Wacker Neuson 803 Dualpower, Service Manual

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SHB 803 en – Edition 2.4 * 803s20IVZ.fm
I-3
Table of contents
Engine compartment ....................................................................................... 3-55
Threaded fittings and attachments .................................................................. 3-55
Pivots and hinges ............................................................................................ 3-55
Preparatory work before taking out of service ....................................................... 3-56
Maintenance if the machine is out of service for a longer period of time ............... 3-56
Putting into operation again ............................................................................. 3-56
Engine
Overview of engine 3TNV70-VNS (Tier IV final up to 2012) .................................... 4-2
Fuel system ............................................................................................................. 4-3
Checking and adjusting valve clearance ................................................................. 4-5
Tightening order for cylinder head bolts .................................................................. 4-6
Checking the injection nozzles ................................................................................ 4-7
Pressure check .................................................................................................. 4-7
Checking the nozzle jet ............................................................................................ 4-7
Injection time ............................................................................................................ 4-8
Checking and adjusting injection time ............................................................... 4-8
Replacement of fuel injection pump .................................................................. 4-9
Adjusting engine speed ......................................................................................... 4-10
Compression .......................................................................................................... 4-10
Checking the coolant thermostat ........................................................................... 4-10
Checking the thermal switch .................................................................................. 4-11
Oil pressure switch ................................................................................................ 4-11
Checking the coolant circuit ................................................................................... 4-12
Engine trouble ........................................................................................................ 4-13
Overview of engine 3TNV74F-SNNS (Tier IV final from 2012) .............................. 4-15
Fuel system ........................................................................................................... 4-17
Cooling system ...................................................................................................... 4-18
Altitude-dependent output reduction ...................................................................... 4-19
Checking and adjusting valve clearance ............................................................... 4-20
Tightening order for cylinder head bolts ................................................................ 4-22
Order for removing the cylinder-head bolts: .................................................... 4-22
Order for installing the cylinder-head bolts: ..................................................... 4-22
Checking the injection nozzles .............................................................................. 4-23
Pressure check ................................................................................................ 4-23
Checking the nozzle jet .......................................................................................... 4-24
Injection time .......................................................................................................... 4-24
Checking injection time .................................................................................... 4-24
Setting injection time ....................................................................................... 4-26
Removing and installing the injection pump .......................................................... 4-27
Removing the injection pump .......................................................................... 4-27
Fitting the fuel injection pump .......................................................................... 4-28
Measuring and adjusting the engine speed ........................................................... 4-30
Compression .......................................................................................................... 4-30
Checking the coolant thermostat ........................................................................... 4-31
Checking the temperature sensor .......................................................................... 4-31
Oil pressure switch ................................................................................................ 4-32
Checking the coolant circuit ................................................................................... 4-32
Cleaning the cooling water channels ..................................................................... 4-32
Coolant and fuel hoses .......................................................................................... 4-33
Crankcase vent ...................................................................................................... 4-33
Replacing the glow plugs ....................................................................................... 4-33
Engine trouble ........................................................................................................ 4-34
Hydraulic system
Hydraulic pump PGP505B0050CA1H2NJ7J5C-505A00 (Tier IV final up to 2012) . 5-2