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Wacker Neuson 803 803 dualpower Track excavator Service Manual

Service Manual Wacker Neuson 803 803 dualpower Track excavator;
Content:

OPERATION
Information on this service manual
Identification of warnings and dangers
Designated use and exemption from liability
Labels
Machine overview (up to serial no. AI00966)
Machine overview (from serial no. AI00967)
Control stand overview (up to serial no. AI00814)
Control stand overview (from serial no. AI00815)
Display elements (overview)
Engine compartment overview (up to serial no. AI00814)
Engine compartment overview (from serial no. AI00815)

TECHNICAL DATA
Chassis
Engine
Fuel injection pump
Engine capacities
Engine tightening torques
Hydraulic system
Auxiliary hydraulics oil flow
Travel gear and swivel unit
Stabilizer blade
Screwable hose burst valve
Electrical system
Fuses behind the right-hand trim
Relays behind the right-hand trim
Fuses and relays with Dual Power option
Noise levels
Vibration
Coolant compound table
Model-specific tightening torques
General tightening torques
Tightening torques for hydraulic threaded fittings (dry assembly)
Tightening torques for high-resistance threaded fittings
Dimensions model 803 (up to serial no. AI00966)
Dimensions model 803 with ROPS rollbar (from serial no. AI00967)
Dimensions model 803 without ROPS rollbar (from serial no. AI00967)
Lift capacity table 803 RD
Kinematics

MAINTENANCE
Fluids and lubricants
Additional oil change and filter replacement (hydraulic system)
Maintenance label
Explanation of symbols on the maintenance label
Maintenance label (up to serial number AF02412)
Maintenance label (from serial number AF02413)
Maintenance plan (overview)
Service package
Introduction
Safety-relevant parts
Fuel system
Specific safety instructions
Refueling
Stationary fuel pumps
Diesel fuel specification
Bleeding the fuel system
Fuel prefilter with water separator
Replacing the fuel filter
Engine lubrication system
Checking the oil level
Adding engine oil
Changing engine oil
Replacing the engine-oil filter cartridge
Cooling system
Specific safety instructions
Checking the coolant level/adding coolant
Draining coolant
Air filter (up to serial no. AI00875)
Replacing air filter elements
Air filter (from serial no. AI00876)
Replacing air filter elements
V-belt
Checking V-belt tension
Retensioning the V-belt
Pressure check
General
Pressure check of gear pump P2
Pressure check of gear pump P1
Test report
Hydraulic system
Specific safety instructions
Checking the hydraulic oil level
Adding hydraulic oil
Changing hydraulic oil
Replacing the filter cartridge
Checking hydraulic pressure lines
Tracks
Checking track tension
Setting the tracks
Lubrication points on boom (up to serial number AI00966)
Lubrication strip
Overview of lubrication points (from serial no. AI00967)
Parking the machine
Lubrication points on the stabilizer blade and stabilizer blade cylinder
Lubrication points on swiveling console
Swiveling cylinder lubrication points
Lubrication points on live ring (ball bearing)
Lubrication points of live ring teeth
Ball sockets (ISO/SAE changeover option)
Maintenance of attachments
Electrical system
Specific safety instructions
Servicing and maintenance at regular intervals
Instructions concerning specific components
Alternator
Battery
General maintenance
Cleaning
General instructions for all areas of the machine
Control stand
Exterior of the machine
Engine compartment
Threaded fittings and attachments
Pivots and hinges
Preparatory work before taking out of service
Maintenance if the machine is out of service for a longer period of time
Putting into operation again

ENGINE
Overview of engine 3TNV70-VNS (Tier IV final up to 2012)
Fuel system
Checking and adjusting valve clearance
Tightening order for cylinder head bolts
Checking the injection nozzles
Pressure check
Checking the nozzle jet
Injection time
Checking and adjusting injection time
Replacement of fuel injection pump
Adjusting engine speed
Compression
Checking the coolant thermostat
Checking the thermal switch
Oil pressure switch
Checking the coolant circuit
Engine trouble
Overview of engine 3TNV74F-SNNS (Tier IV final from 2012)
Fuel system
Cooling system
Altitude-dependent output reduction
Checking and adjusting valve clearance
Tightening order for cylinder head bolts
Order for removing the cylinder-head bolts:
Order for installing the cylinder-head bolts:
Checking the injection nozzles
Pressure check
Checking the nozzle jet
Injection time
Checking injection time
Setting injection time
Removing and installing the injection pump
Removing the injection pump
Fitting the fuel injection pump
Measuring and adjusting the engine speed
Compression
Checking the coolant thermostat
Checking the temperature sensor
Oil pressure switch
Checking the coolant circuit
Cleaning the cooling water channels
Coolant and fuel hoses
Crankcase vent
Replacing the glow plugs
Engine trouble

HYDRAULIC SYSTEM
Hydraulic pump PGP505B0050CA1H2NJ7J5C-505A00 (Tier IV final up to 2012)
Pump unit: exploded view
Hydraulic pump PGP505B0040CA1H2NJ7J5C-505A0040XB1J5B1B1 (Tier IV final
from 2012)
Pump unit: exploded view
Main valve block
Connections
Legend
Main valve block diagram
Pressure limiting valves
Pump assignment
Traveling drive
Function
Swivel unit
Swivel unit
Swivel joint
Sealing
Mechanical control
Control levers (up to serial no. AI00814)
Drive levers (up to serial no. AI00814)
Control levers (from serial number AI00815)
Drive levers (from serial number AI00815)
Lock lever (from serial number AI00815)
Troubleshooting in the hydraulic system
Plastic trims
Hydraulics diagram (legend)
Hydraulics diagram
Hydraulics diagram (Dual Power option)
Main valve block diagram

ELECTRICAL SYSTEM
Ohms Law (current, voltage, resistance); power
Measuring equipment, measuring methods
Cable color coding
Relays
Use, mode of function
Electrical system
Fuses behind the right-hand trim
Relays behind the right-hand trim
Fuses and relays with Dual Power option
Control lever push button
Right handle
Working light
Dynamo
Rectifier
Starter
Engine wiring harness legend (Tier IV final up to 2012)
Engine wiring harness (Tier IV final up to 2012)
Engine wiring harness legend (Tier IV final from 2012)
Engine wiring harness (Tier IV final from 2012)
Wiring harness for indicators (up to serial number WNCE0801TPAL00923)
Wiring harness for indicators (from serial number WNCE0801PPAL00924)
Traveling signal wiring harness (option)
Horn wiring harness
Battery lead
Indicating instrument wiring harness (Dual Power option)
Engine/chassis wiring harness (Dual Power option)
Seat console wiring harness
Wiring diagram
Wiring diagram Tier IV (Yanmar)
Wiring diagram (Dual Power option)

OPTIONS
Rollbar
TOPS rollbar up to serial number AF01416
Lowerable ROPS rollbar (from serial no. AF01417 to serial no. AI00966)
Raising/lowering the rollbar:
Lowering and raising the rollbar
Lowerable ROPS rollbar from serial no. AI00967
Raising/lowering the rollbar:
ISO/SAE changeover (option)
Traveling signal (option)
Telematic
Connections
Functional check/diode
Zero-emission Dual Power drive
Overview

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