Wacker Neuson 803 dual power Operator'S Manual Download

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Operator's Manual

Track Excavator

803

803 dual power

Machine type

E08-01

Edition

3.7

Order no

1000287384

Language

This Operator's Manual includes the AEM

Safety Manual CE-1009

Summary of Contents for 803 dual power

Page 1: ...Operator s Manual Track Excavator 803 803 dual power Machine type E08 01 Edition 3 7 Order no 1000287384 Language us 1 0 0 0 2 8 7 3 8 4 This Operator s Manual includes the AEM Safety Manual CE 1009...

Page 2: ...s 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 pro...

Page 3: ...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 Modifica...

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...

Page 5: ...7 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 transpo...

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 tre...

Page 7: ...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 Cont...

Page 8: ...vels 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 withou...

Page 9: ...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 s...

Page 10: ...eight 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 le...

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 abs...

Page 12: ...rial 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 b...

Page 13: ...tside 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...

Page 14: ...e 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 fo...

Page 15: ...ective 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...

Page 16: ...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 c...

Page 17: ...ir 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 fo...

Page 18: ...telle Fachausschuss Bauwesen Landsberger Str 309 80687 Munich Germany Distinguishing EU number 0515 Notified body involved in procedure T V S D Industrie Service GmbH Westendstr 199 D 80686 Munich Dir...

Page 19: ...ation 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 chap...

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: ...ced 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...

Page 22: ...m 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 M...

Page 23: ...hapter 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 Positi...

Page 24: ...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 Fi...

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: ...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 th...

Page 27: ...or 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 Machi...

Page 28: ...ng 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 th...

Page 29: ...ed 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 Me...

Page 30: ...e 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 Connect...

Page 31: ...ption 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 bra...

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

Page 33: ...sequences 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...

Page 34: ...ne 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 i...

Page 35: ...le 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 Operato...

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 Qualificat...

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 st...

Page 38: ...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...

Page 39: ...iately 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 haz...

Page 40: ...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 with...

Page 41: ...g 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 co...

Page 42: ...evel 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...

Page 43: ...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 h...

Page 44: ...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 per...

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 o...

Page 46: ...g 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 requi...

Page 47: ...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...

Page 48: ...xposed 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...

Page 49: ...ge 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 p...

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

Page 51: ...ling 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 veh...

Page 52: ...able 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...

Page 53: ...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...

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

Page 55: ...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...

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: ...mation 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 g...

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...

Page 59: ...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 Auxil...

Page 60: ...ew 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 te...

Page 61: ...ead 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 instruct...

Page 62: ...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...

Page 63: ...ernator 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 bla...

Page 64: ...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 th...

Page 65: ...verheating 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 malfun...

Page 66: ...s 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 Bl...

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...

Page 68: ...t 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...

Page 69: ...e 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 j...

Page 70: ...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...

Page 71: ...tart 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...

Page 72: ...r 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...

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...

Page 74: ...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 downhi...

Page 75: ...gle 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...

Page 76: ...ance 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 mac...

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 e...

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 tra...

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 th...

Page 80: ...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 mac...

Page 81: ...mation 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 possi...

Page 82: ...krest 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...

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...

Page 84: ...d 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...

Page 85: ...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 th...

Page 86: ...ry 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 prohibite...

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 t...

Page 88: ...ury 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 o...

Page 89: ...ide 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 In...

Page 90: ...b330 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 Fi...

Page 91: ...egularly 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...

Page 92: ...elt 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 th...

Page 93: ...at 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 S...

Page 94: ...er 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 Unfa...

Page 95: ...erforming 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 compartmen...

Page 96: ...rrupted 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...

Page 97: ...achine 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...

Page 98: ...ns 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...

Page 99: ...indow 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 mach...

Page 100: ...d 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 plat...

Page 101: ...e 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...

Page 102: ...cause 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 immediate...

Page 103: ...de 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 brac...

Page 104: ...cture 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 p...

Page 105: ...ulic 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...

Page 106: ...use 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 Forwa...

Page 107: ...rd 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 t...

Page 108: ...rious 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 d...

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...

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...

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 oper...

Page 112: ...nufac 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...

Page 113: ...es 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 pe...

Page 114: ...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 righ...

Page 115: ...n 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 Pus...

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...

Page 117: ...er 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...

Page 118: ...g 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...

Page 119: ...und 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 sp...

Page 120: ...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 connectio...

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 b...

Page 122: ...on 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...

Page 123: ...cument 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 Indi...

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 excavat...

Page 125: ...mes 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...

Page 126: ...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 i...

Page 127: ...th 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 env...

Page 128: ...e 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 prohi...

Page 129: ...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 groun...

Page 130: ...hments 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...

Page 131: ...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 F...

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 halfwa...

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 diggin...

Page 134: ...o 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 s...

Page 135: ...le 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 trenc...

Page 136: ...mmend 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 wh...

Page 137: ...nger 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...

Page 138: ...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 Ca...

Page 139: ...nnections in starter circuit Malfunctioning starter or pinion does not engage Wrong valve clearance Malfunctioning injection nozzle Malfunctioning cutoff solenoid Malfunctioning fuse Engine starts but...

Page 140: ...il 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 inclinatio...

Page 141: ...to 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...

Page 142: ...ealth 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 eq...

Page 143: ...er 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 dra...

Page 144: ...hine 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...

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 re...

Page 146: ...uantity 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 change...

Page 147: ...vel 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 eng...

Page 148: ...e 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 maintenan...

Page 149: ...ntly 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 ra...

Page 150: ...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 r...

Page 151: ...mage 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...

Page 152: ...ntenance 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 t...

Page 153: ...e 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...

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...

Page 155: ...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 ba...

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...

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 i...

Page 158: ...f 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...

Page 159: ...hem 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 ho...

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 Lu...

Page 162: ...er 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 l...

Page 163: ...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 poin...

Page 164: ...rk 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 lowe...

Page 165: ...evel 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...

Page 166: ...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 val...

Page 167: ...e 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 t...

Page 168: ...ther 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 pr...

Page 169: ...s 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 F...

Page 170: ...en 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 st...

Page 171: ...mmable 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 us...

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...

Page 173: ...ore 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 lea...

Page 174: ...rn 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...

Page 175: ...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...

Page 176: ...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...

Page 177: ...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...

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 Hydraul...

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 injectio...

Page 180: ...ck 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 Oper...

Page 181: ...htness 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 Coolin...

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 a...

Page 183: ...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 th...

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

Page 185: ...iesel 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 5...

Page 186: ...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...

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 pr...

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...

Page 189: ...ted 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 num...

Page 190: ...lity 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...

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...

Page 192: ...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 mac...

Page 193: ...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 volum...

Page 194: ...ic 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...

Page 195: ...4 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...

Page 196: ...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 7...

Page 197: ...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...

Page 198: ...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...

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 53...

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

Page 201: ...hat 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 acce...

Page 202: ...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 Copyri...

Page 203: ...our 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 o...

Page 204: ...tion 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 Th...

Page 205: ...rtness 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...

Page 206: ...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 I...

Page 207: ...quipment 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 superv...

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 Prot...

Page 209: ...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 f...

Page 210: ...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 instr...

Page 211: ...tion 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 p...

Page 212: ...hile 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 B...

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 manufactu...

Page 214: ...re 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 Safe...

Page 215: ...ffs 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 Worksit...

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 machi...

Page 217: ...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 m...

Page 218: ...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 operat...

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...

Page 220: ...ive atmospheres can result in res 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 Atmosp...

Page 221: ...ff 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 manufactu...

Page 222: ...s 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 Re...

Page 223: ...ance 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...

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...

Page 225: ...jury from explosion Lead acid batteries produce extremely explosive gases especially when being charged Keep arcs sparks ames and lighted tobacco away Do not smoke near batteries Check battery cables...

Page 226: ...nce 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 repl...

Page 227: ...tuation 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 t...

Page 228: ...uson com Belangrijk Neem contact op met uw Wacker Neuson dealer of bezoek de website van Wacker Neuson op http www wackerneuson com voor meer informatie over reserveonderdelen Importante Para obter in...

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