which if ...

Page 34: ...ine Wacker Neuson will not be liable for damage resulting from use other than mentioned above The operator alone will bear the risk 3 Designated use also includes observing the instructions set forth in the Operator s Manual and observing the maintenance schedule 4 Machine safety can be negatively affected by performing out machine modifications without proper authority and by using spare parts eq...

Page 35: ...ble condition and if necessary or required by law to require the operating or servicing persons to wear protective clothing and safety equipment Operator training and knowledge Always keep this Operator s Manual and other manuals that accompany the machine in their storage compartment provided in the operator station on the machine Immedi ately replace an incomplete or illegible Operator s Manual ...

Page 36: ... work on load bearing elements Spare parts must comply with the technical requirements specified by Wacker Neuson Contact your Wacker Neuson dealer for assistance 2 6 Operator and Technician Qualifications and Basic Responsibilities Operator Owner responsibility Only allow trained and experienced individuals to operate maintain or repair the machine NEVER let unauthorized or underaged persons oper...

Page 37: ... change the seat position when operating the machine Make sure that all safety devices are properly installed and functional before starting work Before putting the machine attachment into operation starting moving ensure that no one in the immediate vicinity will be at risk Starting and stopping Perform starting and stopping procedures according to this Operator s Manual Observe all indicator lig...

Page 38: ...t additional equipment or material The danger zone also includes the area affected by falling material equipment or constructions debris The danger zone must be extended by 0 5m 20 in in the immediate vicinity of buildings scaffolds or other elements of construction Seal off the danger zone if it is not possible to keep a safe distance Stop work immedi ately if persons do not leave the danger zone...

Page 39: ...diately Traveling Before moving the machine always check whether the supplementary equipment and the attachments have been safely stowed away or attached Careful when reversing the machine accident hazard Persons in the blind spot of the machine cannot be seen by the operator Ensure that nobody is within the danger zone of the machine when changing the traveling direction Use the rearview mirrors ...

Page 40: ...y 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 Traveling without TOPS rollbar up to serial no AF01416 Traveling without ROPS rollbar WARNUNG DANGER Accident hazard Do not operate the machine with a lowered rollbar Failure to follow this precautionary measure w...

Page 41: ...ng cutting or grinding Do not mount any brackets Do not perform any welding bonding work 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 Do not ...

Page 42: ...level ground Avoid tipping movements of the machine under all circumstances Machine operation in areas involving a risk of falling objects is prohib ited Do not fasten the seat belt in order to be able to leave the machine immediately in an emergency Wear protective equipment protective clothing safety glasses for example 2 10 Attachments General information regarding attachments Prior to travelin...

Page 43: ...3 19 Pressure release on the auxiliary hydraulics on page 3 75 Operate the machine only if all protective devices for the attachments have been installed and are functional and if all brake light and hydraulic connections have been connected If optional equipment is installed all light installations indicator lights etc that are required in addition must be installed and functional Prior to fittin...

Page 44: ...d have the error repaired immediately Working with a hammer NOTICE Always observe the following instructions Do not use the impact force of the attachment to perform demolition work Keep the hammer perpendicular to the surface max deviation to all sides is 2 Never move the hammer as you drive it into the material After you have driven the hammer into the material do not try to fragment the materia...

Page 45: ... Safety Guidelines for Maintenance General maintenance notes Operational readiness and the service life of machines are heavily dependent on maintenance It is therefore in the interest of the machine owner to perform the prescribed mainte nance The manufacturer requires the owner to perform maintenance under all circumstances Otherwise warranty shall not be given in full Adhere to prescribed inter...

Page 46: ...ng procedures set forth in the Operator s Manual and the information on maintenance Prior to performing assembly work on the machine ensure that no movable parts will roll away or start moving If required secure the maintenance area appropriately In accordance with this Operator s Manual and instructions for the respective assembly release the pressure in all system sections and pressure lines hyd...

Page 47: ...g maintenance and repairs After cleaning remove all covers and tapes applied for that purpose After cleaning examine all fuel lubricant and hydraulic oil lines for leaks chafe marks and damage Rectify all defects without delay Observe the adjustment maintenance and inspection activities and intervals set forth in the Operator s Manual including information on the replacement of parts partial equip...

Page 48: ...exposed lines Safely fasten lines if vibration or shocks to these lines must be avoided Overhead electric lines WARNUNG DANGER Personal injury hazard due to electrical shocks Will cause severe injuries or death During machine operation maintain a safe distance from overhead electric lines If work must be performed close to overhead lines the equipment attachments must be kept well away from them I...

Page 49: ...age Repair any damage and leaks immediately Splashed oil can cause injury and fire In accordance with the Operator s Manual for the respective assembly release the pressure in all system sections and pressure lines hydraulic system to be opened before performing any implementing repair work Hydraulic and compressed air lines must be laid and fitted properly Ensure that no connections are interchan...

Page 50: ...2 18 OM 803 us Edition 3 7 803b210us fm Safety instructions Check track tension at regular intervals ...

Page 51: ...eling Can cause severe injury or death Read and follow the warning instructions and the safety guidelines below CALIFORNIA Proposition 65 Warning Engine exhaust some of its constituents and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Running the engine When running the engine Keep the area around...

Page 52: ...table mounting points and load securing devices The recommissioning procedure must be strictly in accordance with the Operator s Manual Dual Power option Operating radius 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 Position Function A Hydraulic excavator 803 B Elect...

Page 53: ...s 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 anything down on the hydraulic hoses Do not put the connecting cable over edges ...

Page 54: ...2 22 OM 803 us Edition 3 7 803b210us fm Safety instructions ...

Page 55: ...n of digits or a combination of digits and letters for example 40 18 or 40 A used for identifying the control elements means fig no 40 control element no 18 or position A in fig no 40 Figures carry no numbers if they are placed to the left of the text The symbols used in the description have the following meanings Identifies a list Subdivision within lists or an activity Follow the steps in the re...

Page 56: ...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: ...rmation see page 1 Operator seat 3 28 2 Upper carriage lock 3 25 3 Engine cover lock 3 41 4 Starter 3 10 5 Stabilizer blade telescopic travel gear lever 3 22 3 24 6 Stabilizer blade telescopic travel gear changeover lever 3 24 7 Boom swivel pedal 3 53 8 Engine cover 9 Handhold ...

Page 58: ... 17 18 6 Pos Description For more information see page 10 Auxiliary hydraulics pedal 3 55 11 Footrest 12 Lock lever 3 62 13 Throttle 3 10 14 Control lever left 3 52 15 Travel lever left 3 16 16 Travel lever right 3 16 17 Control lever right 3 52 18 Display element 3 6 ...

Page 59: ...4 Starter 3 10 5 Stabilizer blade telescopic travel gear lever 3 22 3 24 6 Stabilizer blade telescopic travel gear changeover lever 3 24 7 Boom swivel pedal 3 53 8 Engine cover 3 42 9 Handhold 10 Auxiliary hydraulics pedal 3 55 11 Footrest 12 Lock lever 3 62 13 Throttle 3 10 14 Control lever left 3 52 15 Travel lever left 3 16 16 Travel lever right 3 16 17 Control lever right 3 52 18 Display eleme...

Page 60: ...iew 20 24 22 21 23 Pos Description For more information see page 20 Indicator light red alternator charge function 3 11 21 Indicator light red engine oil pressure 3 11 22 Indicator light red coolant temperature 3 12 23 Indicator light yellow fuel gage 3 12 24 Hour meter 3 12 ...

Page 61: ...read and understood this Operator s Manual before putting the machine into operation The machine may only be used in technically perfect condition in accordance with its designated use and the instructions set forth in the Operator s Manual and only by safety conscious persons who are fully aware of the risks involved in operating the machine Go through the Start up checklist in the following chap...

Page 62: ...e water separator 5 5 4 Engine oil level OK 5 7 5 Oil level in hydraulic oil reservoir OK 5 17 7 V belt condition and tension checked 5 15 8 Lubrication points greased 5 27 9 Tracks checked for cracks cuts etc 5 25 10 Light system acoustic warning system indicator and warning lights OK 3 27 3 11 11 Are the lights and the footholds clean 12 Raise the lock lever 3 62 13 Attachment safely locked 3 75...

Page 63: ...ternator charge function gone out 3 11 3 Do the travel levers and pedals work correctly 3 16 4 Telescopic travel gear extended 3 24 No Question 1 Attachments lowered to the ground 3 26 2 Stabilizer blade lowered to the ground 3 Lock lever raised especially if the machine cannot be supervised 3 62 4 Machine keys removed especially if the machine cannot be supervised 3 26 When parking on public road...

Page 64: ...d 1 0 2 3 Fig 49 Preheating start switch 4 Position Function Power consumer 0 Insert or remove the starting key None 1 ON travel position Feed pump switched on Indicator lights illuminate 2 Preheats the engine 10 15 seconds Glow plugs 3 Starts the engine Starter Fig 50 Engine speed control up to serial no AI00814 13 B A Fig 51 Engine speed control from serial no AI00815 13 B A ...

Page 65: ...overheating or breakdown hazard If the indicator light illuminates with the engine running Stop the engine immediately and have the cause repaired by a Wacker Neuson service center The V belt is malfunctioning or there is an error in the charging circuit of the alternator if the indicator light illuminates with the engine running The battery is no longer charged The indicator light illuminates whe...

Page 66: ...es after stopping the engine Wear protective gloves and clothing Open the cap to the first notch and release the pressure Fuel level indicator Fill up immediately if this indicator light illuminates Bleed the fuel system if the tank has been run empty Hour meter Counts the operating hours when the engine or the electrohydraulic power unit is running if the machine is equipped with the Dual Power o...

Page 67: ... Seat belt option on page 3 37 Check whether all levers and pedals are in neutral position Move the throttle to the center position between minimum and maximum if the engine is cold Starting the engine general The starter cannot be actuated if the engine is already running start repeat interlock Do not run the starter for more than 10 seconds Wait about 1 minute so the battery can recover before t...

Page 68: ...ut Let the engine warm up At cold temperatures Increase the engine speed slowly Apply full load to the engine only after the warm up phase Engine and machine warm up Once it has started let the engine warm up about 5 Minutes at slightly increased idling rpm Actuate the operating hydraulics to warm up the hydraulic oil and the components more quickly Set the engine speed lever to the center positio...

Page 69: ...ve the jump starting vehicle close enough to the machine so that the jump leads can reach to connect the two batteries Let the engine of the jump starting vehicle run First connect one end of the red jump lead to the terminal of the empty battery then connect the other end to the terminal of the starting battery Connect one end of the black jump lead to the terminal of the starting battery Connect...

Page 70: ...r light goes out Slowly actuate the travel lever Machine moves off Operating temperature range The following operating conditions must be fulfilled in order to ensure optimal output and a long service life of the machine Do not operate the machine at ambient temperatures above 38 C 100 F or below 15 C 5 F Travel levers Warning WARNING Accident hazard The machine moves in the opposite direc tion if...

Page 71: ...start ing work The changeover is located under both covers 1 on the control stand Switching is possible between Operating Pattern A ISO controls and Operating Pattern B SAE controls 1 Park the machine on level and firm ground lower the boom to the ground stop the engine and remove the starting key 2 Raise covers 1 3 Slide the knurled sleeve 2 upward and hold unhitch and grease it 4 Slide the knurl...

Page 72: ...er than the permissible travel speed Information 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 Fig 58 Ball pin position 2 A B 2 B A Fig 59 ISO SAE changeover B A A B Wiring diagram Controls A ISO controls Europe Op...

Page 73: ... upper layer of the ground can drastically affect machine traction and stability The machine can slip sideways on gravel or loose rocky soil The stability of the machine can be reduced on rough terrain Newly filled or muddy ground can give away under the weight of the machine or the tracks can dig into the ground and increase the angle of the machine maximum gradient angle and maximum lateral angl...

Page 74: ...2 in off the ground and position it straight ahead at the center of the machine Do not exceed a maximum gradient angle of 15 Traveling downhill During downhill travel the control stand must face downhill Set the stabilizer blade downhill 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 Fig 6...

Page 75: ...ngle 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 inclination 10 Fig 65 Platform 10 ...

Page 76: ...tance see Grading on page 3 83 Slightly raise the stabilizer blade Information Check the position of the stabilizer blade before machine travel Changing the width of the stabilizer blade NOTICE The machine can be damaged if the telescopic travel gear and the stabilizer blade are set to different widths for example when traveling through a door frame Adjust the stabilizer blade and the telescopic t...

Page 77: ... A on either side Increasing 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 out the stabilizer blade extensions B on either side Insert pins A on either side Fig 67 Changing the width of the stabilizer blade A Fig 68 Changing the width of the stabilizer blade B A Fig 69 Changing the width of the stabilizer blade B A...

Page 78: ... lower the boom immediately to increase stability This prevents the machine from tipping over in case of a hydraulic hose rupture on the telescopic cylinder A hydraulic hose rupture might cause the travel gear to retract and reduce stability Warning WARNING Crushing hazard when retracting the telescopic travel gear Can cause serious injury or death Do not allow anyone to stay in the danger zone NO...

Page 79: ... death Lock the upper carriage Secure the machine and the attachments correctly The upper carriage lock prevents the upper carriage from rotating during machine travel over longer distances or locks the upper carriage during transport 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 Fig 71 Telescopic trave...

Page 80: ...g speed with no load for at least 5 minutes before you switch it off Secure the machine against unauthorized operation Raise the lock lever Remove the starting key and carry it with you Parking the machine on slopes Avoid stopping the machine abruptly Always ensure that there is enough space for stopping the machine Park the machine on firm level and horizontal ground Never park on slopes If you c...

Page 81: ...rmation The Dual Power option includes a power saving LED light see chapter LED working light on page 3 73 Power outlet The control stand is equipped with a 12 V outlet on the right This makes it possible to operate a 12 V rotating beacon for example NOTICE There must be no consumer connected to the 12 V outlet during Dual Power operation The 12 V outlet may only be used during diesel operation si...

Page 82: ...ckrest with his back Pull lever H upward and at the same time Move the seat forward or backward 3 8 Access to the control stand Warning WARNING Injury hazard when entering or exiting Can cause serious injury or death Bear in mind the following before accessing the control stand The footholds and handles must be free of snow ice oil grease mud or other dirt Stop the machine on firm level and horizo...

Page 83: ... 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: ...ed ROPS rollbar on page 2 9 Warning WARNING Injury hazard due to unfastened seat belt Can cause serious injury or death Use the seat belt only if the rollbar is raised Warning WARNING Injury hazard due to damaged rollbar Can cause serious injury or death Machine operation with a damaged rollbar is prohibited Contact a Wacker Neuson service center NOTICE The boom must not be moved if the rollbar is...

Page 85: ...d Stop the engine Raise the lock lever Remove the starting key Information In order to raise it the rollbar must be held by one person on either side 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 82 Lowering the rollbar A Fig 83 Lowering the rollbar Fig 84 Raising the r...

Page 86: ...ury or death Use the seat belt only if the rollbar is raised Warning WARNING Injury hazard due to damaged rollbar Can cause serious injury or death Machine operation with a damaged rollbar is prohibited Contact a Wacker Neuson service center NOTICE The boom must not be moved if the rollbar is lowered Bracket P for installing a rotating beacon is located on top of the rollbar Lowering the rollbar S...

Page 87: ... the lock nuts every time they are loosened Lowering 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 lower it the rollbar must be held by one person on either side Remove the split pins and pins B on either side Slowly and carefully lower the rollbar toward C to the limit S Raising the rollbar Sto...

Page 88: ...jury hazard due to unfastened seat belt Can cause serious injury or death Use the seat belt only if the rollbar is raised Warning WARNING Injury hazard due to damaged rollbar Can cause serious injury or death Machine operation with a damaged rollbar is prohibited Contact a Wacker Neuson service center NOTICE The boom must not be moved if the rollbar is lowered Lowering the rollbar Information Remo...

Page 89: ...side Slowly and carefully lower the rollbar as far as it will go 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 must be held by one person on either side Slowly and carefully lower the rollbar Fig 86 Lowering the rollbar B Fig 87 Rollbar lowered Fig 88 Lowering the ro...

Page 90: ...3b330 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: ...regularly Have damaged parts immediately replaced by a Wacker Neuson service center Always keep the seat belt clean as coarse dirt can impair proper functioning Seat belt buckle must not be obstructed by foreign bodies otherwise the buckle latch cannot lock into place Depending on the situation traveling over very short distances with a low ered rollbar is allowed in case of low clearance heights ...

Page 92: ...belt must be tightly in place over the hips Unfastening the seat belt Unfasten seat belt C as follows Hold the seat belt Press button D on buckle B Latch A is released by spring pressure Unfastening the seat belt Longer shorter seat belt adjustment Lengthen the seat belt as follows Hold buckle latch A at a right angle to the seat belt and pull the seat belt to the required length To shorten the se...

Page 93: ...eat belt Check the seat belt condition regularly Have damaged parts immediately replaced by a Wacker Neuson service center Always keep the seat belt clean as coarse dirt can impair proper functioning Seat belt buckle must not be obstructed by foreign bodies otherwise the buckle latch cannot lock into place Depending on the situation traveling over very short distances with a low ered rollbar is al...

Page 94: ...ver the hips to buckle B Insert buckle latch A into buckle B until it engages audibly pull test The retracting seat belt must be tightly in place over the hips Unfastening the retracting seat belt Unfasten retracting seat belt C as follows Hold the retracting seat belt Press button D on buckle B Latch A is released by spring pressure Unfastening the retracting seat belt Fig 94 Fastening the retrac...

Page 95: ...performing work in the engine compartment Raise the lock lever Remove the starting key Let the engine cool down Information Close and lock the engine cover after finishing work in the engine compartment Opening Press lock 3 Pull the engine cover upward Closing Firmly press down the engine cover until lock 3 engages with an audible click Locking and unlocking Close the engine cover with the startin...

Page 96: ...errupted electric power supply in the HPU operation Can cause serious injury or death HPU operation with interrupted electric power supply is forbidden as safety related functions e g light horn do not work From serial number WNCE0801VPAL01769 the vehicle has a battery isolator switch The battery isolator switch is located under the engine cover Interrupt the electric power supply Flip up the batt...

Page 97: ...machine must be loaded with a crane If necessary contact a Wacker Neuson service center for towing the machine away Fasten the towing equipment only on the towing eye hook provided for this The maximum permissible load of the towing eye hook is equal to 1 5 times the dead weight of the machine A tractor vehicle of the same weight category must be used as a minimum In addition the tractor vehicle m...

Page 98: ...ons relevant in your country Lock the upper carriage see chapter Upper carriage lock on page 3 25 Ensure that the lifting gear has the required lengths L1 and L2 NOTICE In order to avoid damage to the machine and the lifting gear Lower the rollbar during crane lifting see Lowering the rollbar on page 3 34 Remove the window if the machine is equipped with the shatter protection option see Shatter p...

Page 99: ...window if the machine is equipped with the shatter protection option Lower the rollbar if the machine is equipped with this option 17 Install suitable slings at the points provided for lifting the machine 18 Install the lifting gear at the point on the boom provided for lifting the machine 19 Install the lifting gear at the points on the stabilizer blade provided for lifting the machine Ensure tha...

Page 100: ...rd quarter of 2014 on page 3 49 If an additional cross brace is installed from the 2nd quarter of 2014 the shatter protection does not have to be removed before transporting the machine on an open platform Place the access ramps at the smallest possible angle Ensure that the grade does not exceed 15 17 Use access ramps with an antiskid surface only Ensure that the loading area is clear and access ...

Page 101: ...de and the boom Firmly tie down the excavator at the swiveling console onto the platform with belts or chains A of adequate size Firmly tie down the excavator at the eye hooks B onto the platform with belts or chains of adequate size Ensure that the operator of the transport vehicle knows the overall height width and weight of his vehicle incl excavator before departure as well as the legal transp...

Page 102: ...ecause a shatter protection cannot be mounted DANGER Accident hazard in conditions of restricted visibility due to rain snowfall dust etc Causes serious injury or death Stop machine operation immediately Information The shatter protection protects the operator against fragments from the front The machine owner must ensure that the hazard situation is evaluated and that the national regulations are...

Page 103: ...ide rails 7 Secure the shatter protection on either side with two linch pins B Installing from the 3rd quarter of 2014 Perform steps 1 6 as described above Secure the shatter protection with cross brace C and one split pin D on the left and right Removing Remove in the reverse order Job site Height of working area 120 cm 47 in The figures refer to work with a Wacker Neuson hydraulic hammer Informa...

Page 104: ...ucture before starting work The building can collapse causing serious fatal injury and serious damage Do not place the machine directly underneath the workplace during demolition otherwise demolished parts can fall onto the machine or the building can collapse causing serious fatal injury and serious damage Do not use the impact force of the attachment to perform demolition work Falling demolished...

Page 105: ...aulic lines that are to be opened before starting setup or repair work for example fitting removing an attachment with hydraulic functions see Emergency lowering on page 3 60 Machine operation is only allowed if the rollbar is raised and locked and if the seat belt is fastened Machine operation with the rollbar lowered is prohibited Use an external light source in case of poor illumination of the ...

Page 106: ...ause serious injury or death Raise the lock lever Information Always perform smooth control movements Right hand control lever Fig 110 Left hand control lever D C A B 14 Position Lever Function A Forward Extends the stick B To the right Rotates the upper carriage to the right C Backward Retracts the stick D To the left Rotates the upper carriage to the left Fig 111 Right hand control lever H G E F...

Page 107: ...ard after swiveling the boom Boom swivel controls up to serial no AI00975 Warning WARNING Injury hazard when operating the boom swivel mechanism Can cause serious injury or death In order to minimize the risk of unintentional operation flip the pedal for ward after swiveling the boom Unfold the right hand pedal 7 The boom can be swiveled Swiveling the boom to the left Press the front half of the r...

Page 108: ...erious injury or death The pedal is secured with a torsion spring The pedal flips forward when it is released but is not locked Unfold the right hand pedal 7 Keep the right hand pedal in position but do not press it Swiveling the boom to the left Press the front half of the right hand pedal Boom swivels to the left Fig 115 Actuating the swiveling mechanism Fig 116 Swivel controls 7 Fig 117 Keeping...

Page 109: ... actuated ear lier than required Auxiliary hydraulics 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 pedal for ward after actuating the auxiliary hydraulics Unfold the left hand pedal 10 Auxiliary hydraulics can be actuated Actuating the auxiliary hydraul...

Page 110: ... or death The pedal is secured with a torsion spring The pedal flips forward when it is released but is not locked Unfold the left hand pedal 10 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 122 Auxiliary hydraulics 10 Fig 123 Actuating the auxiliary hydraulics ...

Page 111: ... changeover Hammer grab operation changeover is performed with lever 19 Hammer operation enabled Oil flows to the hammer through the pressure line and to the reservoir through the return line Grab operation enabled Press the pedal backward the grab rotates to the left Press the pedal forward the grab rotates to the right Oil flows forward through the left or right hand pressure line Information Ch...

Page 112: ...anufac turer for connecting the auxiliary hydraulics to an attachment Hammer grab operation changeover up to serial number WNCE0801EPAL00209 Hammer grab operation changeover is performed with lever 19 Hammer grab operation changeover from serial number WNCE0801EPAL00210 Hammer grab operation changeover is performed with lever 19 Fig 126 Actuating the auxiliary hydraulics Fig 127 Hammer and grab op...

Page 113: ...tes to the right 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 Keep the left hand pedal in position but do not press it Actuating the auxiliary hydraulics The left hand pedal can be pressed forward or backward Oil flows through the auxiliary hydraulics line Fig 130 Auxiliary hydraul...

Page 114: ...y or death Ensure that no one is in the danger zone Information Lower the boom immediately after stopping the engine Observe the following during emergency lowering 1 Lower lock lever A 2 Push the right hand control lever B forward until the boom is fully lowered to the ground 3 Return control lever B to neutral Fig 133 Emergency lowering A B ...

Page 115: ...on a slope Fast actuation of the control lever rotates the upper carriage fast slow actuation of the control lever rotates the upper carriage slowly Rotate the upper carriage to the left as follows Push the left hand control lever 14 to the left A The upper carriage rotates to the left Rotate the upper carriage to the right as follows Push the left hand control lever 14 to the right B The upper ca...

Page 116: ... swiveled if the lock lever is raised The auxiliary hydraulics can still be operated if the lock lever is raised Lock lever up to serial no AI00814 Locking the 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 Lock lever from serial no AI00815 Locking the lock lever Set lever 12 to position A The ...

Page 117: ...wer unit Do not pull the power unit with the hydraulic hoses see chapter 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 Informat...

Page 118: ...ng or uncoupling hydraulic hoses stop the power unit and the diesel engine of the excavator Environment Possible serious damage to the environment due to unconnected hydraulic lines 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 D C A E A B D B Designation A Split pin B Pins C Lance D H...

Page 119: ...ound 6 Stop the diesel engine 7 Remove the starting key and carry it with you 8 Operate the control lever repeatedly to release the pressure in the hydraulic system 9 Stop the power unit 10 Pull out split pin A and pin B at the front and rear on the power unit and remove lance C from the power unit 11 Fasten a pin and the split pin on the power unit again 12 Insert lance C in the holder on the exc...

Page 120: ...l The power unit and excavator must be filled with HVLP 46 hydraulic oil Operation is prohibited if other oil types grades or biodegradable hydraulic oil is used 14 Connect the hydraulic hose connection D to the excavator 15 Connect the hydraulic hose connection E to the excavator Environment Use a suitable container to collect fluids and lubricants as they flow out and dispose of them in an envir...

Page 121: ... during power unit operation otherwise the hydraulic oil levels of the power unit and excavator are changed The power unit and excavator may only be put into operation if the hydraulic oil levels are between the MIN and MAX marks Both hydraulic oil A and air B must be visible in the sight glass Add hydraulic oil if no hydraulic oil can be seen in one of both sight glasses Do not start operation if...

Page 122: ...ion Key A for changing over between HPU and diesel operation is located in the document box behind the operator seat 1 Stop the HPU press the red push button R 2 Insert key A and turn it anticlockwise to position 1 3 Remove key A and store it in the document box Indication B must be in position 1 4 Start the diesel engine turn the starting key to position 3 Fig 148 Fig 149 7 5 kW version 9 kW vers...

Page 123: ...ocument box behind the operator seat 1 Stop the diesel engine turn the starting key to position 0 2 Insert key A and turn it clockwise to position 2 3 Remove key A and store it in the document box Indication B must be in position 2 Switch on the HPU press the green push button G Fig 153 Fig 154 1 0 2 3 Fig 155 A Fig 156 2 B Fig 157 7 5 kW version 9 kW version G G ...

Page 124: ... the correct boom and stabilizer blade posi tion See Coupling on page 3 65 The power unit and the excavator must be stopped before uncoupling 1 Uncouple the hydraulic hose connection E from the excavator 2 Uncouple the hydraulic hose connection D from the excavator 3 Uncouple the hydraulic hose connections D from the power unit Environment Use a suitable container to collect fluids and lubricants ...

Page 125: ...ames and smoking is prohibited Perform charging only on well ventilated premises Do not charge malfunctioning or frozen batteries DANGER Burn hazard due to hot engine parts Can cause serious burns Stop the excavator engine and let it cool down Wear protective equipment DANGER Injury hazard due to rotating parts Rotating parts can cause serious injury or death Open the excavator engine cover only a...

Page 126: ...r is located in the storage compartment above the hydraulic oil radiator of the power unit For more information refer to the Operator s Manual of the battery charger The Opera tor s Manual is located in the document box of the power unit The excavator battery can be charged in two different ways With the power unit Directly with the 230 V mains Connect the adapter connector and bushing of the batt...

Page 127: ...ith the accessories outlet E of the power unit Charging the battery with the mains Connect safety connector D of the battery charger with a 230 V outlet F Environment Dispose of old batteries in an environmentally friendly manner LED working light The Dual Power option includes an energy saving LED working light that is switched on and off with switch A A Fig 163 D C E A Fig 164 D F Fig 165 A ...

Page 128: ...re a rotating beacon is mandatory during excavator operation 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 B A ...

Page 129: ...k for example fitting removing an attachment Releasing pressure Release the pressure as follows Park the machine on level and horizontal ground Lower the boom and the attachment completely to the ground Stop the engine Lower unlock the lock lever Move the control levers in all directions repeatedly The pressure in the system sections that have been actuated is released This can be seen by the brie...

Page 130: ...chments only with suitable tools Do not align components with your fingers or your hands but use suita ble tools crushing hazard After you have re equipped an attachment or before starting work ensure that the attachment is safely locked in the stick and the joint rod Removing a bucket Lower the bucket to level ground with the flat side facing downward Stop the engine Raise the lock lever Remove t...

Page 131: ...e 3 78 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 changes Information Follow the instructions in the Operator s Manual of the attachment manufac turer for connecting the auxiliary hydraulics to an attachment Connect and disconnect as follows Park the machine on level an...

Page 132: ... the attachment manufac turer for connecting the auxiliary hydraulics to an attachment Connect and disconnect as follows Park the machine on level and horizontal ground Extend the stick cylinder halfway through Stop the engine 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 t...

Page 133: ... The following section describes work operations with the machine equipped with the standard bucket The standard bucket is mainly used for earth moving applications and for loosening pick ing up digging and loading loose material or material to be loosened Inadmissible work procedures Working with the swivel force Do not use the swivel force of the upper carriage to compact the ground or tear down...

Page 134: ...No thrusting the stabilizer blade Do not thrust the stabilizer blade against rocks or blocks to avoid damage to the cylin ders and the blade itself Fully lowering the stabilizer blade Fully lower the stabilizer blade when using it on the side opposite the excavation side Retracting attachments Ensure that the bucket does not hit the stabilizer blade as you retract attachments for traveling or tran...

Page 135: ...ble Move the stick toward the excavator Lower boom With a sufficiently full bucket E Keep on moving the stick toward the excavator and at the same time Curl stick F Excavating trenches Excavating trenches is more efficient by using a suitable bucket for this work and positioning the tracks parallel to the limit line of the trench In case of large trenches first excavate the side sections and then ...

Page 136: ...ommend that you observe the follow ing points Exits from pits must be outside the digging line and as level as possible Dig by removing adjacent strips if possible Ensure that you can travel forward when traveling out of the digging area with a fully loaded bucket Whenever possible travel in reverse when transporting a full bucket down a steep slope Freeing the machine If the machine gets stuck in...

Page 137: ...anger zone when working with the stabilizer blade Grading Lower the stabilizer blade to the ground see chapter Stabilizer blade operation on page 3 22 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 ...

Page 138: ...s with stabilizer blade B at the front ensure that boom A does not touch or rest on stabilizer blade B Fig 185 Stabilizer blade at rear Warning WARNING Falling hazard when working alongside trenches Can cause serious injury or death This work position is prohibited since the machine can tip over forward into the trench We recommend using the first work position Fig 186 described above and to ensur...

Page 139: ...onnections in starter circuit Malfunctioning starter or pinion does not engage Wrong valve clearance Malfunctioning injection nozzle Malfunctioning cutoff solenoid Malfunctioning fuse Engine starts but does not run smoothly or faultless Fuel grade does not comply with specifications 5 35 Dirty fuel filter Wrong valve clearance Air in fuel system Injection line leaks Malfunctioning injection nozzle...

Page 140: ...Oil level too low 5 7 Machine inclination too high max 15 Wrong SAE grade of engine lubrication oil 5 35 Engine oil consumption too high Oil level too high 5 7 Worn oil scraper rings Machine inclination too high max 15 Wrong SAE grade Engine smoke Blue Oil level too high 5 7 Machine inclination too high max 15 Wrong oil White Engine starting temperature too low Fuel grade does not comply with spec...

Page 141: ...nto your face Therefore wear safety glasses protective masks and clothing when using compressed air Daily servicing and maintenance and maintenance according to maintenance plan A must be performed by a specifically trained operator All other maintenance must be per formed by trained and qualified personnel only The following maintenance plans indicate the maintenance to be performed This is neces...

Page 142: ...Health hazard due to diesel fuel Can cause serious injury or death Avoid contact with the skin eyes and mouth Seek medical attention immediately in case of accidents with diesel fuel Wear protective equipment Warning WARNING Fire hazard due to diesel fuel Can cause serious injury or death Fire open flames and smoking is prohibited Adding gasoline is prohibited Before refueling stop the engine rais...

Page 143: ...ter from forming in the fuel tank over night Do not fill the tank completely but leave some space for the fuel to expand Draining fuel Environment Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner Filler inlet A for the fuel tank is located in the engine compartment on the left in traveling direction Proceed as follows Open filler inl...

Page 144: ...chine Start the engine only if the engine cover is closed Bleed the fuel system in the following cases After removing and fitting the fuel filter prefilter or the fuel lines back on again After running the fuel tank empty After running the engine again after it has been out of service for a longer period of time Bleed the fuel system as follows Fill the fuel tank Turn the starting key to the first...

Page 145: ... If the red indicator ring A rises to position C Unscrew threaded fitting D Prepare a suitable container for collecting the fuel water mixture Fuel water mixture drains Wait until the indicator ring returns to the bottom of the water separator Screw threaded fitting D back on again Environment Collect the fuel water mixture as it drains with a suitable container and dispose of it in an environment...

Page 146: ...quantity and grade specified in the fluids and lubricants table 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 Environment Use a suitable containe...

Page 147: ...evel Close and lock the engine cover Adding engine oil Clean the area around oil filler cap B with a lint free cloth Open filler cap B Pull out oil dipstick A and wipe it with a lint free cloth Add engine oil Wait about 3 minutes until all the oil has run into the oil sump Check the oil level see Checking the oil level on page 5 7 Add oil if necessary and check the oil level again Close filler cap...

Page 148: ...le or swallow coolant Avoid contact of the coolant or antifreeze with the skin and eyes Warning WARNING Burn hazard due to coolant or antifreeze Can cause serious injury or death Only perform maintenance on an engine that has cooled down Do not smoke avoid fire and open flames Wear protective equipment Warning WARNING Burn hazard due to hot coolant Can cause serious injury or death Wear protective...

Page 149: ...ently check the cooling system for leaks and or con tact a Wacker Neuson service center Never add cold water coolant if the engine is warm The use of the wrong coolant can destroy the engine and the radiator Therefore Add enough antifreeze compound to the coolant but never more than 50 If pos sible use brand name antifreeze compounds with anticorrosion additives Observe the coolant compound table ...

Page 150: ...l once a day We recommend checking it before starting the engine Adding coolant After the engine has cooled down Release overpressure in the radiator Carefully open cap B to the first notch and fully release the pressure Open filler cap B Add coolant up to the lower edge of the filler inlet radiator Close filler cap B Start the engine and let it warm up for about 5 10 minutes Stop the engine Raise...

Page 151: ...amage the radiator fins as you clean them with a compressed air gun Maintain a sufficient distance from the radiator to avoid damage to the radiator fins Use oil free compressed air 2 bar 29 psi max to clean Radiator A is located on the left hand side under the engine cover 1 Stop the machine on firm level and horizontal ground 2 Position the boom straight ahead at the center of the machine 3 Lowe...

Page 152: ...intenance plan Never reuse damaged filter elements Ensure cleanliness when replacing the filter elements NOTICE Filter elements degrade prematurely when in service in acidic air for longer periods of time This risk is present for example in acid production facilities steel and aluminum mills chemical plants and other nonferrous metal plants Replace air filter element D after 50 operating hours at ...

Page 153: ...he valve with your hand Replacing air filter elements Replace air filter element D as follows Stop the engine Raise the lock lever Remove the starting key and carry it with you Let the engine cool down Open the engine cover Remove dirt and dust from the air filter element and the area around the air filter Open bow clips H on housing section E Remove housing section E Carefully remove air filter e...

Page 154: ... M 6 Carefully remove outside filter G with slightly turning movements 7 Ensure that all contamination dust inside the upper and lower housing sections including the dust valve has been removed 8 Clean the parts with a clean lint free cloth do not use compressed air 9 Carefully remove inside filter H with slightly turning movements 10 Check the new inside filter H and outside filter G for damage a...

Page 155: ...e the starting key and carry it with you Disconnect the battery Let the engine cool down Open the engine cover Carefully check V belt 1 for damage cracks or cuts Replace the V belt if it touches the base of the V belt groove or if the pulleys are damaged Press with your thumb about 100 N 22 5 lbf to check the deflection of the V belt between the crankshaft disc and the fan wheel A new V belt shoul...

Page 156: ... to protect the eyes If oil contacts the eye flush imme diately with clean water and seek medical treatment NOTICE In order to avoid damage to the hydraulic system Use hydraulic oil and grade according to fluids and lubricants table Always add hydraulic oil using the filling screen Check the hydraulic oil level once a day If the hydraulic oil in the sight glass is cloudy this indicates that water ...

Page 157: ... the MIN mark if the machine has not reached its operating temperature yet The oil level must be at the MAX mark after the machine reaches its operating temperature Add hydraulic oil if the oil level is below these marks Adding hydraulic oil 9 Slowly open filler cap B with tool C included in the tool kit 10 Add hydraulic oil up to the corresponding mark 11 Check the hydraulic oil level on sight gl...

Page 158: ...of biodegradable oil ensure that the remaining amount of initial biodegradable oil does not exceed the indications of the manufacturer of biodegradable oil Do not add mineral oil the content of mineral oil should not exceed 2 in order to avoid foaming problems and to ensure biological degradability When running the machine with biodegradable oil the same oil and filter replacement intervals are va...

Page 159: ...them replaced with new ones Never use an unprotected light or open flame to check for minor leaks Have damaged flexible lines replaced by a Wacker Neuson service center only 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 saf...

Page 160: ...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: ... Stop and park the machine Open the engine cover 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 Pos Lubrication point Quantity 1 Bucket cylinder 2 2 Stick cylinder 2 3 Boom cylinder 2 4 Boom 2 5 Stabilizer blade cylinder 2 6 Stabilizer blade 2 7 Stick 1 8 Bucket 2 9 Swiveling console 2 10 Swiveling c...

Page 162: ...per carriage 1 Park the machine on firm level and horizontal ground 2 Lower the boom and the stabilizer blade to the ground 3 Stop the engine remove the starting key and carry it with you 4 Raise the lock lever 5 Apply grease to lubrication point 11 with one stroke of the grease gun 6 Start the engine raise the boom and the stabilizer blade 7 Rotate the upper carriage by 90 8 Repeat steps 2 7 thre...

Page 163: ...l and horizontal ground 2 Lower the boom and the stabilizer blade to the ground 3 Stop the engine remove the starting key and carry it with you 4 Raise the lock lever 5 Apply grease to lubrication point 12 with five strokes of the grease gun 6 Start the engine raise the boom and the stabilizer blade 7 Rotate the upper carriage by 90 8 Repeat steps 2 7 three times until the upper carriage is back i...

Page 164: ...ark 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 engaged in the lower position Lower covers 1 Fig 214 Control stand covers 1 Fig 215 Ball pins SAE controls shown 13 13 ...

Page 165: ...level and horizontal ground 2 Raise the machine evenly and horizontally by means of the boom and the stabi lizer blade 3 Place the tracks so that mark B is in the middle between the drive pinion C and the track tension roller D 4 Stop the engine 5 Raise the control lever base 6 Remove the starting key and carry it with you 7 Adjust the correct track tension if the play between the track roller and...

Page 166: ...y glasses Open the lubricating valve only very carefully and do not unscrew it more than a revolution Loosen no other component except the lubricating valve Keep your face away from the lubricating valve connection 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 ...

Page 167: ...he grease Slowly turn lubricating valve B one revolution counterclockwise to release the grease Retighten the lubricating valve B The grease flows out of the groove of the lubricating valve 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 machine forward and reverse and switching it off agai...

Page 168: ...other conductive articles on the battery short circuit hazard Disconnect the negative battery terminal from the battery before starting repair work on the electrical system Dispose of used batteries properly Servicing and maintenance at regular intervals Before starting machine travel Check every time before starting machine travel Is the light system OK Do the lights and the acoustic warning syst...

Page 169: ...es Blown fuses indicate overloading or short circuits The electrical system must therefore be checked before installing a new fuse Only use fuses with the specified load capacity amperage see chapter Fuses behind the right hand trim on page 6 4 Alternator Observe the following instructions Start the engine only if the battery is connected When connecting the battery ensure that the poles are not i...

Page 170: ...pen battery cells avoid sparks close by and do not smoke otherwise the gas that is also produced during normal bat tery operation not only during battery charging could ignite Do not attempt to jump start the machine if the battery is frozen or if the acid level is low The battery can rupture or explode Replace the battery immediately Always disconnect the negative terminal from the battery before...

Page 171: ...ammable liquids such as gasoline or diesel Cleaning with compressed air Work carefully Wear safety glasses and protective clothing Do not aim the compressed air at the skin or at other people Do not use compressed air for cleaning your clothing Cleaning with a high pressure cleaner or steam jet Electrical components and damping material must be covered and not directly exposed to the jet Cover the...

Page 172: ... only Do not use chemical agents as they can destroy the fabric Exterior of the machine The following articles are generally suitable High pressure cleaner Steam jet Engine compartment Warning WARNING Burn hazard due to hot engine parts Can cause serious injury or death Stop the engine and let it cool down Wear protective equipment Warning WARNING Injury hazard due to rotating parts Can cause seri...

Page 173: ...tore the machine indoors if possible If the machine is stored outdoors place it on a wooden base and cover it with a watertight tarp to protect it against humidity Check whether oil or other fluids leak from the machine Lower the boom and the stabilizer blade to the ground Clean the engine with a high pressure cleaner in a suitable place Observe the following chapter see chapter Cleaning with a hi...

Page 174: ...urn to ON Turn the starter to position 1 for 2 minutes to supply the engine with fuel If the machine was out of service for over 6 months change the oil in the gearbox engine etc and the hydraulic oil reservoir Check the engine oil Also replace hydraulic oil filters return and breather filters if the machine has been out of service for over 6 months Lubricate the machine according to the lubricati...

Page 175: ...e power unit Both must be filled with HVLP 46 Contact a Wacker Neuson service center before using power units from other manufacturers BP BIOHYD SE S 466 Grease Roller and friction bearings KPF 2 K 207 ISO L X BCEB 28 7 KPF 2 K 20 according to DIN 51502 multipurpose lithium grease 8 ISO L X BCEB 2 according to DIN ISO 6743 9 Year round As required Live ring gears Live ring ball bearing Grease nipp...

Page 176: ...r 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 SAE 40 F 4 5 14 23 32 41 50 59 68 77 86 95 104 ...

Page 177: ...r additional maintenance Oil grades for the hydraulic system depending on temperature Application Hydraulic oil Hydraulic oil filter insert Normal work excavation work Replace the first time after 500 o h then every 1000 o h Replace the first time after 50 o h then every 500 o h Percentage of hammer work 20 Every 800 o h 300 o h 40 Every 400 o h 60 Every 300 o h 100 o h Over 80 Every 200 o h Hydra...

Page 178: ... filter changes Perform the following oil and filter changes check oil levels after test run Engine oil 1 Engine oil filter 2 Fuel filter 3 Water separator Coolant Hydraulic oil filter insert 4 Hydraulic oil 5 Drain condensation water from the hydraulic oil reservoir from serial no AH02272 Air filter element up to serial no AI00875 Air filter element according to dirt indicator from serial no AI00...

Page 179: ... V belt Check the exhaust system for damage and condition Check the rollbar for damage Check valve clearance Adjust if necessary Clean and adjust the fuel injection pump 8 Check and adjust the injection pressure of the injection nozzles clean the injection needles nozzles Check and adjust injection time 9 Empty the fuel tank and check for dirt 5 16 Maintenance plan overview Work description For se...

Page 180: ...eck line fixtures Check indicator lights for correct function Couplings dirt pile up on hydraulic system dust caps Check insulating mats in engine compartment for damage condition Check labels and Operator s Manual for completeness and condition Lights and acoustic warning system 11 Check lubricant on live ring 12 Check gearing of swivel unit pinion Lubrication service Lubricate the following asse...

Page 181: ...ghtness leaks and chafing pipes flexible lines and threaded fittings of the following assemblies and components Rectify if necessary Visual check Engine hydraulic system and hydraulic components Cooling circuit Traveling drive 5 16 Maintenance plan overview Work description For servicing and maintenance on the attachment please refer to the operation and maintenance manual of the attachment manufa...

Page 182: ... h the second time then every 1000 o h 6 According to the dirt indicator every 1000 o h or once a year at the latest Replace after 50 o h when in extensive use in environments with acidic air such as acid production facilities steel and aluminum mills chemical plants and other nonferrous metal plants 7 Clean the water ducts every other 1000 o h servicing 8 Clean and adjust the fuel injection pump ...

Page 183: ...l filter clean the fuel prefilter Radiator Check the coolant level Radiator Drain and add new coolant Engine Check valve clearance Adjust if necessary Engine Check the engine oil level Engine Change the engine oil Engine Replace the oil filter Engine Check the V belt tension Hydraulic system Check oil level Hydraulic system Change the hydraulic oil Hydraulic system Replace the hydraulic oil filter...

Page 184: ...5 44 OM 803 us Edition 3 7 803b560 fm Maintenance ...

Page 185: ...diesel engine Number of cylinders 3 Displacement 854 cm 52 1 in3 Nominal bore and stroke 70 x 74 mm 2 8 x 2 9 in Output 9 6 kW at 2100 rpm 12 9 hp 2 100 rpm Max torque 51 5 Nm at 1500 rpm 38 ft lbs 1 500 rpm Max engine speed without load 2270 25 rpm Idling speed 1300 25 rpm 1 300 25 rpm Fuel injection system Indirect injection Starting aid Glow plug preheating time 4 seconds Exhaust values accordi...

Page 186: ...4 x 77 mm 2 9 x 3 0 in Output 11 5 kW at 2500 rpm 15 4 hp 2 500 rpm Max torque 53 Nm at 1800 rpm 39 ft lbs 1800 rpm Max engine speed without load 2675 25 rpm 2 675 25 rpm Idling speed 1300 25 rpm 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 from 2012 Travel gear swivel unit Model 803 Travel spee...

Page 187: ... x 11 35 l min at 2270 rpm 2 x 3 gal min at 2270 rpm Hydraulic pump displacement Tier IV final from 2012 2 x 10 7 l min at 2675 rpm 2 x 2 8 gal min at 2675 rpm Control valve 9 sections Max operating pressure work and drive hydraulics 170 3 bar 2466 psi Main pressure restriction for boom bucket stick 170 3 bar 2466 psi Main pressure restriction for stabilizer blade 170 3 bar 2466 psi Main pressure ...

Page 188: ... output adap tation Yanmar 3TNV74F SNNS F2 10 A Fuse relay indicator cutoff solenoid F3 10 A Fuse horn working light 12 V power outlet up to serial number WNCE0801CPAL0050 travel signal option F4 10 A 12 V power outlet from serial number WNCE0801TPAL0051 Fig 223 Fuses from serial number WNCE0801TPAL0051 F2 F3 F1 F4 Fig 224 Relays K8 K9 K7 Relay no Protected circuit K 7 Starting relay K 8 Cutoff so...

Page 189: ...cted circuit F1 40 A Main fuse air pressure sensor output adap tation Yanmar 3TNV74F SNNS F2 10 A Fuse relay indicator cutoff solenoid F3 10 A Fuse horn working light 12 V power outlet up to serial number WNCE0801CPAL0050 travel signal option F4 10 A 12 V power outlet from serial number WNCE0801TPAL0051 Fig 226 Relay K8 K7 Relay no Protected circuit K7 Starting relay K 8 Cutoff solenoid time lag r...

Page 190: ...ality of suspension system attachments and condition of attachments Precise indications on the vibration degrees cannot be made for the machine Determination of vibration level for the three vibration axes Under typical operating conditions use the average vibration values measured In order to obtain the estimated vibration value for an experienced operator on level ground subtract the factors fro...

Page 191: ... machine Avoid jerky movements during machine operation Keep slopes in a perfect condition Whole body vibration can be reduced with the following guidelines Use a machine and equipment of correct type and size Follow the manufacturer s recommendations for maintenance Tire pressure Brake and steering systems Control elements hydraulic system and linkage Keep the job site in good condition Remove la...

Page 192: ...e vibration values and calculations are based on the indications made in ISO TR 25398 Mechanical Vibrations Guidelines for assessment of exposure to whole body vibration when operating earth moving machines The harmonized data comply with measurements made by international institutes organi zations and manufacturers This publication offers information on the calculation of whole body vibrations fo...

Page 193: ...1 concentration for warm outside temperatures too to ensure protection against corrosion cavitation and deposits Water Coolant2 2 Do not mix the coolant with other coolants Up to C F by volume by volume 37 34 6 50 50 803 without rollbar Operating weight 1 1 Operating weight basic machine full fuel tank backhoe bucket 250 mm 10 in operator 75 kg 165 lbs 1032 kg 2 275 lbs Transport weight2 2 Transpo...

Page 194: ...pic travel gear 700 860 mm 28 34 in Width of stabilizer blade folded in out 700 860 mm 28 34 in Transport length 2747 mm 9 Max digging depth 1731 mm 68 in Stick length 890 mm 35 in Max vertical digging depth 1349 mm 53 in Max digging height 2863 mm 9 5 Max tilt out height 2035 mm 80 in Max digging radius 3074 mm 10 1 Max reach at ground level 3028 mm 9 11 Max breakout force at bucket tooth 899 daN...

Page 195: ...34 in Transport length 2747 mm 9 Max digging depth 1766 mm 70 in Stick length 890 mm 35 in Max vertical digging depth 1320 mm 52 in Max digging height 2853 mm 9 4 Max tilt out height 2008 mm 79 in Max digging radius 3092 mm 10 2 Max reach at ground level 3046 mm 10 Max breakout force at bucket tooth 899 daN 2021 daN Max tearout force 451 daN 1014 daN Min tail end slewing radius 747 mm 29 in Max ta...

Page 196: ...t 2008 mm 79 in Max digging radius 3092 mm 10 2 Max reach at ground level 3046 mm 10 Max breakout force at bucket tooth 899 daN 2021 daN Max tearout force 451 daN 1014 daN Min tail end slewing radius 747 mm 29 in Max tail end lateral projection of upper carriage 90 rotation With retracted extended telescopic travel gear With stabilizer blade folded in out 397 mm 317 mm 16 12 in 397 mm 317 mm 16 12...

Page 197: ...n the table must never be exceeded The lowest value applies Information The indications are only approximate values Attachments uneven ground and soft or bad ground conditions affect lift capacity The operator must take these influences into account All table indications in kg lbs and horizontal position on firm and level ground and without bucket or attachment Calculation basis according to ISO 1...

Page 198: ...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 64 205 453 203 448 1 5 m 59 in 2 40 7 86 191 420 189 416 1 0 m 39 in 2 59 8 49 177 391 185 407 217 478 247 544 0 5 m 20 in 2 65 8 70 166 365 184 407 247 544 366 807 0 0 m 0 0 in 2 60 8 52 155 343 171 377 247 544 379 835 678 1 495 0 5 m 20 in 2 41 7 91 146 323 215 475 325 718 561 1 236 1 0 m 39 in 2 0...

Page 199: ... 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 86 126 277 172 378 1 0 m 39 in 2 59 8 49 109 240 116 255 166 366 247 544 0 5 m 20 in 2 65 8 70 103 227 113 248 158 347 241 531 0 0 m 0 0 in 2 60 8 52 104 230 110 242 150 332 226 499 431 951 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 ...

Page 200: ...6 16 OM 803 us Edition 3 7 803b610 fm Technical data ...

Page 201: ...that have already been delivered and that will not be implemented on these machines Technical data dimensions and weights are only given as an indication Responsibility for errors or omissions not accepted No reproduction or translation of this publication in whole or part without the written consent of Wacker Neuson Linz GmbH All rights under the provision of the Copyright Act are reserved Wacker...

Page 202: ...1 Acknowledgment We wish to acknowledge the contributions of the members of AEM s Compact Loader Compact Excavator Council to the preparation of this Safety Manual NOTICE OF COPYRIGHT PROTECTION Copyright 2010 by the Association of Equipment Manufacturers All rights reserved This work may not be reproduced or disseminated in whole or in part by any means without the prior written permission of the...

Page 203: ...your employer equipment dealer or directly from the manufacturer Keep this safety manual and the manufacturer s manuals with the machine at all times Read and understand all manuals Safety videos and other training resources are available from some manufacturers Operators are encouraged to periodically review the safety video Read And Understand Manuals Before Operating 4 Safety Alerts Symbol This...

Page 204: ...ation must be determined by a safe acceptable and dependable method Other OSHA regulations may also apply to the jobsite Call Before You Dig Dial 811 USA only 888 258 0808 USA and Canada 6 A Word To The User Operator It is YOUR responsibility to read and understand the safety manual and the manufacturer s manuals before operating this machine This safety manual takes you step by step through the w...

Page 205: ...ertness and coordination and the operator s ability to safely operate the equipment Never operate the compact excavator while impaired by use of alcohol or drugs Never knowingly allow the operation of this machine when operator alertness or coordination is impaired An operator taking prescription or over the counter medication must consult a medical professional regarding any side effects of the m...

Page 206: ...f Operation 10 Follow A Safety Program Some Rules You Must Work By Know the limitations and operating characteristics of the compact excavator Do not overload it Always wear the seat belt if equipped If the compact excavator is equipped with a foldable TOPS ROPS do not fasten the seat belt when the TOPS ROPS is in the down position Always have all shields and guards properly installed before opera...

Page 207: ...Equipment Read and understand the DANGER WARNING CAU TION and NOTICE safety signs and other informational signs found on the compact excavator and in the manu facturer s operator manual Ask your supervisor to explain any information you do not understand Failure to obey safety instructions could result in death or serious injury Make sure all the manufacturer s protective structures guards shields...

Page 208: ... the down position WARNING NEVER remove or modify safety equipment Operating a machine without a protective structure TOPS ROPS FOGS FOPS or OPS could result in death or serious injury See page 44 Protective Structure Safety Checklist Follow A Checklist Windshield wipers and washers Window defroster Operating lights Horn 14 Prepare For Safe Operation Check The Machine Before you begin the workday ...

Page 209: ...he Body Wear Eye Protection Do Not Loosen Cap Until Cool 16 Prepare For Safe Operation Check The Machine continued Check the tracks for broken or damaged pins bushings and other parts Check the tracks for proper tension adjustment according to manufacturer s instructions Check the tracks for damage or wear Replace badly worn or damaged tracks Check the slew swing brake for proper operation Inspect...

Page 210: ...e following Manually installing a locking pin actuating a lever or other device Movement of the attached work tool to confirm its engaged lock secure condition A visual check of the components as instructed by the quick coupler manufacturer WARNING A quick coupler that is disengaged when the attachment is in an unstable position could result in death or serious injury Place the attachment in a sta...

Page 211: ...ation Walk Around The Worksite Be Seen Wear Visible Clothing 20 Prepare For Safe Operation Check The Work Area continued Know the exact location of electrical telephone gas or other utility lines See page 5 One Call First DANGER Death or serious injury will result from touching or being near a machine that is in contact with or near an energized electrical source Never approach power lines with an...

Page 212: ...while carrying tools or objects that prevent three point contact Maintain Three Point Contact Face Machine Do Not Jump Off Machine Do Not Use Controls As Handholds 22 Start Safely Look Out For Others Before starting walk completely around the machine operating area Make sure no one is under it on it or close to it Do not start the engine until everyone is clear of the operating area Starting The E...

Page 213: ... plugs or intake manifold preheater Ether cold start fluid is HIGHLY FLAMMABLE Before using it always read the instructions on the ether cold start fluid container and the instructions in the manufacturer s manual s Do not carry loose cans of starting fluid on the machine while operating If booster cables are used follow the instructions in the manufacturer s manual s The operator must be in the o...

Page 214: ...ore operating Be certain you can control speed direction braking and boom motion before operating the machine Read And Understand Manuals Before Operating Check Instruments And Controls 26 Operate Safely Remember Stay in the operator s seat with the seat belt fastened if equipped If the compact excavator is equipped with a foldable TOPS ROPS do not fasten the seat belt when the TOPS ROPS is in the...

Page 215: ...offs Failure to know and observe weight limits and use caution could result in death or serious injury Know Weight Limits Operate Controls Smoothly And Slowly 28 Operate Safely Traveling On The Worksite continued Make sure all surfaces will support the weight of the machine Do not cross ditches creeks or wet draws without an adequate fill or bridge crossing Match travel speed to the traffic weathe...

Page 216: ... capacity chart for the machine Changing conditions such as slopes wind ice mud soft ground type of load or the weight of attachments will affect the capacity and operating characteristics of the machine Consult your lift chart Lifting and handling loads over the end of the machine rather than over either side will improve the lifting performance of the machine The retractable track frame if equip...

Page 217: ...t 32 Operate Safely Locate All Underground Utilities Confirm that One Call has been contacted Confirm that any utilities not subscribing to One Call have been contacted Confirm that the site has been marked or cleared See page 5 One Call First Obtain all information pertaining to the locate request including the One Call confirmation code or ticket number If the facility owner has provided a locat...

Page 218: ...h wall to collapse Keep Personnel Away From Equipment And Attachments 34 Slope And Uneven Terrain Operation Compact excavator stability and load capacity are greatly reduced on slopes Ensure the operation can be done safely Prevent overturns and maintain stability control Use machines equipped with TOPS ROPS and a seat belt Make sure folding TOPS ROPS is raised and locked in place always use the s...

Page 219: ... level the machine Swing Load Uphill When On A Slope Operate Safely 36 Operate Safely Hazardous Conditions When working in hazardous areas be extremely alert Always consult the manufacturer s operator manual for specific instructions Extreme caution is required when working near the edge of an excavation Keep the machine a safe distance away from the edge Avoid undercutting WARNING Never undercut ...

Page 220: ...sive atmospheres can result in fires and explosions causing death or serious injury Use Caution Near Excavation Edge Do Not Undercut Machine Avoid Silica Dust Do Not Operate In Explosive Flammable Atmosphere 38 p Operate Safely Towing Many compact excavators may not be towed Refer to the manufacturer s manual s for specific towing instructions Never straddle a tow line or stand near a tow line unde...

Page 221: ...Off Engine Remove Key Engage Control Lock 40 Load And Unload The Machine Safely Loading And Unloading For Transport All machines are not loaded in the same way and the procedures given in the manufacturer s manual s should always be followed Some precautions apply to all machines Keep bystanders away Wear the seat belt if equipped If the compact excavator is equipped with a foldable TOPS ROPS make...

Page 222: ...is needed to protect yourself do not take chances Maintain Equipment 42 Perform Maintenance Safely WARNING Prevent death or serious injury from entanglement Do not wear loose clothing or accessories Restrain long hair Stay away from all rotating components when the engine is running Contact with or entanglement in rotating or moving parts could result in death or serious injury Wear a rubber apron...

Page 223: ...nance Manual DO NO T OPE RA TE DO NOT OPERATE Use Warning Tags Use Approved Support Device 44 Perform Maintenance Safely Use Approved Ventilation If it is necessary to run an engine in an enclosed area remove the exhaust fumes from the area with an exhaust pipe extension WARNING Prevent possible injury Never work on machinery with the engine running unless instructed by the manufacturer s manuals ...

Page 224: ...ving the cap completely Do Not Loosen Cap Until Cool 46 Perform Maintenance Safely Hydraulic System Hazards The hydraulic system is under pressure whenever the engine is running and may hold pressure even after the engine is shut off Cycle all hydraulic controls including auxiliary controls after the engine is shut down to relieve trapped pressure in the lines During inspection of the hydraulic sy...

Page 225: ...njury from explosion Lead acid batteries produce extremely explosive gases especially when being charged Keep arcs sparks flames and lighted tobacco away Do not smoke near batteries Check battery cables for worn or damaged insulation Keep arcs sparks and open flames away from batteries Provide adequate ventilation Never check the battery by placing a metal object across the battery posts the result...

Page 226: ...ance Instructions 50 Perform Maintenance Safely Complete Service And Repairs Before Machine Is Released Tighten all bolts fittings and connections to torques specified by the manufacturer Clean or replace all damaged missing or painted over signs plates and decals that cannot be read Inspect and install all guards covers and shields after servicing Replace or repair any damaged parts Refill and re...

Page 227: ...ituation you may encounter on a daily basis Knowledge of these safety precautions and your application to the basic rules of safety will help to build good judgment in all situations Our objective is to help you develop establish and maintain good safety habits to make operating a Compact Excavator easier and safer for you FORM CE 1009 Printed in U S A ...

Page 228: ...tes consulte o seu fornecedor da Wacker Neuson ou aceda ao site Web da Wacker Neuson em http www wackerneuson com Ważne W celu uzyskania informacji na temat części zamiennych skontaktuj się z przedstawicielem firmy Wacker Neuson lub skorzystaj z witryny internetowej http wackerneuson com Důležité upozornění Pro informace o náhradních dílech prosím kontaktujte svého Wacker Neuson dealera nebo navšt...

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