Wacker Neuson 803 Dualpower User manual

Service Manual
Track excavator
/
Machine model 803
Edition 2.4
Order no. 1000164843
Language en

Documentation
Title Language Order no.
Operator’s manual de 1000161345
Service manual en 1000164843
Spare parts list de/en/fr 1000161641
de/it/es 1000161643
Legend
Edition Issued
1.0 09/2006
1.1 10/2007
2.0 02/2011
2.1. 08/2012
2.2 06/2013
2.3 02/2014
2.4 04/2015
Copyright – 2015 Wacker Neuson Linz GmbH, Hörsching
Printed in Austria
All rights reserved, in particular the copyright, the right of reproduction and the right of distribution applicable worldwide.
No part of this publication may be reproduced, translated or used in any form or by any means – graphic, electronic or mechanical
including photocopying, recording, taping or information storage or retrieval systems – without prior permission in writing from the
manufacturer.
No reproduction or translation of this publication, in whole or part, without the written consent of Wacker Neuson Linz GmbH.
Violations of legal regulations, in particular of the copyright protection, shall 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 rea-
son,wemayfromtimetotimeneedtomakechangestofiguresanddescriptionsinthisdocumentationwhichdo not reflect products
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.
The cover features the machine with possible optional equipment.
The Operator’s Manual and any amendments to it must always be available at the place of use of the machine. Possible amend-
ments are included at the end of the Operator’s Manual.
Refer to the Operator’s Manual of the machine for information on labels.
Wacker Neuson Linz GmbH
Flughafenstr. 7
A-4063 Hörsching
Phone [phone]
E-mail: [email protected]
www.wackerneuson.com
Document: SHB 803 en
Order no.: 1000164843
Edition: 2.4

SHB 803 en – Edition 2.4 * 803s20IVZ.fm I-1
Table of contents
Table of contents
Operation
Information on this service manual .......................................................................... 1-2
Identification of warnings and dangers .................................................................... 1-3
Designated use and exemption from liability ........................................................... 1-4
Labels ...................................................................................................................... 1-5
Machine overview (up to serial no. AI00966) ........................................................... 1-7
Machine overview (from serial no. AI00967) ........................................................... 1-8
Control stand overview (up to serial no. AI00814) ................................................... 1-9
Control stand overview (from serial no. AI00815) .................................................. 1-11
Display elements (overview) .................................................................................. 1-12
Engine compartment overview (up to serial no. AI00814) ..................................... 1-13
Engine compartment overview (from serial no. AI00815) ...................................... 1-14
Technical data
Chassis .................................................................................................................... 2-2
Engine ...................................................................................................................... 2-2
Fuel injection pump ........................................................................................... 2-4
Engine capacities .............................................................................................. 2-4
Engine tightening torques .................................................................................. 2-4
Hydraulic system ..................................................................................................... 2-4
Auxiliary hydraulics oil flow ................................................................................ 2-5
Travel gear and swivel unit ...................................................................................... 2-5
Stabilizer blade ........................................................................................................ 2-5
Screwable hose burst valve ............................................................................... 2-5
Electrical system ...................................................................................................... 2-6
Fuses behind the right-hand trim ....................................................................... 2-6
Relays behind the right-hand trim ...................................................................... 2-7
Fuses and relays with Dual Power option ......................................................... 2-7
Noise levels ............................................................................................................. 2-8
Vibration ................................................................................................................... 2-8
Coolant compound table .......................................................................................... 2-8
Model-specific tightening torques ............................................................................ 2-9
General tightening torques ...................................................................................... 2-9
Tightening torques for hydraulic threaded fittings (dry assembly) ..................... 2-9
Tightening torques for high-resistance threaded fittings .................................. 2-11
Dimensions model 803 (up to serial no. AI00966) ................................................. 2-12
Dimensions model 803 with ROPS rollbar (from serial no. AI00967) .................... 2-13
Dimensions model 803 without ROPS rollbar (from serial no. AI00967) ............... 2-14
Lift capacity table 803 RD ...................................................................................... 2-15
Kinematics ............................................................................................................. 2-15
Maintenance
Fluids and lubricants ................................................................................................ 3-2
Additional oil change and filter replacement (hydraulic system) ........................ 3-3
Maintenance label .................................................................................................... 3-5
Explanation of symbols on the maintenance label ........................................... 3-5
Maintenance label (up to serial number AF02412) ............................................ 3-6
Maintenance label (from serial number AF02413) ............................................ 3-7
Maintenance plan (overview) ................................................................................... 3-8
Service package .................................................................................................... 3-12
Introduction ............................................................................................................ 3-12
Safety-relevant parts .............................................................................................. 3-12
Fuel system ........................................................................................................... 3-13
Specific safety instructions .............................................................................. 3-13
Refueling ......................................................................................................... 3-13
Stationary fuel pumps ...................................................................................... 3-14
Table of contents

I-2 SHB803en–Edition2.4*803s20IVZ.fm
Table of contents
Diesel fuel specification ................................................................................... 3-14
Bleeding the fuel system .................................................................................. 3-15
Fuel prefilter with water separator ................................................................... 3-15
Replacing the fuel filter .................................................................................... 3-17
Engine lubrication system ...................................................................................... 3-18
Checking the oil level ....................................................................................... 3-18
Adding engine oil ............................................................................................. 3-19
Changing engine oil ......................................................................................... 3-20
Replacing the engine-oil filter cartridge ........................................................... 3-21
Cooling system ...................................................................................................... 3-22
Specific safety instructions .............................................................................. 3-22
Checking the coolant level/adding coolant ...................................................... 3-23
Draining coolant ............................................................................................... 3-25
Air filter (up to serial no. AI00875) ......................................................................... 3-26
Replacing air filter elements ............................................................................ 3-27
Air filter (from serial no. AI00876) .......................................................................... 3-27
Replacing air filter elements ............................................................................ 3-28
V-belt ...................................................................................................................... 3-30
Checking V-belt tension ................................................................................... 3-30
Retensioning the V-belt ................................................................................... 3-31
Pressure check ...................................................................................................... 3-32
General ............................................................................................................ 3-32
Pressure check of gear pump P2 .................................................................... 3-32
Pressure check of gear pump P1 .................................................................... 3-33
Test report .............................................................................................................. 3-34
Hydraulic system .................................................................................................... 3-36
Specific safety instructions .............................................................................. 3-36
Checking the hydraulic oil level ....................................................................... 3-36
Adding hydraulic oil .......................................................................................... 3-38
Changing hydraulic oil ..................................................................................... 3-39
Replacing the filter cartridge ............................................................................ 3-39
Checking hydraulic pressure lines ................................................................... 3-40
Tracks .................................................................................................................... 3-41
Checking track tension .................................................................................... 3-41
Setting the tracks ............................................................................................. 3-42
Lubrication points on boom (up to serial number AI00966) ................................... 3-43
Lubrication strip ............................................................................................... 3-44
Overview of lubrication points (from serial no. AI00967) ....................................... 3-45
Parking the machine ........................................................................................ 3-46
Lubrication points on the stabilizer blade and stabilizer blade cylinder ........... 3-47
Lubrication points on swiveling console ........................................................... 3-47
Swiveling cylinder lubrication points ................................................................ 3-47
Lubrication points on live ring (ball bearing) .................................................... 3-48
Lubrication points of live ring teeth .................................................................. 3-49
Ball sockets (ISO/SAE changeover option) ..................................................... 3-50
Maintenance of attachments ............................................................................ 3-50
Electrical system .................................................................................................... 3-51
Specific safety instructions .............................................................................. 3-51
Servicing and maintenance at regular intervals ............................................... 3-51
Instructions concerning specific components .................................................. 3-52
Alternator ......................................................................................................... 3-52
Battery ............................................................................................................. 3-53
General maintenance ............................................................................................. 3-54
Cleaning ........................................................................................................... 3-54
General instructions for all areas of the machine ............................................ 3-54
Control stand ................................................................................................... 3-54
Exterior of the machine .................................................................................... 3-55

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

I-4 SHB803en–Edition2.4*803s20IVZ.fm
Table of contents
Pump unit: exploded view .................................................................................. 5-3
Hydraulic pump PGP505B0040CA1H2NJ7J5C-505A0040XB1J5B1B1 (Tier IV final
from 2012) ................................................................................................................ 5-4
Pump unit: exploded view .................................................................................. 5-5
Main valve block ...................................................................................................... 5-6
Connections ....................................................................................................... 5-6
Legend ............................................................................................................... 5-7
Main valve block diagram .................................................................................. 5-8
Pressure limiting valves ..................................................................................... 5-9
Pump assignment ............................................................................................ 5-10
Traveling drive ....................................................................................................... 5-11
Function ........................................................................................................... 5-12
Swivel unit .............................................................................................................. 5-14
Swivel unit ........................................................................................................ 5-15
Swivel joint ............................................................................................................. 5-16
Sealing ............................................................................................................. 5-16
Mechanical control ................................................................................................. 5-17
Control levers (up to serial no. AI00814) ......................................................... 5-17
Drive levers (up to serial no. AI00814) ............................................................ 5-18
Control levers (from serial number AI00815) ................................................... 5-19
Drive levers (from serial number AI00815) ...................................................... 5-20
Lock lever (from serial number AI00815) ......................................................... 5-21
Troubleshooting in the hydraulic system ................................................................ 5-22
Plastic trims ............................................................................................................ 5-22
Hydraulics diagram (legend) .................................................................................. 5-24
Hydraulics diagram ................................................................................................ 5-25
Hydraulics diagram (Dual Power option) ............................................................... 5-26
Main valve block diagram ...................................................................................... 5-27
Electrical system
Ohm’s Law (current, voltage, resistance); power ..................................................... 6-2
Measuring equipment, measuring methods ............................................................. 6-2
Cable color coding ................................................................................................... 6-3
Relays ...................................................................................................................... 6-3
Use, mode of function ........................................................................................ 6-3
Electrical system ...................................................................................................... 6-4
Fuses behind the right-hand trim ....................................................................... 6-4
Relays behind the right-hand trim ...................................................................... 6-5
Fuses and relays with Dual Power option .......................................................... 6-5
Control lever push button ......................................................................................... 6-6

SHB 803 en – Edition 2.4 * 803s20IVZ.fm I-5
Table of contents
Right handle ...................................................................................................... 6-6
Working light ............................................................................................................ 6-6
Dynamo ................................................................................................................... 6-7
Rectifier .................................................................................................................... 6-7
Starter ...................................................................................................................... 6-7
Engine wiring harness legend (Tier IV final up to 2012) .......................................... 6-9
Engine wiring harness (Tier IV final up to 2012) .................................................... 6-10
Engine wiring harness legend (Tier IV final from 2012) ......................................... 6-11
Engine wiring harness (Tier IV final from 2012) ..................................................... 6-12
Wiring harness for indicators (up to serial number WNCE0801TPAL00923) ........ 6-13
Wiring harness for indicators (from serial number WNCE0801PPAL00924) ......... 6-14
Traveling signal wiring harness (option) ................................................................ 6-15
Horn wiring harness ............................................................................................... 6-16
Battery lead ............................................................................................................ 6-17
Indicating instrument wiring harness (Dual Power option) ..................................... 6-18
Engine/chassis wiring harness (Dual Power option) .............................................. 6-19
Seat console wiring harness .................................................................................. 6-20
Wiring diagram ....................................................................................................... 6-22
Wiring diagram Tier IV (Yanmar) ........................................................................... 6-23
Wiring diagram (Dual Power option) ...................................................................... 6-24
Options
Rollbar ..................................................................................................................... 7-2
TOPS rollbar up to serial number AF01416 ...................................................... 7-2
Lowerable ROPS rollbar (from serial no. AF01417 to serial no. AI00966) ........ 7-3
Raising/lowering the rollbar: .............................................................................. 7-3
Lowering and raising the rollbar ........................................................................ 7-4
Lowerable ROPS rollbar from serial no. AI00967 .............................................. 7-4
Raising/lowering the rollbar: .............................................................................. 7-5
ISO/SAE changeover (option) ................................................................................. 7-6
Traveling signal (option) .......................................................................................... 7-7
Telematic ................................................................................................................. 7-8
Connections ....................................................................................................... 7-8
Functional check/diode ...................................................................................... 7-8
Zero-emission Dual Power drive .............................................................................. 7-9
Overview ............................................................................................................ 7-9

I-6 SHB803en–Edition2.4*803s20IVZ.fm
Table of contents

Operation

1-2 SHB803en–Edition2.4 * 803s110.fm
Operation
1 Operation
1.1 Information on this service manual
This service manual contains important information on how to work safely, correctly and
economically with the machine. Therefore, it aims not only at new personnel, but it also
serves as a reference for experienced personnel. It helps to avoid hazardous situations
and reduce repair costs and downtimes.
Furthermore, the reliability and the service life of the machine will be increased by follow-
ing the instructions in the service manual.
Careful and prudent working is the best way to avoid accidents!
Operationalsafety and readinessof the machine donot only dependonyour skill, but also
on maintenance and servicing of the machine. This is why regular maintenance and ser-
vicing 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 readiness of your machine, and maintains its value.
• We reserve the right to improve the technical standard of our machines without
adapting the service manual.
• Modifying Wacker Neuson products and fitting them with additional equipment and
attachments not included in our delivery program requires Wacker Neuson’s written
authorization, otherwise warranty and product liability for possible damage caused by
these modifications shall not be applicable.
• Subject to modifications and printing errors.
Your Wacker Neuson dealer will be happy to answer any further questions regarding the
machine or the service manual.
Abbreviations/symbols
• Identifies a list
• Subdivision within lists or an activity. Follow the steps in the recommended order
☞Identifies an activity
➥Description of the effects or results of an activity
n. s. = not shown
“Opt” = option
Stated whenever controls or other components of the machine are installed as an option.
A combination of digits, or a combination of digits and letters, for example 40/18 or 40/A
used for identifying the control elements, means:
Figure no. 40/control element no. 18 or position Ain figure no. 40
Figures carry no numbers if they are placed to the left of the text.
Operation

SHB 803 en – Edition 2.4 * 803s110.fm 1-3
Operation
1.2 Identification of warnings and dangers
Important indications regarding the safety of the personnel and the machine are identified
in this Operator’s Manual with the following terms and symbols:
Danger!
Failureto observe the instructions identified by this symbol can causeinjury or
death for the operator or other persons.
☞Measures for avoiding danger
Caution!
Failuretoobserve the instructionsidentifiedby this symbol cancause damage
to the machine.
☞Measures for avoiding danger for the machine
Notice!
This symbol identifies instructions for a more efficient and economical use of
the machine.
Environment!
Failuretoobserve the instructionsidentifiedby this symbol cancause damage
tothe environment.Theenvironmentis indangerifenvironmentally hazardous
material (for example waste oil) is not subject to proper use or disposal.

1-4 SHB803en–Edition2.4 * 803s110.fm
Operation
1.3 Designated use and exemption from liability
• The machine is intended for:
• Moving earth, gravel or rubble, and for hammer operation
• See chapter 1.5 “Fields of application, attachments”intheOperator’sManualfor
more information on the use of attachments.
• Every other application is regarded as not designated for the use of the machine.
WackerNeusonwillnotbeliablefordamageresultingfromuseotherthanmentioned
above. The user alone will bear the risk.
• Designated use also includes observing the instructions set forthin the Operator’s
Manual and observing the maintenance and service conditions.
• The safety of the machine can be negatively affected by performing machine modifica-
tions without proper authority and by using spare parts, equipment, attachments and
optional equipment that have not been checked and released by Wacker Neuson.
Wacker Neuson will not be liable for damage resulting from this.
• Wacker Neuson Linz GmbH shall not be liable for personal injury and/or damage to
property caused by failure to observe the safety instructions and the Operator’s
Manual, and by the negligence of the duty to exercise due care when:
• handling
• operating
• servicing and performing maintenance and
• repairing the machine. This is also applicable in those cases in which special
attention has not been drawn to the duty to exercise due care, in the safety instruc-
tions, the Operator’s Manuals and maintenance manuals (machine/engine).
• ReadandunderstandtheOperator’sManualbeforestartingup,servicingorrepairing
the machine. Observe all safety instructions!
• The machine may not be used for transport jobs on public roads!
• Hammer operation is only allowed in specified areas.

SHB 803 en – Edition 2.4 * 803s110.fm 1-5
Operation
1.4 Labels
Serial number
The serial number is located on the type label.
The serial number is also stamped on the machine chassis.
Refer to the Operator’s Manual of the machine for more information.
Diesel engine type label
The type label (arrow) is located on the cylinder-head cover (engine).
Hydraulic pump type label
The type label (arrow) is located on the hydraulic pump housing.
Main valve block type label
The type label (arrow) is located on the lower side of the main valve block.
Traveling drive type label
The type label (arrow) is located on the traveling drive.
Fig. 1: Type label (symbolic representation)
Fig. 2: Diesel engine type label
Fig. 3: Hydraulic pump type label
Fig. 4: Main valve block type label
Fig. 5: Traveling drive type label

1-6 SHB803en–Edition2.4 * 803s110.fm
Operation
Swivel unit type label
The type label (arrow) is located on the swivel unit.
Fig. 6: Swivel unit type label

SHB 803 en – Edition 2.4 * 803s110.fm 1-7
Operation
1.5 Machine overview (up to serial no. AI00966)
Fig. 7: Machine outside views
1 Boom light
2 Boom
3Stick
4Track
5 Travel gear
6 Stabilizer blade
7 Handhold
8 Liftingeyefor loading/tyingdownthemachine
9 Engine cover
10 Storage bin for Operator’s Manual
11 Lock lever
12 Track tensioner
12
73
9
8
6
54
8
2
45
6
8
711
10
12
12
3

1-8 SHB803en–Edition2.4 * 803s110.fm
Operation
1.6 Machine overview (from serial no. AI00967)
23
1
4 5 6
8
9
11
7
13
14
12
Fig. 8: Machine outside views
1 Boom light
2 Boom
3Stick
4Track
5 Travel gear
6 Stabilizer blade
7 Handhold
8Lifting eye for loading/tying down the
machine
9 Engine cover
10 Storage bin for Operator’s Manual
11 Lock lever
12 Track tensioner
13 ROPS rollbar (option)
14 Shatter protection (option) 8
45
6
10
11
14
7
2
3
8
12

SHB 803 en – Edition 2.4 * 803s110.fm 1-9
Operation
1.7 Control stand overview (up to serial no. AI00814)
139
8
27
6
4
5
Pos. Designation
1Operator seat
2Upper carriage lock
3Engine cover lock
4Preheating start switch
5Stabilizer blade/telescopic undercarriage lever
6Stabilizer blade/telescopic travel gear changeover lever
7Auxiliary hydraulics
8Engine cover
9Handhold

1-10 SHB803en–Edition2.4*803s110.fm
Operation
10
11
12
13
14
15
17
16
18
Pos. Designation
10 Boom swivel/auxiliary hydraulics pedal
11 Footrest
12 Control lever lock
13 Throttle
14 Control lever (left)
15 Drive lever (left)
16 Drive lever (right)
17 Control lever (right)
18 Indicators

SHB 803 en – Edition 2.4 * 803s110.fm 1-11
Operation
1.8 Control stand overview (from serial no. AI00815)
Pos. Designation
1Operator seat
2Upper carriage lock
3Engine cover lock
4Starter
5Stabilizer blade/telescopic travel gear lever
6Stabilizer blade/telescopic travel gear changeover lever
7Boom swivel pedal
8Engine cover
9Handhold
10 Auxiliary hydraulics pedal
11 Footrest
12 Lock lever
13 Throttle
14 Control lever (left)
15 Drive lever (left)
16 Drive lever (right)
17 Control lever (right)
18 Display element
19 Lever for switching over hammer/grab operation (option)
4
6
1
2
3
5
7
8
10
11 11
12
1314 15 16 17 9
18
19

1-12 SHB803en–Edition2.4*803s110.fm
Operation
1.9 Display elements (overview)
22
20
24
21
23
Pos. Designation
20 Indicator light (red) – alternator charge function
21 Indicator light (red) – engine oil pressure
22 Indicator light (red) – coolant temperature
23 Indicator light (yellow) – fuel gage
24 Hour meter