1999 New Holland EC 215 Excavator Service & Repair Manual (P/N 73179384.00 us)

This factory service and repair manual covers the 1999 New Holland EC 215 hydraulic excavator. Published as the EC 215 Technical Handbook, P/N 73179384.00 us, it includes machine-specific service data for serial numbers 72 1502 and up.

Search, bookmarks and diagram detail: Most instructional text supports search, and embedded bookmarks navigate the technical sections. Hydraulic schematics and machine wiring sheets lack searchable text; small component, connector and wire labels require zooming. The Home Page bookmark points to a separate file outside this PDF.

• Undercarriage and superstructure: Track-chain and idler repair, roller and sprocket replacement, steel-on-steel duo-cone seal assembly, and swing-bearing removal and installation.

• Travel and swing gearboxes: Planetary-drive overhaul, bearing and shim inspection, and wet multi-disk brake dismantling, resealing and reassembly.

• Hydraulic repair: Working and swing pump checks, control-valve testing, cylinder overhaul, and system bleeding and flushing after component failure.

• Electrical diagnostics: Wiring diagrams, On-Board Diagnostic Computer (ODC) fault tables, PCS 3 power-limit control checks, and EDS tester procedures.

• Engine installation: Removal and installation of the 6BTA 5.9-C-160 engine and hydraulic pumps, with resilient-coupling inspection and alignment.

• Equipment and workshop support: Bucket and grab changes, hydraulic fittings and hose assembly, welding references, and sealing and corrosion-protection materials.

Written for experienced service mechanics, this manual assumes familiarity with excavator systems, workshop measurement equipment, and specialized lifting and repair tools.

Undercarriage and Drive Repair

Undercarriage documentation includes wear checks, component dimensions, weights and tightening-torque references. Swing-bearing work includes superstructure removal and tooth-flank clearance checks.

The EC 215 service data identify F44 travel and S10 swing gearboxes. Their incorporated repair references provide cross-section and exploded assembly drawings, bearing-preload adjustments, brake-disc inspection and seal replacement; illustrations for other gearbox variants also appear.

The track-chain instructions explain how incorrect chain orientation accelerates wear on the bushings and sprocket teeth.

Hydraulic Testing and Cylinder Repair

Pressure-test tables distinguish working-pump relief, power boost, swing pressure cut-off and safety-valve settings. Superstructure and undercarriage hydraulic circuit diagrams accompany explanations of the six-way control block, boom regeneration and parallel travel.

Pump checks address demand control, output loss, swing feed pressure and control response. The tool references identify the PCS/EDS tester, solenoid-valve tester, proportional-valve measuring adapter and control-spool stroke equipment used for these checks.

Cylinder repair covers piston-rod removal, guide-bushing work and seal replacement, with specified assembly tools. Reworking damaged cylinder components is assigned to specialist workshops.

Flushing guidance addresses contamination after pump, cylinder or valve failure. The bleeding section explains how trapped air can cause diesel-effect damage to seals and guide components.

PCS 3, ODC and Electrical Fault Diagnosis

PCS 3 documentation connects the A10 load-limit regulator, A100 control panel, speed pickup and Y10 proportional valve. Functional diagrams, pump-output curves and valve characteristics support EDS-based checks of load limiting, operating modes and stored faults.

Mechanics can cross-reference ODC fault tables with electrical test specifications and hydraulic troubleshooting tables to distinguish sensor, wiring or control faults from weak hydraulic performance. This provides a concrete basis for selecting the relevant diagnostic checks before dismantling components.

The machine wiring section adds connector assignments, fuse layouts and cable-harness overviews. General electrical references also cover starter and alternator testing, circuit interpretation and illustrated fault-finding examples.

The incorporated PCS reference discusses CENTRY-equipped variants. Its CENTRY section covers warning indications and flash-code readout for referral to Cummins service personnel.

Engine Scope and Supporting Workshop References

Engine coverage centers on removal, installation and the resilient coupling. Internal engine repair is referred to a separate engine manufacturer's manual.

Supporting chapters cover flange and hose connections, crack testing, repair welding, hard-facing and corrosion protection. Fluid-capacity tables and component-specific torque data support reassembly planning, while the welding reference addresses qualification requirements and material-dependent repair methods.

Safety: High-pressure hydraulics, raised equipment and spring-loaded brakes require trained personnel, suitable supports and the specialized tools specified for the work.

Printable PDF and Included Reference Pages

Supplied as one printable PDF containing the EC 215 handbook and its incorporated component and workshop references. The 716-page total includes the main cover, one section-index page and 714 pages across the manual's 11 sections; individual reference covers, contents pages, notes and appendices are already included.