Wacker Neuson 803 Service 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, we may from time to time need to make changes to figures and descriptions in this documentation which do 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
+43 (0) 7221 63000
Phone
E-mail: office.linz@wackerneuson.com
www.wackerneuson.com
Document: SHB 803 en
Order no.: 1000164843
Edition: 2.4
Table of contents
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
SHB 803 en – Edition 2.4 * 803s20IVZ.fm I-1
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
I-2 SHB 803 en – Edition 2.4 * 803s20IVZ.fm
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
SHB 803 en – Edition 2.4 * 803s20IVZ.fm I-3
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
I-4 SHB 803 en – Edition 2.4 * 803s20IVZ.fm
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
SHB 803 en – Edition 2.4 * 803s20IVZ.fm I-5
Table of contents
I-6 SHB 803 en – Edition 2.4 * 803s20IVZ.fm
Operation
Operation
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 following the instructions in the service manual.
Careful and prudent working is the best way to avoid 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 servicing 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 A in figure no. 40
Figures carry no numbers if they are placed to the left of the text.
1-2 SHB 803 en – Edition 2.4 * 803s110.fm
1.2 Identification of warnings and dangers
Danger!
Caution!
Notice!
Environment!
Important indications regarding the safety of the personnel and the machine are identified
in this Operator’s Manual with the following terms and symbols:
Failure to observe the instructions identified by this symbol can cause injury or
death for the operator or other persons.
☞ Measures for avoiding danger
Failure to observe the instructions identified by this symbol can cause damage
to the machine.
☞ Measures for avoiding danger for the machine
This symbol identifies instructions for a more efficient and economical use of
the machine.
Operation
Failure to observe the instructions identified by this symbol can cause damage
to the environment. The environment is in danger if environmentally hazardous
material (for example waste oil) is not subject to proper use or disposal.
SHB 803 en – Edition 2.4 * 803s110.fm 1-3
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” in the Operator’s Manual for
more information on the use of attachments.
• Every other application is regarded as not designated for the use of the machine.
Wacker Neuson will not be liable for damage resulting from use other than mentioned
above. The user alone will bear the risk.
• Designated use also includes observing the instructions set forth in the Operator’s
Manual and observing the maintenance and service conditions.
• The safety of the machine can be negatively affected by performing machine modifications 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 instructions, the Operator’s Manuals and maintenance manuals (machine/engine).
• Read and understand the Operator’s Manual before starting up, servicing or repairing
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.
1-4 SHB 803 en – Edition 2.4 * 803s110.fm
1.4 Labels
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
Operation
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.
SHB 803 en – Edition 2.4 * 803s110.fm 1-5
Operation
Fig. 6: Swivel unit type label
Swivel unit type label
The type label (arrow) is located on the swivel unit.
1-6 SHB 803 en – Edition 2.4 * 803s110.fm
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 Lifting eye for loading/tying down the machine
9 Engine cover
10 Storage bin for Operator’s Manual
11 Lock lever
12 Track tensioner
1
2
7
3
9
8
6
54
8
2
4
5
6
8
7
11
10
12
12
3
Operation
SHB 803 en – Edition 2.4 * 803s110.fm 1-7
Operation
2
3
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
8
Lifting 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
4
5
6
10
11
14
7
2
3
8
12
1.6 Machine overview (from serial no. AI00967)
1-8 SHB 803 en – Edition 2.4 * 803s110.fm
1.7 Control stand overview (up to serial no. AI00814)
1
3
9
8
2
7
6
4
5
Operation
Pos.
Designation
1
Operator seat
2
Upper carriage lock
3
Engine cover lock
4
Preheating start switch
5
Stabilizer blade/telescopic undercarriage lever
6
Stabilizer blade/telescopic travel gear changeover lever
7
Auxiliary hydraulics
8
Engine cover
9
Handhold
SHB 803 en – Edition 2.4 * 803s110.fm 1-9
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
1-10 SHB 803 en – Edition 2.4 * 803s110.fm
1.8 Control stand overview (from serial no. AI00815)
4
6
1
2
3
5
7
8
10
11
11
12
1314 15 16 17
9
18
19
Operation
Pos. Designation
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Operator seat
Upper carriage lock
Engine cover lock
Starter
Stabilizer blade/telescopic travel gear lever
Stabilizer blade/telescopic travel gear changeover lever
Boom swivel pedal
Engine cover
Handhold
Auxiliary hydraulics pedal
Footrest
Lock lever
Throttle
Control lever (left)
Drive lever (left)
Drive lever (right)
Control lever (right)
Display element
Lever for switching over hammer/grab operation (option)
SHB 803 en – Edition 2.4 * 803s110.fm 1-11
Operation
22
20
24
21
23
1.9 Display elements (overview)
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
1-12 SHB 803 en – Edition 2.4 * 803s110.fm
1.10 Engine compartment overview (up to serial no. AI00814)
29
31
30
25
27
26
32
28
Operation
Pos. Designation
25
Air filter
26
Throttle cable
27
Fuel filter
28
Swivel unit
29
Thermostat
30
Filler neck
31
Coolant filler inlet
32
Coolant reservoir
SHB 803 en – Edition 2.4 * 803s110.fm 1-13
Operation
37
39
38
33
34
35
40
36
1.11 Engine compartment overview (from serial no. AI00815)
Pos. Designation
33
Air filter
34
Fuel filter
35
Throttle cable
36
Swivel unit
37
Thermostat
38
Filler neck
39
Coolant filler inlet
40
Coolant reservoir
1-14 SHB 803 en – Edition 2.4 * 803s110.fm
Technical data
Technical data
Technical data
2 Technical data
2.1 Chassis
2.2 Engine
Sturdy steel sheet chassis, rubber-mounted engine
Engine Model 803
Product Yanmar diesel engine
Type 3TNV70-VNS
Design Water-cooled 4 stroke diesel engine
Number of cylinders 3
Fuel injection system Indirect injection
Aspiration Natural aspiration
Cooling system Water-cooled/blowing fan
Lubrication system Force-feed lubrication with trochoidal pump
Displacement 854 cm³ (52.1 in³)
Nominal bore and stroke 70 x 74 mm (2.75 x 2.91")
Output 9.6 kW (12.9 hp) at 2100 rpm
Max. torque 51.5 Nm (38 ft lbs) at 1500 rpm
Max. engine speed without load 2270 +/− 25 rpm
Idling speed 1300 +/− 25 rpm
Valve clearance (intake = outlet) 0.15 – 0.25 mm/(0.006 – 0.01") cold
Compression 32.4 +/− 1 bar (469.9 +/− 15 psi) at 250 rpm
Engine oil pressure 2.9 – 4.4 bar (42 – 64 psi) at rated output
Pressure switch for engine oil pump 0.5 +/− 0.1 bar (7.25 +/− 1.45 psi)
Thermostat opening temperature 69.5 – 72.5 °C (157 – 163 °F)
Thermal switch 107 – 113 °C (225 – 235 °F)
Firing order 1 – 3 – 2 – 1
Direction of rotation
Starting aid Glow plugs (preheating time 4 seconds)
Specific fuel consumption 272 g/kWh (lb/hph)
Max. engine droop
(all 2 pumps under full load)
Anticlockwise
(as seen from the flywheel)
By about 90 rpm
Exhaust values according to EPA TIER IV final (up to 2012)
2-2 SHB 803 en – Edition 2.4 * 803s210.fm
Technical data
Engine Model 803
Product Yanmar diesel engine
Type 3TNV74F-SNNS
Design Water-cooled 4 stroke diesel engine
Number of cylinders 3
Fuel injection system Indirect injection
Aspiration Natural aspiration
Cooling system Water-cooled/blowing fan
Lubrication system Force-feed lubrication with trochoidal pump
3
Displacement 993 cm³ (60.6 in
Nominal bore and stroke 74 x 77 mm (2.9 x 3.0 in)
Output
Max. torque
Max. engine speed without load
Idling speed
11.5 kW at 2500 rpm
(15.4 hp/2,500 rpm)
53 Nm at 1800 rpm
(39 ft.lbs/1800 rpm)
2675 +/− 25 rpm
(2,675 +/− 25 rpm)
1300 +/− 25 rpm
(1,300 +/− 25 rpm)
Valve clearance (intake = outlet) 0.15 – 0.25 mm/(0.006 – 0.01") cold
)
Compression 32.4 +/− 1 bar (469.9 +/− 15 psi) at 250 rpm
Engine oil pressure 3 – 4.5 bar (43.5 – 65.3 psi) at rated output
Pressure switch for engine oil
pump
0.5 +/− 0.1 bar (7.25 +/− 1.45 psi)
Thermostat opening temperature 71 °C (160 °F)
Thermal switch 107 °C (230 °F)
Firing order 1 – 3 – 2 – 1
Direction of rotation
Anticlockwise
(as seen from the flywheel)
Starting aid Glow plugs (preheating time 4 seconds)
Specific fuel consumption 279 g/kWh (lb/hph)
Max. engine droop (all 2 pumps
under full load)
By about 110 rpm
Exhaust values according to EPA TIER IV final (from 2012)
SHB 803 en – Edition 2.4 * 803s210.fm 2-3
Technical data
Fuel injection pump
Engine capacities
Engine tightening torques
Type
Design In-line pump
Injection pressure 118 – 128 bar (1711 – 1856 psi)
Engine speed control Mechanical
Lubrication system Force-feed engine oil lubrication
Capacities Model 803
Fuel tank 7 l (1.85 gal)
Engine oil (max./effect.) 2.8 l/1.3 l (0.74/0.34 gal)
Coolant (with radiator) 2.9 l (0.77 gal)
Coolant reservoir 1.1 l (0.29 gal)
Overview of capacities – see Fluids and lubricants on page 3-2
Tightening torques Model 803
Cylinder-head bolt
1
Connecting rod bearing screw
1
54 – 58 Nm (M9x1.25) (40 − 43 ft lbs)
22.6 − 27.5 Nm (M7x1.0) (16.6 − 20.3 ft lbs)
2.3 Hydraulic system
Main bearing screw 75.5 – 81.5 Nm (M10x1.25) (55.7 – 60 ft lbs)
Flywheel screw 80.4 – 86.4 Nm (M10x1.25) (59.3 – 63.7 ft lbs)
1. Screws must be oiled!
Hydraulics Model 803
Pump (Tier IV final up to 2012) Twin gear pump 2 x 5 cm³ (2 x 0.3 in³/rev)
Flow rate (Tier IV final up to 2012)
2 x 11.35 l/min at 2270 rpm
(2 x 3 gal/min at 2270 rpm)
Pump (Tier IV final from 2012) Twin gear pump 2 x 4 cm³ (2 x 0.24 in³/rev)
Flow rate (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
Main pressure limiting valve for pumps
P1, P2
Secondary pressure limiting valve
for swivel unit
Secondary pressure limiting valve, stick 250 +/−5 bar (3625.9 +/−72.5
170 +/− 3 bar (2465.64 +/− 44 psi)
70
-0/+0.5
bar (1015.3
-0/+7 psi
gal/min)
) at 11.5 l/min (3
psi)
Hydraulic reservoir capacity 13.8 l (3.6 gal)
2-4 SHB 803 en – Edition 2.4 * 803s210.fm
Auxiliary hydraulics oil flow
Notice!
2.4 Travel gear and swivel unit
Travel gear/swivel unit Model 803
Travel speeds 1.82 kph (1.13 mph)
Technical data
Pressure (bar/psi) P1 + P2 (l/min / gal/min)
12.5/181.3 22/5.8
37.8/548.2 20.8/5.5
50/725.2 20.4/5.4
79/1145.8 19.7/5.2
140/2030.5 18.5/4.8
160/2320.6 10.5/2.7
168/2436.6 5/1.3
Output indications for auxiliary hydraulics with unpressurized return line
2.5 Stabilizer blade
Screwable hose burst valve
Hill climbing ability
(no longer than 3 minutes)
Track width 180 mm (7.09'')
No. of track rollers on either side 2
Ground clearance 132 mm (5.2'')
Ground pressure 0.24 kg/cm² (3.4 psi)
Upper carriage swivel speed 8 rpm
Stabilizer blade Model 803
Width (folded in/out) 700/860 mm (27.55"/33.85")
Height 198 mm (7.8'')
Max. lift over/under subgrade 197/174 mm (7.76"/6.85")
Location Thread Gap dimension
Stabilizer blade 3/8" 0.3 mm (0.012'')
30°/58 %
SHB 803 en – Edition 2.4 * 803s210.fm 2-5
Technical data
F1
F2F3
Fig. 9: Fuses (up to serial number
WNCE0801CPAL0050)
F1
F2F3
Fig. 10: Fuses (from serial number WNCE0801TPAL0051)
F4
2.6 Electrical system
Fuses behind the right-hand trim
Electrical system
Dynamo 12 V 20 A
Starter 12 V 1.1 kW (1.5 hp)
Battery 12 V 30 Ah
Socket For 12 V power outlet, for example; 15 A max.
Fuse no. Rated current (A) Protected circuit
F1 40 A
F2 10 A
F3 10 A
F4 10 A
Main fuse: air-pressure sensor/output adaptation
(Yanmar 3TNV74F-SNNS)
Fuse: relay, indicator, cutoff solenoid
Fuse: horn, working light 12 V power outlet (up to
serial number WNCE0801CPAL0050, travel signal
(option)
12 V power outlet (from serial number
WNCE0801TPAL0051)
2-6 SHB 803 en – Edition 2.4 * 803s210.fm
Relays behind the right-hand trim
K8
K9
K7
Fig. 11: Relays
Fig. 12: Fuses and relays with Dual Power option
F1
F4
F2
F3
K7K9
Fig. 13: Relay K8
K8
Technical data
Relay no. Protected circuit
K 7 Starting relay
K 8 Cutoff solenoid time lag relay 1s
K 9 Cutoff solenoid switching relay
Fuses and relays with Dual Power option
If the machine is equipped with the Dual Power option, the fuses and relays are located
under the base plate.
Fuse no. Rated current (A) Protected circuit
F1 40 A
F2 10 A
Main fuse: air-pressure sensor/output adaptation
(Yanmar 3TNV74F-SNNS)
Fuse: relay, indicator, cutoff solenoid
Fuse: horn, working light 12 V power outlet (up to
F3 10 A
serial number WNCE0801CPAL0050, travel signal
(option), battery control (Dual Power option)
F4 10 A
12 V power outlet (from serial number
WNCE0801TPAL0051)
Relay no. Protected circuit
K 7 Starting relay
K 8 Cutoff solenoid time lag relay 1s
K 9 Cutoff solenoid switching relay
K 116 Battery control
SHB 803 en – Edition 2.4 * 803s210.fm 2-7
Technical data
Notice!
2.7 Noise levels
2.8 Vibration
Sound power level Model 803
1
Sound power level (L
Operator-perceived sound pressure level (L
Uncertainty (K
1. ISO 6395 (EC Directives 2000/14/EC and 2005/88/EC)
2. EN ISO 4871 (EC Directives 2000/14/EC and 2005/88/EC)
3. ISO 6394 (EC Directives 84/532/EEC, 89/514/EEC, 95/27/EEC)
PA
)
WA
PA
3
)
2
)
93 dB (A)
77 dB (A)
1.2 dB (A)
Measurements performed on asphalted surface.
Vibration
2.9 Coolant compound table
Effective acceleration value for the upper extremities of the
body (hand-arm vibration)
< Trigger value
< 2.5 m/s
Effective acceleration value for the body (whole-body vibration) < 0.5 m/s
Vibration values indicated in m/s².
Coolant
Outside temperature
Water Anticorrosion agent Antifreeze agent
Up to °C (°F)
% by
volume
cm³/l / (in3/gal) % by volume % by volume
-37 (-34.6) 50 10 (2.6) 1 50
Use the 1:1 concentration for warm outside temperatures, too:
Protection against corrosion, cavitation and deposits
Do not mix the coolant with other coolants.
Machine filled at the factory with Eurolub SF D12 coolant (ethylene glycol basis).
2
2
2-8 SHB 803 en – Edition 2.4 * 803s210.fm
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