Description
New Holland E215B Crawler Excavator Workshop Service Manual Download
The New Holland E215B Crawler Excavator Workshop Manual will provide you with all the necessary information required to repair and keep the product working very well. The information is provided with step by step guidelines. You will be able to learn what technicians know very well already. Once you apply this knowledge, you will know what to do when an issue appears. You will learn how to perform a simple or a complex repair for the New Holland E215B Crawler Excavator.
CONTENTS:
0-SAFETY
0.1 GENERAL SAFETY INFORMATION ……………………………………………………………………….. 0-2
0.2 SAFETY PRECAUTIONS ………………………………………………………………………………………. 0-3
1-OUTLINE
1.1 GENERAL PRECAUTIONS FOR MAKING REPAIRS ………………………………………………1-3
1.1.1 PREPARATION BEFORE DISASSEMBLING ………………………………………………….1-3
1.1.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING…………………………………..1-3
1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT …………………..1-3
1.1.4 ELECTRICAL EQUIPMENT ………………………………………………………………………….1-4
1.1.5 HYDRAULIC PARTS ……………………………………………………………………………………1-5
1.1.6 WELD REPAIR ……………………………………………………………………………………………1-5
1.1.7 ENVIRONMENTAL ISSUES………………………………………………………………………….1-5
1.2 INTERNATIONAL UNIT SYSTEM ………………………………………………………………………….1-6
2-SPECIFICATIONS
2.1 NAME OF COMPONENTS……………………………………………………………………………………2-3
2.2 GENERAL DIMENSIONS ……………………………………………………………………………………..2-4
2.2.1 SK2108 [5.65m (18ft-6in) Boom+2.94m (9ft-8in) Standard Arm+0.80m3
(1.05cuyd) Bucket Shoe] ……………………………………………………………………………..2-4
2.2.2 SK2108 [5.65m (18ft-6in) Boom+3.5m (11ft-6in) Long Arm+0.70m3
(0.92cuyd) Bucket Shoe] ……………………………………………………………………………..2-4
2.3 WEIGHT OF COMPONENTS………………………………………………………………………………..2-5
2.4 TRANSPORTATION …………………………………………………………………………………………….2-7
2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER ………………………………….2-7
2.4.2 DIMENSIONS OF ATTACHMENT………………………………………………………………….2-8
2.5 SPECIFICATIONS AND PERFORMANCE………………………………………………………………2-9
2.5.1 SPEED AND CLIMBING CAPABILITY……………………………………………………………2-9
2.5.2 ENGINE ……………………………………………………………………………………………………..2-9
2.5.3 HYDRAULIC COMPONENTS ……………………………………………………………………….2-9
2.5.4 WEIGHT……………………………………………………………………………………………………..2-9
2.6 TYPE OF CRAWLER……………………………………………………………………………………………2-10
2.7 COMBINATIONS OF ATTACHMENT……………………………………………………………………..2-12
2.8 ENGINE SPECIFICATIONS ………………………………………………………………………………….2-13
2.8.1 SPECIFICATIONS……………………………………………………………………………………….2-13
3-ATTACHMENT DIMENSIONS
3.1 BOOM ………………………………………………………………………………………………………………..3-3
3.1.1 BOOM DIMENSIONAL DRAWING…………………………………………………………………3-3
3.1.2 BOOM MAINTENANCE STANDARD ……………………………………………………………..3-4
3.2 ARM …………………………………………………………………………………………………………………..3-6
3.2.1 ARM DIMENSIONAL DRAWING……………………………………………………………………3-6
3.2.2 ARM MAINTENANCE STANDARD ………………………………………………………………..3-7
3.3 BUCKET AND PIN ……………………………………………………………………………………………….3-10
3.3.1 BUCKET AND PIN DIMENSIONAL DRAWING………………………………………………..3-10
3.3.2 BUCKET AND PIN DIMENSIONAL TABLE……………………………………………………..3-11
MAINTENANCE SECTION
11-TOOLS
11.1 STANDARD TORQUE SPECIFICATIONS FOR CAPSCREWS AND NUTS………………11-3
11.2 SCREW SIZE…………………………………………………………………………………………………….11-5
11.2.1 CAPSCREW (BOLT) ………………………………………………………………………………….11-5
11.2.2 CAPSCREW (SOCKET BOLT)…………………………………………………………………….11-5
11.2.3 SOCKET SET SCREW……………………………………………………………………………….11-5
11.3 TORQUE SPECIFICATIONS FOR HOSE AND FITTINGS ………………………………………11-6
11.3.1 JOINT (O-RING TYPE)……………………………………………………………………………….11-6
11.3.2 HYDRAULIC HOSE (30° FLARE TYPE) ……………………………………………………….11-6
11.3.3 JOINT (ORS TYPE) ……………………………………………………………………………………11-6
11.3.4 SPLIT FLANGE………………………………………………………………………………………….11-6
11.4 TORQUE SPECIFICATIONS FOR NUTS AND SLEEVES ………………………………………11-7
11.5 PLUG ……………………………………………………………………………………………………………….11-8
11.5.1 PLUG FOR HYDRAULIC PIPE JOINT ………………………………………………………….11-8
11.5.2 PLUG FOR HYDRAULIC EQUIPMENT ………………………………………………………..11-9
11.6 SPECIAL SPANNER FOR TUBE …………………………………………………………………………11-11
11.7 SPECIAL TOOLS……………………………………………………………………………………………….11-12
11.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND……11-14
11.9 SUCTION STOPPER………………………………………………………………………………………….11-15
11.9.1 COMPONENTS …………………………………………………………………………………………11-15
11.9.2 DIMENSION………………………………………………………………………………………………11-15
11.9.3 APPLICABLE MODEL ………………………………………………………………………………..11-15
11.10 COUNTER WEIGHT LIFTING JIG……………………………………………………………………….11-16
111.10 UPPER FRAME LIFTING JIG …………………………………………………………………………….11-17
11.11 ENGINE TURNOVER STAND ……………………………………………………………………………..11-18
11.13 TRACK SPRING SET JIG……………………………………………………………………………………11-19
12-STANDARD MAINTENANCE TIMETABLE
12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR….12-4
13-MAINTENANCE STANDARD AND TEST PROCEDURE
13.1 HOW TO USE THE MAINTENANCE STANDARD………………………………………………….13-3
13.2 PERFORMANCE INSPECTION STANDARD TABLE ……………………………………………..13-4
13.3 MEASUREMENT OF ENGINE SPEED …………………………………………………………………13-6
13.3.1 MEASUREMENT OF ENGINE SPEED …………………………………………………………13-6
13.4 MEASUREMENT OF HYDRAULIC PRESSURE…………………………………………………….13-7
13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE …………………………………13-7
13.4.2 PLACE TO INSTALL PRESSURE GAUGE……………………………………………………13-7
13.4.3 PRESSURE ADJUSTMENT POSITION………………………………………………………..13-8
13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE………………………………………….13-10
13.5 MEASURING TRAVEL PERFORMANCES ……………………………………………………………13-12
13.5.1 TRAVEL SPEED………………………………………………………………………………………..13-12
13.5.2 DEVIATION OF TRAVEL…………………………………………………………………………….13-12
13.5.3 PERFORMANCES OF PARKING BRAKE …………………………………………………….13-13
13.5.4 DRAIN RATE OF TRAVEL MOTOR……………………………………………………………..13-14
13.6 MEASURING SWING PERFORMANCES……………………………………………………………..13-15
13.6.1 SWING SPEED………………………………………………………………………………………….13-15
13.6.2 PERFORMANCE OF SWING BRAKE…………………………………………………………..13-15
13.6.3 PERFORMANCE OF SWING PARKING BRAKE …………………………………………..13-16
13.6.4 DRAIN RATE OF SWING MOTOR……………………………………………………………….13-17
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES ………………………………13-18
13.7.1 OPERATING TIME OF CYLINDERS…………………………………………………………….13-18
13.7.2 CYLINDER LEAK CHECK …………………………………………………………………………..13-19
13.8 MEASURING PERFORMANCES OF SWING BEARING…………………………………………13-20
13.9 MECHATRO CONTROLLER ……………………………………………………………………………….13-21
13.9.1 ENGINE CONTROL INPUT / OUTPUT …………………………………………………………13-21
13.9.2 ENGINE CONTROL……………………………………………………………………………………13-22
13.9.3 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT
(A-B-C ADJUSTMENT)……………………………………………………………………………….13-24
13.9.4 OPERATIONS IN THE EVENT OF A MECHATRO CONTROLLER FAILURE……13-29
SYSTEM SECTION
21-MECHATRO CONTROL SYSTEM
21.1 SUMMARY OF MECHATRO CONTROL SYSTEM…………………………………………………21-4
21.1.1 MECHATRO CONTROL SYSTEM IN GENERAL …………………………………………..21-4
21.1.2 UNLOAD VALVE CONTROL……………………………………………………………………….21-6
21.1.3 POSITIVE CONTROL & P-Q CONTROL ………………………………………………………21-7
21.1.4 BOOM UP CONFLUX CONTROL ………………………………………………………………..21-9
21.1.5 ARM IN RECIRCULATION & CONFLUX CONTROL………………………………………21-10
21.1.6 ARM-IN ANTI-CAVITATION CONTROL………………………………………………………..21-12
21.1.7 ARM-OUT CONFLUX CONTROL ………………………………………………………………..21-13
21.1.8 BUCKET DIGGING (DUMP) CONFLUX CONTROL ……………………………………….21-14
21.1.9 BUCKET DIGGING ANTI-CAVITATION CONTROL ……………………………………….21-15
21.1.10 SWING PRIORITY CONTROL …………………………………………………………………….21-17
21.1.11 TRAVEL STRAIGHT CONTROL ………………………………………………………………….21-18
21.1.12 TRAVEL INDEPENDENT CONTROL……………………………………………………………21-20
21.1.12 PRESSURE RELEASE CONTROL ………………………………………………………………21-22
21.1.13 N&B SWITCH CONTROL (OPTION)…………………………………………………………….21-23
21.1.14 OPTION CONFLUX CONTROL (OPTION) ……………………………………………………21-24
21.2 MECHATRO CONTROLLER ……………………………………………………………………………….21-25
21.2.1 SUMMARY OF MULTI DISPLAY………………………………………………………………….21-25
21.2.2 SELF DIAGNOSIS DISPLAY……………………………………………………………………….21-30
21.2.3 SERVICE DIAGNOSIS DISPLAY FUNCTION ……………………………………………….21-32
21.2.4 TROUBLE HISTORY DIAGNOSIS ……………………………………………………………….21-42
21.2.5 TROUBLE DIAGNOSIS MODE ……………………………………………………………………21-43
21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE …………………………………….21-44
21.2.7 ADJUSTING PROCEDURE OF DISPLAY …………………………………………………….21-45
21.2.8 MECHATRO CONTROL EQUIPMENT …………………………………………………………21-49
22-HYDRAULIC SYSTEM
22.1 SUMMARY………………………………………………………………………………………………..22-3
22.2 HYDRAULIC CIRCUITS AND COMPONENTS………………………………………………22-4
22.3 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS………………………….22-8
22.4 NEUTRAL CIRCUIT……………………………………………………………………………………22-8
22.5 TRAVEL CIRCUIT ……………………………………………………………………………………..22-10
22.6 BUCKET CIRCUIT……………………………………………………………………………………..22-12
22.7 BOOM CIRCUIT ………………………………………………………………………………………..22-14
22.8 SWING CIRCUIT ……………………………………………………………………………………….22-18
22.9 ARM CIRCUIT …………………………………………………………………………………………..22-20
22.10 COMBINED CIRCUIT …………………………………………………………………………………22-26
22.11 PRESSURE DRAINING (RELEASING) CIRCUIT …………………………………………..22-30
23-ELECTRICAL SYSTEM
23.1 ELECTRIC CIRCUIT DIAGRAM …………………………………………………………………………..23-3
23.2 ELECTRICAL EQUIPMENT LIST …………………………………………………………………………23-7
23.3 HARNESS…………………………………………………………………………………………………………23-9
23.3.1 HARNESS LIST …………………………………………………………………………………………23-9
23.3.2 INSTRUMENT PANEL ASSY ………………………………………………………………………23-10
23.3.3 CONTROLLER INSTALL…………………………………………………………………………….23-11
23.3.4 TUNER INSTALL ……………………………………………………………………………………….23-11
23.3.5 UPPER ELECTRIC ASSY …………………………………………………………………………..23-12
23.3.6 UPPER HARNESS ASSY……………………………………………………………………………23-13
23.3.7 UPPER HARNESS ASSY (FLOOR PLATE) ………………………………………………….23-24
23.3.8 CAB HARNESS ASSY………………………………………………………………………………..23-30
23.3.9 BOOM HARNESS ASSY …………………………………………………………………………….23-33
23.3.10 INSTALLING BOOM LIGHT ………………………………………………………………………..23-33
23.3.11 INSTALLING UPPER LIGHT ……………………………………………………………………….23-34
23.3.12 FLASHER LAMP INSTALL………………………………………………………………………….23-35
21.1.13 ALARM ASSEMBLY …………………………………………………………………………………..23-36
24-COMPONENTS SYSTEM
24.1 HYDRAULIC COMPONENTS………………………………………………………………………………24-3
24.1.1 HYDRAULIC PUMP, REGULATOR ……………………………………………………………..24-3
24.1.2 CONTROL VALVE……………………………………………………………………………………..24-21
24.1.3 PILOT VALVE (ATT)…………………………………………………………………………………..24-59
24.1.4 PILOT VALVE (TRAVEL)…………………………………………………………………………….24-63
24.1.5 SWING MOTOR UNIT ………………………………………………………………………………..24-65
24.1.6 TRAVEL MOTOR……………………………………………………………………………………….24-75
24.1.7 SWIVEL JOINT ………………………………………………………………………………………….24-89
24.1.8 CYLINDER………………………………………………………………………………………………..24-91
24.2 ELECTRIC EQUIPMENT …………………………………………………………………………………….24-97
24.2.1 ELECTRIC EQUIPMENT LIST …………………………………………………………………….24-97
24.2.2 SPECIFICATION OF ELECTRIC EQUIPMENT ……………………………………………..24-100
25-AIR CONDITIONER SYSTEM
25.1 BASIC AIR CONDITIONER SYSTEM (HVAC AIR CONDITIONER)………………………….25-2
25.1.1AIR CYCLE ……………………………………………………………………………………………………….25-3
25.1.2 AUTO AIR CONDITIONER SYSTEM OUTLINE …………………………………………….25-4
25.2 COMPONENT AND CONSTRUCTION …………………………………………………………………25-5
25.2.1 COMPONENT……………………………………………………………………………………………25-5
25.2.2 CONSTRUCTION ………………………………………………………………………………………25-6
25.3 PIPING ……………………………………………………………………………………………………………..25-9
25.3.1 AIR CONDITIONER……………………………………………………………………………………25-9
25.3.2 RECEIVER DRYER ASSY ………………………………………………………………………….25-11
25.4 FUNCTION………………………………………………………………………………………………………..25-12
25.4.1 MECHANISM OF COOLING CIRCUIT………………………………………………………….25-12
25.4.2 COOLING CIRCUIT……………………………………………………………………………………25-14
25.4.3 COMPONENT PARTS………………………………………………………………………………..25-15
25.5 DISASSEMBLY AND ASSEMBLY………………………………………………………………………..25-19
25.5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION……………………………………25-19
25.5.2 DISASSEMBLY AND ASSEMBLY OF UNIT ………………………………………………….25-20
25.6 CHARGING REFRIGERANT ……………………………………………………………………………….25-24
25.6.1 PRECAUTIONS TO BE EXERCISED IN OPERATION……………………………………25-24
25.6.2 OPERATING PROCEDURE………………………………………………………………………..25-25
25.6.3 CHARGING PROCEDURE………………………………………………………………………….25-26
25.7 ELECTRIC CIRCUIT…………………………………………………………………………………………..25-32
25.7.1 WIRING DIAGRAM AND CONNECTORS……………………………………………………..25-32
25.7.2 STRUCTURE AND OPERATION OF EACH PART AND INSPECTION…………….25-34
25.8 TROUBLESHOOTING ………………………………………………………………………………………..25-37
25.9 SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL ……………………………………….25-44
25.9.1 POSITION OF INDICATION FOR FAILURE. …………………………………………………25-44
25.9.2 EXPLANATION OF INDICATION FOR FAILURE. ………………………………………….25-44
25.9.3 EXPLANATION OF MONITOR MODE ………………………………………………………….25-46
DISASSEMBLING SECTION
31-DISASSEMBLY AND ASSEMBLING
31.1 DISASSEMBLY & ASSEMBLY OVERVIEW…………………………………………………………..31-3
31.1.1 GENERAL INFORMATION………………………………………………………………………….31-3
31.1.2 TORQUE SPECIFICATIONS……………………………………………………………………….31-3
32-ATTACHMENT
32.1 REMOVING AND INSTALLING ……………………………………………………………………………32-3
32.1.1 ATTACHMENT ASSEMBLY ………………………………………………………………………..32-3
32.1.2 BUCKET …………………………………………………………………………………………………..32-3
32.1.3 ARM …………………………………………………………………………………………………………32-6
32.1.4 BOOM ………………………………………………………………………………………………………32-9
32.2 DISASSEMBLING AND ASSEMBLING…………………………………………………………………32-13
32.2.1 CYLINDER………………………………………………………………………………………………..32-13
33-UPPER STRUCTURE
33.1 OPERATOR SEAT……………………………………………………………………………………………..33-3
33.1.1 OPERATOR SEAT …………………………………………………………………………………….33-3
33.1.2 CAB………………………………………………………………………………………………………….33-4
33.1.3 BATTERY …………………………………………………………………………………………………33-6
33.1.4 GUARD …………………………………………………………………………………………………….33-7
33.1.5 UNDER COVER ………………………………………………………………………………………..33-13
33.1.6 FUEL TANK ………………………………………………………………………………………………33-14
33.1.7 HYDRAULIC TANK…………………………………………………………………………………….33-16
33.1.8 HYDRAULIC PUMP……………………………………………………………………………………33-20
33.1.9 AIR CLEANER …………………………………………………………………………………………..33-25
33.1.10 MUFFLER…………………………………………………………………………………………………33-26
33.1.11 COUNTERWEIGHT……………………………………………………………………………………33-28
33.1.12 RADIATOR & OIL COOLER ………………………………………………………………………..33-29
33.1.13 ENGINE ……………………………………………………………………………………………………33-35
33.1.14 CONSOLE COVER…………………………………………………………………………………….33-38
33.1.15 CONTROL VALVE……………………………………………………………………………………..33-39
33.1.16 PILOT VALVE (FOR ATT) …………………………………………………………………………..33-42
33.1.17 PILOT VALVE (FOR TRAVEL) …………………………………………………………………….33-43
33.1.18 SWING MOTOR UNIT ………………………………………………………………………………..33-45
33.1.19 SWIVEL JOINT ………………………………………………………………………………………….33-47
33.1.20 UPPER FRAME…………………………………………………………………………………………33-50
33.2 DISASSEMBLING AND ASSEMBLING…………………………………………………………………33-53
33.2.1 HYDRAULIC PUMP REGULATOR …………………………………………………………….33-53
33.2.2 CONTROL VALVE……………………………………………………………………………………..33-79
33.2.3 PILOT VALVE (ATT)…………………………………………………………………………………..33-110
33.2.4 PILOT VALVE (FOR TRAVEL) …………………………………………………………………….33-120
33.2.5 SWING MOTOR UNIT ………………………………………………………………………………..33-129
33.2.6 SWIVEL JOINT ………………………………………………………………………………………….33-156
34-TRAVEL SYSTEM
34.1 REMOVING AND INSTALLING……………………………………………………………………………34-3
34.1.1 TRAVEL SYSTEM …………………………………………………………………………………….34-3
34.1.2 CRAWLER ………………………………………………………………………………………………..34-3
34.1.3 UPPER ROLLER ……………………………………………………………………………………….34-7
34.1.4 LOWER ROLLER ………………………………………………………………………………………34-13
34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY) …………………………………………………..34-21
34.1.6 SPROCKET ………………………………………………………………………………………………34-30
34.1.7 TRAVEL MOTOR………………………………………………………………………………………34-33
34.1.8 SWING BEARING………………………………………………………………………………………34-35
34.2 REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT………………………………….34-38
34.2.1 TRAVEL MOTOR……………………………………………………………………………………….34-38
TROUBLESHOOTING SECTION
46-TROUBLESHOOTING (BY ERROR CODES)
46.1 EVALUATION OF ACTUAL PROBLEM AT THE SITE…………………………………………….46-3
46.2 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING………………………………….46-4
46.3 MECHATRO CONTROLLER BLOWN FUSE ………………………………………………………..46-4
46.4 TROUBLESHOOTING BY ERROR CODE…………………………………………………………….46-4
47-TROUBLESHOOTING (BY SYMPTOM)
47.1 HYDRAULIC SYSTEM………………………………………………………………………………………..47-3
47.2 ELECTRIC SYSTEMS ………………………………………………………………………………………..47-27
47.2.1 WIRING CHECKING PROCEDURE……………………………………………………………..47-27
47.2.2 TROUBLE …………………………………………………………………………………………………47-30
47.3 ENGINE RELATED TROUBLESHOOTING……………………………………………………………47-33
48-TROUBLESHOOTING (BY DIAGNOSIS MODE)
48.1 TROUBLE DIAGNOSIS MODE ……………………………………………………………………………48-3
ENGINE SECTION
51-ENGINE
SECTION 1 – DIAGNOSTICS ……………………………………………………………………………….. EW – 1-1
SECTION 2 – 6.7 L T/A ENGINE OVERHAUL…………………………………………………………..EW – 1-2
SECTION 3 – RECHARGING AND START-UP …………………………………………………………EW – 1-3
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If you always wanted to know how to use the New Holland E215B Crawler Excavator properly, then download this PDF version of the manual today, it will make things a whole lot easier for you!
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