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INDEX

E225BSR

Title

Index

No.

SPE

CIFICA

TIONS

OUTLINE

SPECIFICATIONS

ATTACHMENT DIMENSIONS

MAIN

TENANC

TOOLS

STANDARD MAINTENANCE TIME SCHEDULE

MAINTENANCE STANDARD AND TEST PROCEDURE

SYS

TEM

MECHATRO CONTROL SYSTEM

HYDRAULIC SYSTEM

ELECTRIC SYSTEM

COMPONENTS SYSTEM

AIR-CONDITIONER SYSTEM

DISAS

SEMBLING

DISASSEMBLING AND ASSEMBLING

ATTACHMENT

UPPER STRUCTURE

TRAVEL SYSTEM

TROUBLESH

OOTING

BY ERROR CODES

BY TROUBLE

TROUBLE DIAGNOSIS MODE

E/G

ENGINE

APPLICABLE MACHINES

Содержание E225BSR

Страница 1: ...PROVEN PERFORMANCE E225BSR Workshop manual Workshop manual Printed No 87709239A English Printed in Italy E225BSR ...

Страница 2: ...Find manuals at https best manuals com ...

Страница 3: ...E225BSR WORKSHOP MANUAL ENGLISH Print No 87709239A Edition 09 2007 English Printed in Italy Printed by Studio ti 40307 Find manuals at https best manuals com ...

Страница 4: ...Find manuals at https best manuals com ...

Страница 5: ...intenance instruction manual Spare parts catalog DESCRIPTION OF THE WORKSHOP MANUAL This repair manual consists of one single volume identified with E235BSR Workshop Manual Mini excavator The Mini excavator Workshop Manual contains the technical information necessary for machine service and repair the service equipment the information on maintenance standards the removal and installing procedures ...

Страница 6: ...ance against an accident The complete observance of one simple rule would prevent many thousand serious injuries each year That rule is Never attempt to clean oil or adjust a machine while it is in motion S 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 se...

Страница 7: ... marks The safety information contained in the manual is intended only to supplement safety codes insurance requirements local laws rules and regulations 3 Messages of safety appear in the manual and on the machine All messages of safety are identified by either word of DANGER WARNING and CAUTION 1 DANGER Indicates an imminently hazardous situation which if not avoided will result in death or seri...

Страница 8: ...st Always use blocks or jack stands capable of supporting the machine before performing any disassembly Do not operate this machine unless you have read and understand the instructions in the OP ERATOR S MANUAL Improper machine opera tion is dangerous and could result in injury or death 6 Relieve all pressure in air oil or water systems be fore any lines fittings or related items are discon nected...

Страница 9: ...of a falling attachment Don t fail to lower the attach ment and place the bucket to the ground before starting the work 19 Loose or damaged fuel lubricant and hydraulic lines tubes and hoses can cause fires Do not bend or strike high pressure lines or install ones which have been bent or damaged Inspect lines tubes and hoses carefully Do not check for leaks with your hands Very small pinhole leaks...

Страница 10: ...0 4 Find manuals at https best manuals com ...

Страница 11: ...NTENANCE STANDARD AND TEST PROCEDURE 13 SYSTEM MECHATRO CONTROL SYSTEM 21 HYDRAULIC SYSTEM 22 ELECTRIC SYSTEM 23 COMPONENTS SYSTEM 24 AIR CONDITIONER SYSTEM 25 DISASSEMBLING DISASSEMBLING AND ASSEMBLING 31 ATTACHMENT 32 UPPER STRUCTURE 33 TRAVEL SYSTEM 34 TROUBLESHOOTING BY ERROR CODES 46 BY TROUBLE 47 TROUBLE DIAGNOSIS MODE 48 E G ENGINE 51 APPLICABLE MACHINES ...

Страница 12: ...y mounted on the upper structure and undercarriage and the assembling and disassembling of the associated hydraulic equipment The Chapter Troubleshooting describes how to find the fault equipment The Chapter Engine describes the engines mak ing use of the Maintenance Manual provided by the suppliers This Manual may be properly revised due to the im provement of products modification of specificati...

Страница 13: ...REPARATION 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 ...

Страница 14: ...1 OUTLINE 1 2 ...

Страница 15: ...maintenance stop the engine 4 Confirm the position of first aid kit and fire extinguisher and also where to make contact for emergency measure and ambulance to prepare for accidents and fire 5 Choose a hard lever and safe place and put attachment on the ground without fail 6 Use hoist etc to remove parts of heavy weight 23kg 50 lb or more 7 Use proper tools and change or repair defective tools 8 M...

Страница 16: ...required in the following cases 1 Change of hydraulic oil 2 Replacement of parts on suction pipe side 3 Removing and attaching hydraulic pump 4 Removing and attaching swing motor 5 Removing and attaching travel motor 6 Removing and attaching hydraulic cylinder If hydraulic oil and lubricating oil are not filled and also air bleed is not performed the hydraulic equipment may be damaged 3 For air bl...

Страница 17: ...ality differs depending on the materials to be seated So choose proper O ring Fit O ring so as to be free from distortion and bend Floating seal should be put in pairs 2 Flexible hose F hose Even if the connector and length of hose are the same the parts differ according to the withstanding pressure Use proper parts Tighten it to the specified torque and check that it is free from twist over tensi...

Страница 18: ...quare meter Cubic meter Meter per second Meter per second second Kilogram per cubic meter m2 m3 m s m s2 kg m3 SI unit system Prefixes of SI n th power of 10 where n is an integer Table 1 5 SI units Base units Table 1 1 Supplemen tary units Table 1 2 Derived units of base units Table 1 3 Derived units bearing peculiar designations Table 1 4 Derived units Table1 4 QUANTITY UNIT SYMBOL FORMULA Frequ...

Страница 19: ...t Conversion Table QUANTITIES JIS SI REMARKS Mass kg kg Force kgf N 1kgf 9 807N Torque kgf m N m 1kgf m 9 807N m Pressure kgf cm2 MPa 1kgf cm2 0 098MPa Motive power PS kW 1PS 0 7355kW Revolution r p m min 1 1r p m 1min 1 ...

Страница 20: ...1 OUTLINE 1 8 MEMO ...

Страница 21: ...TATION 2 6 2 4 1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER 2 6 2 4 2 DIMENSIONS OF ATTACHMENT 2 7 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 TYPE OF BUCKET 2 10 2 8 COMBINATIONS OF ATTACHMENT 2 11 2 9 ENGINE SPECIFICATIONS 2 12 2 9 1 SPECIFICATIONS 2 12 2 9 2 ENGINE CH...

Страница 22: ...2 SPECIFICATIONS 2 2 ...

Страница 23: ...M IDLER LINK BUCKET LINK BOOM CYLINDER BUCKET SHOE FRONT IDLER IDLER ADJUST BATTERY UPPER ROLLER LOWER ROLLER TRACK GUIDE SLEWING BEARING TRAVEL MOTOR AIR CLEANER SWIVEL JOINT COUNTER WEIGHT ENGINE HYDRAULIC PUMP MUFFLER GUARD FUEL TANK HYDRAULIC TANK SLEWING MOTOR RADIATOR CONTROL VALVE OIL COOLER ...

Страница 24: ...3 1 05cu yd Bucket Unit mm ft in Dimensions marked do not include the height of the shoe lug include LC specifications 1680 5 6 8680 28 6 8830 29 4170 13 8 4450 14 7 8290 27 2 2800 9 2 2990 9 10 3130 10 3 3130 10 3 160 6 3 600 23 6 3000 9 10 3030 9 11 Lower roller Q tys 7 8 R2030 6 8 R1680 5 6 R1680 5 6 1020 3 4 445 17 5 ...

Страница 25: ...ller 20 44 4 2 5 Lower roller 30 66 14 30 66 16 2 6 Front idler 110 240 2 2 7 Idler adjuster 100 220 2 2 8 Sprocket 50 110 2 2 9 Swivel joint 30 66 2 10 Track link with 600mm 23 6in shoes assy Track link with 700mm 27 6in shoes assy Track link with 800mm 31 5in shoes assy Track link with 600mm 23 6in flat shoes assy 1 250 2 760 2 1 450 3 200 2 1 580 3 485 2 1 500 3 310 2 1 330 2 930 2 1 550 3 420 ...

Страница 26: ...bricant and water Assembly of following 490 1 080 4 1 Hydraulic oil 200 440 4 2 Engine oil 20 44 4 3 Fuel 250 550 4 4 Water 20 44 Shoe type 600mm 23 6in 600mm 23 6in LC Item Width mm ft in 2 800 9 2 2 990 9 10 Weight kg lbs 22 300kg 49 200 lbs 22 700kg 50 100 lbs Unit kg lb Model E225BSR E225BSRLC Item 8320 27 4 270 10 6 3610 11 10 3130 10 3 600 23 6 3730 12 3 3130 10 3 150 5 9 ...

Страница 27: ...Width L H W m ft in 5 82 1 50 0 67 19 1 4 11 2 2 Weight kg lbs 1 600 3 530 Type 2 87m 9ft 5in Arm 0 80m 3 1 05cu yd Bucket Item Length Height Width L H W m ft in 5 17 0 9 1 16 17 2 11 4 Weight kg lbs 1 590 3 510 Type 2 87 m 9ft 5in Arm Item Length Height Width L H W m ft in 3 83 0 82 0 56 12 7 2 8 1 10 Weight kg lbs 950 2 090 ...

Страница 28: ...idth L H W m ft in 1 37 1 26 0 87 4 6 4 2 2 10 1 37 1 26 1 07 4 6 4 2 3 6 1 37 1 26 1 16 4 6 4 2 3 10 1 37 1 26 1 33 4 6 4 2 4 4 Weight kg lbs 520 1 150 630 1 390 640 1 410 710 1 560 Bucket capacity m3 cu yd 0 51 0 67 0 70 0 92 STD 0 80 1 05 0 93 1 22 Hoe bucket ...

Страница 29: ... 61 cu in Rated output Engine speed 114 kW 155 PS 2 000 min 1 Maximum torque Engine speed 572 N m 422 lbf ft 1 600 min 1 Starter 24 V 5 0kW Alternator 24 V 1 2kW Hydraulic pump Variable displacement axial piston pump 2 gear pump 1 Hydraulic motor swing Axial piston motor 1 Hydraulic motor travel Variable displacement axial piston motor 2 with counterbalance valve Control valve 8 spool control valv...

Страница 30: ...6 STD 2 800 9 2 50 7 25 LC 2 990 9 10 47 6 82 700 27 6 STD 2 900 9 6 44 6 38 LC 3 090 10 2 41 5 95 800 31 5 STD 3 000 9 10 39 5 66 LC 3 190 10 6 36 5 22 Hoe bucket Heaped capacity m3 cu yd Struck m3 cu yd Outer width mm ft in Number of tooth W or W O side cutter Availability of face shovel Weight kg lbs With side cutter Without side cutter 0 51 0 67 0 39 0 51 870 2 10 770 2 6 3 W YES 520 1 150 0 7...

Страница 31: ...mended by manufacturer The trouble due to the use in the condition Use not allowed described in the above table is not included in our responsibility Do not turn the bucket back to front to use as a shovel If the bucket other than backhoe bucket is used in reversed position it causes damage of arm and bucket Bucket Available Arm Type Heaped capacity m3 cu yd Struck m3 cu yd 2 87m 9ft 5in Arm STD 2...

Страница 32: ... Compression pressure MPa psi at min 1 3 4 3 7 493 537 at 280 Fuel injection timing Degree BTDC 0 Valve clearance Valve clearance Open Close Intake valve 0 3 mm at cool 14 before top dead center 30 after bottom dead center Exhaust valve 0 45 mm at cool 54 before bottom dead center 13 after top dead center Starter capacity V kW 24 5 0 Generator capacity Alternator V A 24 50 Cooling fan drive method...

Страница 33: ...ling fan and rotation ratio is 0 89 marks show the rated point Fuel consumption volume Fuel consumption rate X kW X Load factor 0 835 X 1000 217g kW h X 114kW X 0 835 X 1000 29 6 L h Standard load factor 0 70 0 80 Fuel consumption in regular operation load factor 0 70 0 80 20 7 L h 23 7 L h ENGINE SPEED min 1 SHAFT OUTPUT SHAFT TORQUE FUEL CONSUMPTION RATE ...

Страница 34: ...2 SPECIFICATIONS 2 14 MEMO ...

Страница 35: ...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 3 10 3 3 1 BUCKET DIMENSIONAL DRAWING 3 10 3 3 2 BUCKET DIMENSIONAL TABLE 3 10 3 3 3 LUG SECTION DIMENSIONAL DRAWING 3 11 3 3 4 BOSS SECTION DIMENSIONAL DRAWING 3 12 ...

Страница 36: ...3 ATTACHMENT DIMENSIONS 3 2 ...

Страница 37: ...uter width 482 19 E Height of boom cylinder rod pin 984 3 3 F Height of arm cylinder head side pin 1 133 3 9 G Distance between pins of boss R2 560 8 5 H Distance between pins of bracket R2 633 8 8 I Arm cylinder head side inner width 126 4 96 J Outer width of bracket on the arm cylinder rod side mounting 468 18 4 d1 Boom foot pin dia ø 90 3 54 d2 Boom cylinder rod side pin dia ø 85 3 35 d3 Pin di...

Страница 38: ...ard value Repairable level Service limit A Boom foot ø 90 3 5433 0 020 0 0008 0 020 0 0008 0 217 0 0085 0 071 0 0028 0 237 0 0093 0 051 0 0020 More than 2 0 0 08 2 5 0 1 Replace bushing or pin B Boom cylinder Head side ø 85 3 3465 0 0 040 0 0016 0 250 0 010 0 050 0 0020 0 290 0 0114 0 050 0 0020 C Boom cylinder Rod side 0 020 0 0008 0 020 0 0008 0 270 0 0106 0 030 0 0010 D Arm cylinder Head side ø...

Страница 39: ...mit No Length A A Boom foot Boom L1 670 26 4 0 5 0 02 or less 2 0 0 08 2 5 0 10 PL1 843 33 2 Shim adjust ment Upper frame 676 26 6 B B Boom cylinder Head side Boom cylinder L2 105 4 13 0 6 1 0 0 02 0 04 PL2 222 8 74 Upper frame 111 4 37 C C Boom cylinder Rod side Boom cylinder L3 105 4 13 0 6 2 0 0 02 0 08 3 0 0 12 4 0 0 16 PL3 736 29 0 Boom L3 468 18 4 D D Arm cylinder Head side Arm cylinder L4 1...

Страница 40: ... 8 D2 I D of boss ø80 3 15 Q Bucket link dimension 525 20 7 D4 I D of boss ø95 3 74 R Height between pins of boss and center 45 1 77 E Distance between pins of boss and bracket R2 185 7 2 d1 Pin dia ø80 3 15 F Distance between pins of boss and boss R330 13 0 d2 Pin dia ø65 2 56 G Height between pins of boss and bracket 644 25 4 d3 Pin dia ø80 3 15 H Height between pins of boss and bracket 214 8 4 ...

Страница 41: ...n B Bucket link Bucket side 0 220 0 009 0 076 0 0030 0 280 0 0110 0 096 0 0038 C Idler link Connected part of arm ø65 2 5591 0 0 0 040 0 0016 0 234 0 0092 0 097 0 0038 0 274 0 0108 0 097 0 0038 D Bucket link Idler link side ø70 2 7559 0 231 0 0091 0 091 0 0036 0 271 0 0107 0 091 0 0036 D Bucket cylinder Rod side 0 243 0 0096 0 085 0 0033 0 283 0 0112 0 085 0 0033 E Bucket cylinder Head side 0 020 ...

Страница 42: ... thrust direction Fig 3 6 Clearance of arm and cylinder installing sections in thrust direction D D D D B B C C E E G G F F A A X1 L1 PL1 X L3 PL3 PL5 X L5 X L6 PL6 X7 L7 PL7 X L4 X4 L4 PL4 X2 L2 PL2 SECTION B B SECTION D D SECTION G G SECTION F F SECTION E E SECTION C C SECTION A A ...

Страница 43: ...L2 Bucket 327 12 87 C C Idler link Arm connection Arm L3 318 12 52 0 5 0 02 1 0 0 04 PL3 413 16 3 Link side D D Bucket link Idler link connection Rod side L4 0 6 1 0 0 024 0 04 2 0 0 08 PL4 Link side 318 12 52 D D Bucket link Rod side Rod side L4 100 3 94 Link side 106 4 17 E E Bucket cylinder Head side Head side L5 100 3 94 0 6 2 0 0 024 0 08 3 0 0 12 4 0 0 16 PL5 226 8 90 Arm 106 4 17 F F Arm cy...

Страница 44: ... teeth E Inner width of lug d1 Outer dia of bushing F Outer width of side cutter d2 Pin dia Unit mm ft in Type Normal digging Capacity STD 0 80 0 70 m3 0 51 0 45 m3 0 70 0 61 m3 0 93 0 80 m3 1 05 0 90 m3 A R430 16 9 B R1 440 4 9 C 1 003 3 3 711 28 0 922 36 3 1 173 3 10 1 303 4 3 3 D 399 15 7 E 327 12 9 F 1 157 4 870 34 3 1 080 3 6 5 1 330 4 4 4 1 460 4 9 5 G 863 34 572 22 5 785 30 9 1 036 3 4 8 1 ...

Страница 45: ...e bottom surface is to be 100S or less in range of diameter 39mm And M16 bolt is to be installed 3 places Type of bucket Bucket capacity SAE heaped Struck STD 0 80 0 70 0 51 0 45 0 70 0 61 0 93 0 80 1 05 0 90 Normal digging A B D E F G H J M N Capacity of bucket SAE heaped m3 cu yd Unit mm ft in Pin hole dia Lug plate thickness Hole dia Spring pin dia Boss outer dia Screw dia Boss width Boss outer...

Страница 46: ...t in Type of bucket Capacity of bucket m3 cu yd øA øB øC øD E F øG H I Normal digging STD 0 80 0 70 114 3 4 50 84 3 31 105 5 4 15 111 5 4 39 23 0 91 38 1 50 17 0 669 13 0 512 2 5 0 098 0 51 0 45 0 70 0 61 0 93 0 80 1 05 0 90 Bucket capacity SAE heaped Struck A E H 5 0 197 15 0 591 F o G o A o B o C o D DETAIL A ...

Страница 47: ...3 4 SPLIT FLANGE 11 6 11 4 TIGHTENING TORQUES 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 1...

Страница 48: ...11 TOOLS 11 2 ...

Страница 49: ... 36 3 3 9 26 8 2 9 31 4 2 9 23 2 2 1 79 4 7 8 58 6 5 8 66 7 6 9 49 2 5 1 143 15 105 11 121 12 89 2 8 9 M14 P 2 57 9 5 9 42 7 4 4 49 0 4 9 36 1 3 6 126 13 92 9 9 6 106 10 78 2 7 4 226 20 167 15 191 19 141 14 M16 P 2 88 3 8 8 65 1 6 5 74 5 6 9 55 0 5 1 191 20 141 15 161 16 119 12 343 39 253 29 284 29 209 21 M18 P 2 5 122 12 90 0 8 9 103 10 75 8 7 2 265 29 195 21 226 20 167 15 481 49 355 36 402 39 29...

Страница 50: ...2 9 33 3 2 9 24 6 2 1 85 3 8 8 62 9 6 5 71 6 6 9 52 8 5 1 154 16 114 12 129 13 95 2 9 6 M16 P 1 5 92 2 8 8 68 0 6 5 77 5 7 8 57 2 5 8 196 20 145 15 169 17 125 13 363 39 268 29 304 29 224 21 M20 P 1 5 186 19 137 14 155 16 114 12 402 39 297 29 333 29 246 21 726 69 535 51 608 59 448 44 M24 P 2 314 29 232 21 265 29 195 21 686 69 506 51 569 59 420 44 1240 118 915 87 1030 98 760 72 M30 P 2 637 59 470 44...

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