Wacker Neuson 803 User manual

Operator's Manual

Electro-hydraulic

Power unit

HPU8

Machine type A01-01/A01-02

Edition 1.1.0

Order no 5200023696

Language us

Dokument ationen

Documentations Language Order no

Operator's Manual [us] 5200023696

Spare parts list

[de en fr] 1000315132

[de it es] 1000315133

Printed in Michigan, USA

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, will 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 reason, we

may from time to time need to make changes to diagrams and descriptions in this documentation which do not reflect products which

have already been delivered and which will not be implemented on these machines.

Technical data, dimensions and weights are given as an indication only. Responsibility for errors or omissions not accepted. Non-metric

weights and measurements are approximate.

The cover features machines with possible optional equipment.

Pictures and graphics are symbolic representations and can differ from the actual product.

Wacker Neuson Linz GmbH

Flughafenstraße 7

A-4063 Hörsching

Legend

Original Operator‘s Manual x

Translation of original Operator‘s

Manual

–

Edition 1.1.0

Date 10/2014

Document OM HPU8 us

OM HPU8 us 1.1.0 * HPU8en1_1_0IVZ.fm I-1

Table of contents

EC Declaration of Conformity.............................................................................................................. EG-1

1Foreword

1.1 Operator’s Manual ................................................................................................................................ 1-1

1.2 Warranty and liability ............................................................................................................................ 1-6

2 Safety

2.1 Safety symbols and signal words ......................................................................................................... 2-1

2.2 Qualification of operating personnel ..................................................................................................... 2-2

2.3 Conduct ................................................................................................................................................ 2-3

2.4 Operation.............................................................................................................................................. 2-4

2.5 Loading and transporting...................................................................................................................... 2-8

2.6 Maintenance ......................................................................................................................................... 2-9

2.7 Measures for avoiding risks................................................................................................................ 2-11

3 Introduction

3.1 Overall view (7.5 kW version) ............................................................................................................... 3-1

3.2 Overall view (9 kW version).................................................................................................................. 3-2

3.3 Brief description of power unit .............................................................................................................. 3-3

3.4 Information and regulations on use ...................................................................................................... 3-3

3.5 Labels ................................................................................................................................................... 3-4

4 Putting into operation

4.1 Overview of control elements ............................................................................................................... 4-1

4.2 Indicator lights and warning lights (overview)....................................................................................... 4-3

4.3 Preparations for starting ....................................................................................................................... 4-3

4.4 Starting and stopping the power unit .................................................................................................... 4-5

5Operation

5.1 Charging the excavator battery ............................................................................................................ 5-1

5.2 Putting out of operation/back into operation ......................................................................................... 5-5

5.3 Permanently putting out of operation.................................................................................................... 5-6

6 Transportation

6.1 Loading the power unit ......................................................................................................................... 6-1

6.2 Transporting the power unit.................................................................................................................. 6-2

7 Maintenance

7.1 Information on maintenance ................................................................................................................. 7-1

7.2 Maintenance overview.......................................................................................................................... 7-2

7.3 Fluids and lubricants............................................................................................................................. 7-4

7.4 Cleaning and maintenance................................................................................................................... 7-4

7.5 Cooling system ..................................................................................................................................... 7-7

7.6 Hydraulic system .................................................................................................................................. 7-8

7.7 Electrical system................................................................................................................................. 7-11

7.8 Tires.................................................................................................................................................... 7-12

7.9 Maintenance of the lifting point........................................................................................................... 7-12

8 Malfunctions

8.1 Malfunctions of the hydraulic system.................................................................................................... 8-2

8.2 Malfunctions of the electrical system .................................................................................................... 8-2

Table of contents

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9 Technical data

9.1 Models and trade names ...................................................................................................................... 9-1

9.2 Tires...................................................................................................................................................... 9-1

9.3 Operating hydraulics............................................................................................................................. 9-1

9.4 Electrical system................................................................................................................................... 9-2

9.5 Tightening torques ................................................................................................................................ 9-2

9.6 Noise emissions.................................................................................................................................... 9-4

9.7 Vibration................................................................................................................................................ 9-4

9.8 Weight................................................................................................................................................... 9-4

9.9 Dimensions ........................................................................................................................................... 9-5

Index

Index ..............................................................................................................................................................S-1

OM HPU8 us 1.1.0 * HPU8konf.fm EG-1

Declaration of conformity

EC Declaration of Conformity

Manufacturer

Wacker Neuson Linz GmbH, Flughafenstr. 7, 4063 Hörsching, Austria

Product

Declaration of conformity

Notified body according to Directive 2006/42/EC, appendix XI:

Notified body involved in procedure

Fachausschuss Bauwesen, Landsberger Str. 309, 80687 Munich, Germany

Directives and standards

We hereby declare that this product corresponds to the relevant regulations of the following Directives

and standards:

2006/42/EC, 2000/14/EC;

DIN EN ISO 12100:2010, DIN EN ISO 13857:2008, DIN EN ISO 4413:2011, DIN EN ISO 3744:2010

Authorized representative for the compilation of technical documentation

Thomas Köck, team leader technical documentation

Flughafenstr. 7

4063 Hörsching/Austria

Austria

Machine designation Electro-hydraulic power unit

Model/version A01-01

Trade name HPU8

Serial number --

Output in kW 7.5

Measured sound power level dB(A) 90.3

Guaranteed sound power level dB(A) 93

Johannes Mahringer,

Managing director

Robert Plomberger,

Technical director

Markus Huber,

Technical director

EC Declaration of Conformity

Original declaration of conformity

Declaration of conformity

EG-2 OM HPU8 us 1.1.0 * HPU8konf.fm

Notes:

OM HPU8 us 1.1.0 * HPU8v100.fm 1-1

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1 Foreword

1.1 Operator’s Manual

Information on this Operator’s Manual

The Operator’s Manual is stored in the document box above the control

box

This Operator’s Manual contains important information on how to work

safely, correctly and economically with the power unit. Therefore, it aims

not only at new personnel, but it also serves as a reference for

experienced personnel.

Furthermore, the reliability and the service life of the power unit will be

increased by following the instructions in the Operator’s Manual. This is

why the Operator’s Manual must be kept at hand in the power unit.

The operator must carefully read and understand the Operator’s Manual

before starting up, servicing or repairing the power unit.

This Operator’s Manual will help to familiarize yourself more easily with

the power unit, thereby enabling you to use it more safely and efficiently.

This Operator’s Manual does not include special superstructures.

The Operator’s Manual for the battery charger of the excavator is also

located in the document box mentioned above.

Please contact your dealer if you require more information on the power

unit or the Operator’s Manual.

Foreword

Table of contents

Index

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Explanation of symbols and abbreviations

Explanation of symbols

• Identifies a list

- Identifies a subdivision of a list

➥ Description of a result

1. Identifies an activity

Follow the order of the activity!

2. Continuation of an activity

Follow the order of the activity!

A Identifies an alphabetical list

B Continuation of an alphabetical list

Cross references: see page 1-1 (page)

Cross references: 7 (pos. no. or table no.)

Cross references: Fig. 5 (fig. no. 1)

Cross references: – see chapter “5.2 Accelerator actuation” on page 5-1

(see chapter)

Cross references: – see “Accelerator actuation” on page 5-1 (– see text)

Information

Identifies an information that, when followed, provides for a more efficient

and economical use of the power unit.

Environment

Failure to observe the instructions identified by this symbol can cause

damage to the environment.

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Abbreviations

Definitions

Fig. Figure

o/h Operating hours

approx. approximately

max. maximum

min. minimum

Pos. Position

e.g. for example

Power unit

The electro-hydraulic power unit HPU8 is referred to as “power unit” in this

Operator’s Manual.

Excavator

Unless otherwise indicated, the term excavator refers to the Wacker Neuson

803 dual power hydraulic excavator.

Operation

All work (for example traveling, excavating, daily maintenance, power unit

operation) an operator is allowed to or has to perform in connection with the

machine. The term “operation” does not include maintenance only a Wacker

Neuson service center is allowed to perform.

Three-phase connector

400 V (16 A) CEE three-phase connector according to IEC 60309, used for the

power supply of the power unit.

Operators

Persons either traveling or working with a construction machine, or operating

the power unit.

Machine

The term machine refers to a construction machine supplied with oil by the

power unit (hydraulic excavator 803, for example), or a construction machine

in general (the power unit itself, for example, when speaking in general terms).

Operating company/person

A company or person operating the machine and/or the power unit at a spe-

cific moment.

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Target-group definition

This Operator’s Manual is intended both for professional personnel on

construction sites accustomed to handling construction machines, and

also for private persons, for example, renting and operating a construction

machine after they have been instructed by the machine owner/operating

company in the proper use of the machine.

A dealer or person renting the machine must instruct the operator and

have this confirmed in writing.

The Operator’s Manual has been written in a way that allows power unit

operation by trained private persons without any special knowledge. As

far as possible, no technical terms specific to construction machines are

used.

This Operator’s Manual must be fully read and understood both by private

persons and the professional personnel on construction sites.

Operator qualification and requirements for safe operation

Among other things, safe machine operation depends on the following

points:

• Model and equipment

• Maintenance

• Nature of ground and work environment

The most important points are the operator’s qualification and power of

judgement. A well-trained operator following the Operator’s Manual and

maintenance plan ensures a long service life and durability of the

machine.

Specific training enables the operator to acquire, among other things, the

following skills:

• Correct assessment of work situations.

• Recognition of possible risk situations.

• Safe working by making the correct decisions for man, machine and

the environment.

The operator is at risk if the power unit is not operated correctly.

Follow the operating procedures and instructions described for the power

unit.

Children and persons under the influence of alcohol, drugs or medicine

are not allowed to access the power unit or operate it.

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Conversion table

The rounded imperial values are indicated in brackets, for example 1060

cm³ (64.7 in³).

Volume unit

1 cm³ (0.061 in³)

1 m³ (35.31 ft³)

1 ml (0.034 US fl.oz.)

1 l (0.26 gal)

1 l/min (0.26 gal/min)

Unit of length

1 mm (0.039 in)

1 m (3.28 ft)

Weight

1 kg (2.2 lbs)

1 g (0.035 oz)

Pressure

1 bar (14.5 psi)

1 kg/cm² (14.22 lbs/in²)

Force/output

1 kN (224.81 lbf)

1 kW (1.34 hp)

1 PS (0.986 hp)

Torque

1 Nm (0.74 ft.lbs.)

Speed

1 kph (0.62 mph)

Acceleration

1 m/s² (3.28 ft/s²)

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1.2 Warranty and liability

Exemption from warranty and liability

Warranty

Warranty claims can be made only if the conditions of warranty have been

observed. They are included in the General Conditions of Sales and

Delivery for new machines and spare parts sold by the dealers of Wacker

Neuson Linz GmbH. Furthermore, all instructions in this Operator’s

Manual must be observed.

Have the maintenance, delivery inspection and the entries in the service

booklet performed by a Wacker Neuson service center, otherwise

warranty claims will not be acknowledged.

Liability

• Modifying Wacker Neuson products and fitting them with additional

equipment and attachments not included in the delivery program

requires Wacker Neuson’s written authorization, otherwise warranty

and product liability for possible damage caused by these modifica-

tions shall not be applicable.

• The safety of the power unit can be negatively affected by performing

power unit modifications without proper authority and by using spare

parts, equipment, attachments and optional equipment that have not

been checked and released by Wacker Neuson. Warranty and product

liability for possible damage caused by these modifications shall not be

applicable.

• Wacker Neuson Linz GmbH shall not be liable for personal injury and/

or damage to property caused by failure to observe the safety instruc-

tions 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 power unit. 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 as well as in the Operator’s and

maintenance manuals.

- Read and understand the Operator’s Manual before starting up,

servicing or repairing the power unit. Observe all safety instructions.

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2 Safety

2.1 Safety symbols and signal words

Explanation

The following symbol identifies safety instructions. It is used for warning

against potential personal risk or danger.

DANGER

DANGER identifies a situation causing death or serious

injury if it is not avoided.

Consequences in case of non-observance.

► Avoidance of injury or death.

WARNING

WARNING identifies a situation that can cause death or

serious injury if it is not avoided.

Consequences in case of non-observance.

► Avoidance of injury or death.

CAUTION

CAUTION identifies a situation that can cause injury if it is

not avoided.

Consequences in case of non-observance.

► Avoidance of injury.

INFORMATION

INFORMATION identifies a situation that causes damage to the

power unit if it is not observed.

► Avoidance of damage to property.

Safety

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2.2 Qualification of operating personnel

Owner’s duties

• Only allow specifically authorized, trained and experienced persons to

operate and perform maintenance on the power unit.

• Do not allow persons to be trained or instructed by anyone other than

an authorized and experienced person.

• Have persons to be trained or instructed practise under supervision

until they are familiar with the power unit and its behavior.

• Children and persons under the influence of alcohol, drugs or medicine

are not allowed to access the power unit or operate it.

• Clearly and unequivocally define the responsibilities of the operating

and maintenance personnel.

• Clearly and unequivocally define the responsibilities on the job site,

also in view of traffic regulations.

• Give the operator the authority to refuse instructions by other persons

that are contrary to safety.

• Have the power unit serviced and repaired only by a Wacker Neuson

service center.

Required knowledge of operator

• The operator is responsible for other persons.

• Avoid any operational mode that might be prejudicial to safety.

• The power unit may only be operated by authorized and safety-

conscious persons who are fully aware of the risks involved in

operating the power unit.

• The operator and owner are obligated to operate the power unit only in

a safe and working condition.

• All persons working on or with the power unit must have read and

understood the safety instructions in this Operator’s Manual before

starting work.

• Follow, and instruct the operator in, legal and other mandatory regula-

tions relevant to accident prevention.

• Observe and instruct the operator in regulations regarding road traffic

and environmental protection.

• Observe the national and regional regulations, standards and guide-

lines regarding accident prevention in connection with electrical

systems, devices and their operation.

Preparatory measures for the operator

• In order to ensure safe work, check the power unit before starting it.

• Tie back long hair and remove all jewellery.

• Wear close-fitting work clothes that do not hinder movement.

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2.3 Conduct

Prerequisites for operation

• The power unit has been designed and built in accordance with state-

of-the-art standards and the recognized safety regulations.

Nevertheless its use can cause danger to the operator or other

persons, or damage to the power unit.

• Store this Operator’s Manual in the place provided for this in or on the

power unit. Immediately replace a damaged or illegible Operator’s

Manual and any supplements to it.

• The power unit must only be operated in accordance with its desig-

nated use and the instructions set forth in this Operator’s Manual.

• The operator and owner are obligated not to put into operation or

operate a faulty or malfunctioning power unit.

- If a damage or error occurs during operation, put the power unit out

of operation immediately and secure it against restart.

- Have all malfunctions jeopardizing the safety of the operator or other

persons immediately repaired by an authorized service centre.

• Do not put the power unit into operation or operate it after an accident;

have it inspected for damage by a Wacker Neuson service center.

• The owner is responsible for requiring the operating and maintenance

personnel to wear protective clothing and equipment as required by the

circumstances.

• Put and operate the power unit on horizontal, level and firm ground.

• Keep the power unit at least one meter away from facilities, buildings

and other machines during operation.

• Remove all tools, connecting cables and other loosed objects from the

power unit before starting it.

• The power unit connector must fit into the outlet. The connector must

not be modified under any circumstances.

Do not used adapter connectors.

Electric extension cables may be used if they have equivalent or higher

specifications than the cable to be extended.

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2.4 Operation

Preparatory measures

• For connection to the mains supply of a building, the power unit must

comply with the power, voltage and frequency conditions of the

equipment in the building. Different power, voltage, or frequency, or the

wrong connection can cause damage to the equipment, fire, personal

injury or even death.

• Keep the power unit clean. This reduces injury, accident and fire

hazards.

• Safely store objects you carry with you at the places provided for this

(storage compartment, for example).

• Do not carry objects with you that protrude into the operator’s work

space. They can create another danger in case of an accident.

• Observe all safety, warning and information labels.

• Ensure that all safety devices are properly installed and functional

before starting work.

• Before putting the power unit into operation, ensure that nobody is in

the danger zone.

• Do not operate the power unit near flammable fluids.

• Immediately replace damaged connecting cables.

• Do not use the connecting cable to carry or hang up the power unit, or

to pull the connector out of the outlet.

• Keep the connecting cable away from heat, oil, sharp edges or moving

parts of devices.

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Work area

• The operator is responsible for other persons.

• Before starting work, familiarize yourself with the work area. This

applies to, for example:

- Obstacles in the working and traveling area

- Any barriers separating the work area from public roads

- Soil weight-bearing capacity

- Existing overhead and underground lines

- Special operating conditions (dust, steam, smoke, asbestos, for

example)

• The maximum dimensions of the power unit must be known to the

operator – see the Technical data.

• Maintain a safe distance (buildings, edges of building pits, for

example).

• When working in buildings or in enclosed areas, look out for:

- Height of the ceiling/clearances

- Width of entries/passages

- Maximum load of ceilings and floors

• Due to hot machine parts, maintain a safe distance from easily

flammable material (hay, dry leaves, for example).

Operating radius

Position Function

A Electrohydraulic power unit HPU8

B Hydraulic excavator 803

C Minimum operating radius with connected power unit (1.5 m/59 in)

D Maximum operating radius with connected power unit (10 m/33 ft)

-- Minimum bending radius of Dual Power hydraulic hoses: 30 cm (12 in)

Fig. 1: Operating radius 803 with HPU8

B

A

C

D

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Danger zone

• The danger zone is the area in which persons are in danger due to the

movements of the power unit, the attachment, and/or the load.

• The danger zone also includes the area that can be affected by falling

material, equipment or by parts that are thrown out.

• Extend the danger zone sufficiently in the immediate vicinity of

buildings, scaffolds or other elements of construction.

• Seal off the danger zone should it not be possible to keep a sufficient

safety distance.

• Stop work immediately if persons do not stay clear of the danger zone.

Carrying passengers

• Carrying passengers with the power unit is not allowed.

• Carrying passengers on or in attachments/tools is not prohibited.

• Carrying passengers on or in trailers is not prohibited.

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Mechanical integrity

• The operator and owner are obligated to operate the power unit only in

a safe and working condition.

• Operate the power unit only if all protective and safety-oriented

equipment (removable safety devices, for example) is installed and

functional.

• Check the power unit for visible damage and defects.

• In case of damage and/or unusual behavior, put the power unit out of

operation immediately and secure it against restart.

• Have all malfunctions jeopardizing the safety of the operator or other

persons immediately repaired by an authorized service centre.

Starting the electric motor

• Start the engine only according to the Operator’s Manual.

• Observe all warning and indicator lights.

Operation

• Put the power unit into operation only if visibility is sufficient (have

another person guide you if necessary).

• Operate the power unit only on horizontal, level and firm ground.

• The power unit must be at the same level as the excavator.

• Do not pull the power unit with the hydraulic hoses.

• The operator must have permanent visual contact with the power unit.

• Never get on a moving power unit and never jump off the power unit.

• Do not lay the connecting cable on vibrating or hot parts.

• Do not cover a hot or running power unit.

• Do not exceed the maximum power output (1000 W).

• Do not let untrained personnel operate the power unit.

• Keep the immediate area around the power unit clean, tidy and free of

flammable material.

Stopping the electric motor

• Only stop the electric motor according to the Operator’s Manual.

Stopping and securing the power unit

• Before leaving the power unit, secure it to prevent it from rolling away

(suitable wheel chocks, for example).

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2.5 Loading and transporting

Crane-lifting

• Seal off the danger zone.

• The crane and the lifting gear must have suitable dimensions.

• Observe the power unit’s overall weight – see “Technical data”.

• Wear protective clothing and equipment when fastening, guiding and

removing the power unit (hard hat, safety glasses, safety boots, for

example).

• Use only lifting and fastening gear certified by a test/certification body

(cables, belts, hooks, shackles, for example), observe the inspection

intervals.

• Do not use any lifting and fastening gear that is dirty, damaged or not

of sufficient size.

• Perform a visual check to ensure that all slinging points are neither

damaged nor worn (no widening, no sharp edges, no cracks).

• Have loads fastened and crane operators only guided by experienced

persons.

• The person guiding the crane operator must be within sight or sound of

him.

• Observe all movements of the power unit and lifting gear.

• Secure the power unit against unintentional movement.

• Raise the power unit only after it is safely attached and the person

attaching the power unit has given his approval.

• Use only the slinging points provided for fastening the lifting gear

(cables, belts, for example).

• Do not attach the power unit by twining the lifting gear (cables, belts,

for example) around it.

• Ensure an even load distribution (center of gravity!) when fastening the

lifting gear.

• Ensure that no-one is on or under the power unit when loading the

power unit.

• Observe the national regulations (for example “Merkheft Erdbau-

maschinen” of the German employers’ liability insurance association

for construction engineering).

• Load the power unit only in accordance with this Operator’s Manual to

avoid damage to the power unit.

• Do not raise a power unit that is stuck or frozen onto the ground, for

example.

• Bear in mind the weather conditions (wind force, visibility conditions,

for example).

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