New Holland E16, E18 Mini Crawler Excavators Service Repair Workshop Manual
New Holland E16, E18 Mini Crawler Excavators Service Repair Workshop Manual
New Holland E16, E18 Mini Crawler Excavators Service Repair Workshop Manual
WORKSHOP MANUAL
ENGLISH
Print No. 604.13.396
Edition: 01/2005
English - Printed in Italy
TO THE READER
• This manual has been written for a skilled NEW HOLLAND KOBELCO CONSTRUCTION
technician, in order to give him the information MACHINERY S.p.A.
necessary to repair this machine. Strada di Settimo, 323
San Mauro Torinese (TO)
- Read this manual carefully for correct 10099 ITALIA
information about repair procedures. PRODUCT SUPPORT
Fax. ++39 011 0077357
- For any question or comment, or in case you
notice a mistake in this manual content, please
contact:
AVOID ACCIDENTS
ATTENTION
On machines having hydraulically, mechanically and/or cable
controlled equipment (such as showels, loaders, dozers, scrapers
etc.) be certain the equipment is lowered to the ground before servicing,
adjusting and/or repairing.
If it is necessary to have the equipment partially or fully raised to gain
access to certain items, be sure the equipment is suitably supported
by means other than the hydraulic lift cylinders, cable and/or mechanical
device used for controlling the equipment.
All rights reserved. Reproduction of text and illustrations in whole or in part, is strictly
prohibited.
E16 - E18
INDEX
SECTION 3 - PRELIMINARY
General precautions for repairs ..................................................................................................................... 3-1
Escaping procedure in case of emergency ................................................................................................... 3-6
International unit conversion system ............................................................................................................. 3-7
SECTION 4 - SPECIFICATION
Foreword ....................................................................................................................................................... 4-1
Identification data .......................................................................................................................................... 4-2
Noise levels (2000/14/EC) ............................................................................................................................ 4-3
Summary plate for maintenance operations ................................................................................................. 4-4
Basic components of the mini excavator ....................................................................................................... 4-5
Technical specifications ................................................................................................................................ 4-7
Digging performances (canopy) .................................................................................................................... 4-8
Digging performances (cab) .......................................................................................................................... 4-9
Transport dimensions (canopy) ................................................................................................................... 4-10
Transport dimensions (cab) ........................................................................................................................ 4-11
Lifting capacities (cab) ................................................................................................................................ 4-12
Lifting capacities (canopy) ........................................................................................................................... 4-13
Machine and components weight (dry) ....................................................................................................... 4-14
Buckets application ..................................................................................................................................... 4-15
Filling chart .................................................................................................................................................. 4-16
SECTION 5 - TOOLS
Tools of cylinders .......................................................................................................................................... 5-1
Tool of hydraulic pump .................................................................................................................................. 5-4
Tool of pilot valve track ................................................................................................................................. 5-4
Tool of roller track ......................................................................................................................................... 5-4
Tool of idler adjuster ...................................................................................................................................... 5-5
Tools of engine .............................................................................................................................................. 5-5
Tools of travel motor ..................................................................................................................................... 5-8
1-1
SECTIONS INDEX
SECTION 10 - ATTACHMENT
Attachment assy and name ......................................................................................................................... 10-1
Bucket ......................................................................................................................................................... 10-2
Arm .............................................................................................................................................................. 10-5
Boom ......................................................................................................................................................... 10-10
Swing ........................................................................................................................................................ 10-15
Dozer ......................................................................................................................................................... 10-22
Hydraulic cylinders .................................................................................................................................... 10-26
1-2
SECTIONS INDEX
SECTION 16 - ENGINE
Specifications and Performance ............................................................................................................... 16-1
Cross Sectional Views .............................................................................................................................. 16-15
Cooling water, lubricating oil and fuel oil .................................................................................................. 16-17
Troubleshooting ........................................................................................................................................ 16-21
Measuring instruments .............................................................................................................................. 16-25
Measurement, inspection and adjustment ................................................................................................ 16-29
Adjustment the valve head clearance ....................................................................................................... 16-31
Checking the v-belt tension ....................................................................................................................... 16-32
Measuring and checking the injection pressure and spray patterns of the fuel injection valve ................. 16-32
Checking and adjustament the fuel injection timing .................................................................................. 16-36
Adjustament the no-load maximum (or minimum) revolutions .................................................................. 16-38
Checking the cooling water system and radiator for water leakage .......................................................... 16-38
Checking the battery ................................................................................................................................. 16-39
Checking the sensors ................................................................................................................................ 16-41
Checking the oil cooler .............................................................................................................................. 16-42
Checking the piston cooling nozzle ........................................................................................................... 16-43
Measuring Procedure, Service Data and Corrective Action ...................................................................... 16-45
Disassembly and reassembly ................................................................................................................... 16-73
Service data .............................................................................................................................................. 16-83
Tightening torque ...................................................................................................................................... 16-89
Fuel injection pump for indirect injection system ....................................................................................... 16-91
Fuel Injection Pump for Direct Injection System ....................................................................................... 16-97
Governor ................................................................................................................................................. 16-111
Turbocharger ........................................................................................................................................... 16-123
1-3
INTRODUCTION
INTRODUCTION
INTRODUCTION
This service manual has been prepared in order to increase repair quality, providing to the technicians the
elements for a good knowledge of the product and showing the proper procedures to carry out the maintenance
operations. We recommend to thoroughly read the content and follow it when necessary.
It is a concise guide. It covers construction features, operation principle, troubleshooting, disassembly and
assembly of components and repair action.
Using this manual in systematic and rational way it is possible to reduce the repairing errors and delay that could
cause machine stop with a detriment of cost management.
The information quoted in this service manual are supplied also to be used for training aids. Therefore it is
advisable to be used in the training of new personnel that will be employed in the machine maintenance.
All the information, illustrations and specifications contained in this service manual are based on the latest product
information available at the time of publication.
The dealer reserves the right to makes changes at any time without notice to this service manual for technical
or trading reasons.
MANUAL HANDLING
This service manual is carried out in loose-leaf and therefore can be easily kept up-to-date.
The personnel in charge is responsible for updating the manual and will insert the changes or supplements that
the Dealer will issue to its service organisation.
1-4
INTRODUCTION
In this service manual, symbols and indications are used to draw the attention on important points for safety and
quality.
SAFETY
This safety symbol is used for important safety message. When you see this symbol, be alert to the
potential for personal injury. Strictly follow the recommended precautions.
INDICATIONS
Reading this service manual you can find indications as “IMPORTANT” or “NOTE” that have the following
meaning:
• IMPORTANT
Indicates a situation which, if not avoided, could caused damages to the machine.
• Note
Indicates supplementary technical information or know-how.
1-5
FEATURES OF THE MANUAL
MANUAL COMPOSITION
This service manual is divided into ten Sections. The Section names and its contents are as below. To fully
use this service manual it is essential to understand how it is organised. Therefore, in order to speed up the
searching of wished subject, it is advisable to carefully read this chapter.
SECTION 3 - PRELIMINARY
This Section contains the information related to general precautions for repairs and escaping procedure in can
of emergency.
SECTION 4 - SPECIFICATION
This Section quotes the specification and data of the machine.
SECTION 5 - TOOLS
This Section contains the list of special tools.
1-6
FEATURES OF THE MANUAL
SECTION 10 - ATTACHMENT
This Section describes the attachments and its components and maintenance rules with related disassembly/
assembly.
SECTION 16 - ENGINE
This section descibes specifications, performance, measurament, inspection, disassembly/assembly and
service data of engine.
1-7
FEATURES OF THE MANUAL
The manual is divided into sections, each of them quotes a specific portion of the machine or a specific related
subject.
Some sections (those related to main mechanical assembly) are divided into:
• Operation Principle
• Disassembly/Assembly
In the Operation Principle, the assemblies and their components are described with technical data.
In the Disassembly and Assembly section the procedures are described to perform, repair or overhaul, with
special tools required and technical data.
• example:
2-1
▼
Section number.
1-8
E16 - E18
INDEX
SAFETY PRECAUTIONS Keep head, body, limbs, hands and feet inside the
operator’s compartment at all times to reduce
GENERALITIES exposure to external hazards.
Be careful of possible slippery conditions of the
Read the Operation and Maintenance Instruction steps and hand rails as well as of the ground
Manual carefully before starting, operating, main- around the machine.
taining, fuelling or servicing the machine. Wear protective boots or shoes with the soles
Carefully read the explanation to each and all made of highly no-slip rubber.
safety signs in the special section of this Manual Do not leave the machine until it has come to a
before starting, operating, maintaining, fuelling or complete stop.
servicing the machine. Always check height, width and weight limitations
Machine-mounted safety plates are colour coded which may be encountered in the working site and
yellow with black borders when they refer to points ensure the machine does not exceed them.
where special WARNING must be paid and failure Assess exact paths of gas ducts, water mains,
to observe them may cause a serious DANGER to telephone lines, sewers, overhead and under-
the integrity of machine operators. ground electric lines and all other possible ob-
They are white with red borders and black lettering stacles.
when they refer to a FORBIDDEN practice. Such paths should be opportunely defined by
It is fundamental that all machine operators know competent Authorities.
very well the meaning of each safety plate as this If necessary, require that the service is interrupted
considerably decreases operating hazards and or said installations are moved prior to starting the
accidents. work.
Do not allow unauthorised personnel to operate or You must know the working capacity of the machi-
service this machine. ne.
Do not wear rings, wrist watches, jewellery, loose Define the rear upperstructure swing area and
or hanging garments, such as ties, torn clothing, provide for opportune barriers to prevent access
scarves, unbuttoned or unzipped jackets that can into it.
get caught in moving parts. Never exceed machine lifting capacity.
Wear certified safety clothes such as: hard hat, no- Remain within the limits shown in the loading
slip footwear, heavy gloves, ear protection, safety capacity chart located on the machine.
glasses , reflector vests, respirators every time the
job requires it.
Ask your employer about safety regulations in STARTING
force and protective equipment.
Always keep the operator’s compartment, step Never start or operate a failed machine. Walk
plates, grab-rails and handles clean and clear of all around the machine before mounting.
foreign objects, oil, grease, mud or snow to mini- Before operating the machine, make sure that any
mise the danger of slipping or stumbling. possible dangerous condition has been properly
Remove mud or grease from your shoes before removed.
operating the machine. Before starting machine, check that steering and
Do not jump on or off the machine. Always keep attachment controls are in the neutral position and
both hands and one foot, or both feet and one the safety lever is in the LOCK position.
hand in contact with steps and/or grab rails. Immediately report any malfunction of parts or
Do not use controls or hoses as hand holds. systems to the maintenance managers for proper
Hoses and controls are movable parts and do not action.
provide solid support. Prior to starting the engine, check, adjust and lock
Besides, controls may be inadvertently moved the driver’s seat for maximum riding comfort and
and cause unexpected movement of the machine control accessibility.
or its attachments. Prior to operating the machine and/or its attach-
Never operate the machine or its attachments ments, check that bystanders are outside the
from any position other than sitting in the driver’s machine operating range. Sound the horn.
seat. Obey all hand signals, safety indications and signs.
2-1
SAFETY PRECAUTIONS
2-2
SAFETY PRECAUTIONS
and lines as well as width limits of corridors, roads We emphasise the danger represented in these
and narrow passages. conditions by large tree limbs (possibly falling on
Also, get to know load limits of the ground and the machine) and large roots (which may act as a
paving type of the ramps you are to work on. leverage under the machine when up-rooted and
Beware of fog, smoke or dust that obscure visibi- cause the unit to overturn).
lity. Position the machine dependent upon the loading
Always inspect the working area to identify poten- and unloading areas in order to swing leftwards to
tial risks such as: inclines, overhangs, trees, de- load to obtain best visibility.
molition bble, fires, ravines, steep slopes, rough Never use the bucket or attachment as a man
terrain, ditches, crowns, ridge trenches, diggings lift or carry riders.
in traffic areas, crowded parking lots, crowded Never use the machine as a work platform or
service areas, fenced zones. In such conditions, scaffolding.
proceed with extreme care. The machine must not be improperly used for
Whenever possible, avoid crossing over obstacles works not consistent with its features (such as
such as very rough terrain, rocks, logs, steps, pushing railway cars, trucks or other machines).
ditches, railroad tracks. Always pay attention to people within the machine
When obstructions must be crossed, do so with operating range.
extreme care and at a square angle, if possible. Never move or stop the bucket, other loads or the
Slow down. attachment above ground personnel or truck cabs.
Ease up to the break-over point, pass the balance Ensure the truck driver is in a safe place before
point slowly and ease down the other side also loading the truck.
using the attachment, if necessary. Load trucks from side or rear.
To overcome deep trenches or sinking ground, Use only the type of bucket recommended consi-
place the machine perpendicular to the obstacle, dering machine type, materials to be handled,
drastically reduce ground speed and start cros- material piling up and loading characteristics,
sing using also the attachment if necessary, only ground type and other typical conditions of the
after assessing that ground conditions allow the work to be performed.
traverse safely and without risks. When travelling with a loaded bucket, keep it as
The gradient you may attempt to overcome is rolled-back as possible. Keep boom and arm as
limited by factors such as ground conditions, load low as possible.
being handled, machine type and speed, and Ground speed should be adequate to the load and
visibility. ground conditions.
There is no substitute for good judgement and The load must always be properly arranged in the
experience when working on slopes. bucket; move with extreme care when transpor-
Avoid operating the attachment too close to an ting oversize loads.
overhang or high wall, either above or below the Do not lift and move the bucket overhead where
machine. persons are standing or working, nor downhill
Beware of caving edges, falling objects and land- when working on a slope as this would decrease
slides. Remember that such hazards are likely to machine stability. Load the bucket from the uphill
be concealed by bushes, undergrowth and such. side.
Avoid faggots, bushes, logs and rocks. Loads to be raised using the machine should be
Never drive over them, nor over any other surface exclusively hooked to the hitch specially provided.
irregularities that discontinue adherence or trac- The excavator is no lifting and transportation me-
tion with the ground, especially near slopes or ans, therefore it should not be used to position
drop-offs. loads accurately.
Be alert to avoid changes in adherence conditions Should it be exceptionally used to lift and lay
that could cause loss of control. building components, special caution must be
Work with extreme care on ice or frozen ground taken as follows:
and on stepped slopes or near drop-offs. • The machine should necessarily be equipped
The word “bulldozing” generally refers to work in with the special option supplied by Dealer.
virgin rough terrain, characterised by the presen- Follow also safety rules for the excavator used
ce of all the perils and risks listed above. as lifting means.
2-3
SAFETY PRECAUTIONS
• Secure the loads to be raised using cables or Do not swing the upperstructure, raise the load or
chains fastened with appropriate hooking brake abruptly if not required. This may cause
mechanisms. accidents.
• Nobody should be allowed to remain under the Prior to beginning the work near gas distribution
raised load or within the excavator operating mains or other public utilities:
range for any reason whatever. • Contact the company owner of the gas mains or
Never exceed specified loading capacity. Incor- its nearest branch before starting the work. Look
rect fastening of slings or chains may cause boom/ up the number in the telephone directory.
arm failure or failure of the lifting means with • Define together which precautions should be
consequent bodily injuries and even death. taken to guarantee work safety.
Always ensure that slings and chains used for • Decrease work speed. Reaction time could be
lifting are adequate to the load and in good condi- too slow and distance evaluation wrong.
tion. • When working near gas mains or other public
All loading capacities are referred to the ma- utilities installations, appoint a person in charge
chine on a level surface and should be disre- of signalling duties. This person will have the
garded when working on a slope. responsibility of observing the machine, any
Avoid travelling across slopes. Proceed from uphill part of it and/or the load approaching the gas
downhill and vice-versa. mains from a standpoint more favourable than
If machine starts slipping sideways when on a the Operator’s. This signal man (flag-man) must
slope, lower the bucket and thrust bucket teeth be in direct communication with the Operator
into the ground. and the Operator must pay undivided attention
Working on slopes is dangerous. Grade the working to the signals supplied.
area if possible. • The gas distributing Company, if previously
Reduce work cycle time if it is not possible to grade advised and involved in the work, as well as
the working area. machine Operator, Owner and/or any natural
Do not move full bucket or a load from uphill person or legal entity having rent or leased the
downhill as this would reduce machine stability. machine or being responsible at the time by
Do not work with the bucket turned to the uphill contract or by law, are liable for the adoption of
side. the necessary precautions.
Do not work with the bucket turned uphill as coun- Working near electric lines can be very dange-
terweights protruding downhill would reduce ma- rous, therefore some special precautions must be
chine stability on the slope and increase risk of observed.
overturning. Within this Manual, “work near electric lines” me-
We recommend to work on slopes with the bucket ans when the attachment or load raised by the
downhill, after checking machine stability with the excavator (in any position) may reach the mini-
bucket empty and attachment retracted, by slowly mum safety distance established by local or inter-
swinging the upper structure by 360°. national Safety Regulations.
Position the carriage at a right angle relative to To work without risks, keep maximum possible
slopes, hanging walls, etc. to exit the working area distance from electric lines and never trespass
easily. minimum safety distance.
Be aware when the upperstructure is turned by Ensure that local or national safety regulations
180°, steering and travel controls are reversed. concerning work near electric lines are observed.
Properly judge ground conditions with particular Prior to beginning the work near electric lines:
attention to consistency of the area you are going • Contact the Company owner of the electric lines
to work on. or its nearest branch before starting the work.
Keep the machine sufficiently far from the ditch Look up the in the telephone directory.
edge. • Define together with the Company representative
Never dig under the machine. which precautions should be taken to guarantee
Should it be necessary to dig under the machine, work safety.
always ensure that digging walls are opportunely • All electric lines should be considered as opera-
propped up against landslide to prevent the ma- tive live lines even though it might be well
chine from falling into the trench. known that the line in question is out of work and
2-4
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