Bobcat Ingersoll-Rand ZX75 ZX125 Crawler Excavator Workshop Repair Service Manual + Operating & Maintenance Manual PDF - MBOBCZXOPES.zip

A full service and repair guide, complete with electrical wiring schematics, for the Bobcat Ingersoll-Rand ZX75 and ZX125 Excavators — containing the technical data needed to maintain, troubleshoot, fix, and service these machines the way professional technicians do.

The Bobcat Ingersoll-Rand ZX75, ZX125 Excavators workshop service and repair manual covers:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

22509384 (8-04) - Ingersoll-Rand ZX75 Crawler Excavator Operating & Maintenance Manual.pdf

22509392 (8-04) - Ingersoll-Rand ZX125 Crawler Excavator Operating & Maintenance Manual.pdf

22856462 (3-06) - Ingersoll-Rand ZX75, ZX125 Load Excavator Service Manual.pdf

22856462 (6-12) - Ingersoll-Rand ZX75, ZX125 Load Excavator Service Manual.pdf

22990683 (6-12) - Ingersoll-Rand ZX75 Service Manual.pdf

22990683 (10-06) - Ingersoll-Rand ZX75 Service Manual.pdf

Total Pages: 2,021 pages

File Format: PDF (bookmarked, Searchable, Printable, high quality)

Language: English

MAIN SECTIONS

22509384 (8-04) - Ingersoll-Rand ZX75 Crawler Excavator Operating & Maintenance Manual....2

TABLE OF CONTENTS....4

Introduction....8

General....9

Warranty....10

Notes on Using the Instruction Book....11

Environmental Requirements....11

Pictograms....12

Safety & Prevention of Accidents....16

Introductory Remarks....17

Proper Use....17

General Safety Notes....17

Operation....18

Danger Zone....19

Transport of Persons....19

Stability....19

Travel Operation....20

Operation....20

Guides....21

Danger of Falling Objects....21

Working in the Vicinity of Underground Power Lines....21

Working in the Vicinity of Overhead Power Lines....22

Operation in Closed Rooms....22

Work Stoppages....23

Crane Operations....23

Change of Work Attachments, Maintenance, Repair....24

Recovery, Loading & Transportation....25

Monitoring & Inspections....26

Fire Protection....27

Emergency Exit....27

Other Dangers....27

Technical Data....28

Diesel Engine....29

Electrical System....29

Crawler Unit....29

Steering....30

Brakes....30

Hydraulic System....30

Hydraulic Pumps....30

Lubricants....31

Filling Quantities....31

Fuel, Lubricant & Coolant Specifications....32

Alternative Recommendation for Other Temperature Ranges....33

Specific Ground Pressure....33

Sound Level Values, Vibration....34

Dimensions & Weights....34

Excavator Installation....35

Work Attachments....36

Optional Equipment....37

Operation....38

Operator Controls....39

Instrument Panel....41

Engine....43

Starting the Engine....43

Monitoring During Operation....45

Switching off the Engine....47

Driver's Seat....47

Heating/Ventilation/Air Conditioning....48

Heating....48

Ventilation....48

Air Conditioning (Option)....49

Front Window....49

Ventilation Position....49

Tracking and Steering....50

Tracking Forward or Reverse....50

Taking Bends....50

Spot - Turning....50

Turning Over One Crawler....51

Rubber Crawler Chains....52

Parking the Machine....54

Working Operation....56

General....57

Operation of Work Functions....58

Operation of Work Equipment....58

Operation - Articulation....60

Operation - Dozer Blade....61

Float Position....61

Operation - Additional Control Circuit....62

Rock Breaker Operations....62

Grab Operations, Swing Bucket, etc...62

Changing Work Attachments....64

General....64

Assembly of Work Attachments....64

Procedure for Changing Work Attachments....65

Clamshell Grab....66

Changing Procedure....66

Hydraulic Rock Breaker....68

Attachment....68

Working with the Hydraulic Rock Breaker....68

Maintenance....69

Using the Machine for Load Hook Applications....70

Overload Warning Device....70

Using the Machine for Load Hook Applications....71

Possible Forms of Attachment, Attaching Loads....71

Attaching and Guiding Loads....72

Checking the Overload Warning Device....72

Work Equipment - Monobloc and Boom....72

Tiedown & Transport....74

Tiedown of the Machine....75

Loading the Machine by use of a Crane....75

Transport of the Machine....77

Care & Maintenance....78

General Notes....79

Intervals....79

Regular Oil Analysis....80

Advantages of an Oil Analysis....80

Oil Analysis Intervals....80

Warranty....80

Inspection Parts & Aids....81

Lubricants....82

Care & Cleaning....82

Notes for Winter Operation....83

Hydraulic Oil....83

Engine Oil....83

Coolant....83

Battery Charge....83

Fuel....83

Checking, Maintenance & Inspection Plans....85

Initial Inspection (Delivery/Handing-Over Inspection)....85

Daily and Weekly Tasks....87

Daily....88

Weekly....88

Overview of Lubricating Points....89

Inspection Plan....92

Inspection & Maintenance Work....95

Engine Oil....95

Checking the Engine Oil Level....95

Engine Oil Change....95

Engine Oil Filter....97

Engine Oil Cooling System/Hydraulic Oil Cooler....98

Fuel System....99

Fuel Level....99

Draining Water from the Fuel Filter....99

Fuel Filter....99

Fuel Tank....100

Air Filter, Air Intake....101

Dust Ejection Valve....101

Air Intake....101

Cartridge Maintenance Interval....102

Air Filter - Main Cartridge....102

Air Filter Safety Cartridge....102

Cartridge Replacement....103

Main Cartridge....103

Safety Cartridge....103

V-Belts....105

Checking the V-Belt Tension....105

Checking the V-Belt Tension without a Measuring Device....105

Tensioning V-Belts....106

Replacing V-Belts....106

Checking the Valve Lash....107

Checking & Adjusting....108

Hydraulic Oil Tank....109

Checking the Hydraulic Oil Level....109

Changing the Hydraulic Oil....109

Hydraulic Oil Return Filter....110

Cartridge Maintenance Interval....110

Breather of Hydraulic Oil Tank....112

Crawler Gear Units....113

Checking the Oil Level in the Crawler Gear Unit....113

Oil Change....113

Crawler Chains....114

Checking the Crawler Chain Tension....114

Rubber Crawler Chain....114

Steel Crawler Chain....114

Tensioning the Crawler Chain....116

Releasing the Crawler Chain Tension....116

Replacing Track Shoes....118

Replacement....118

Swing Gear....118

Swing Bearing....119

Lubrication of Toothing....119

Lubrication of Bearing Races....119

Checking the Fastening....120

Dust Filter for Cab Ventilation....121

Removal....121

Re-installation....121

Windshield Washer System....122

Electrical Equipment....123

Battery....123

Disconnecting the Battery....124

Installing the Battery....124

Lighting & Warning Equipment....124

Shutdown....125

Preservation (Temporary Shutdown)....125

During Shutdown....125

After Shutdown....126

Trouble-Shooting....128

General....129

Engine....129

Appendix....132

Immobilizer....133

Activating the system....133

The Immobilizer is Self-Activating....133

Deactivating the System....134

Operating Malfunctions....135

Possible Sources of Malfunction....135

Damaged or Lost Code Keys....135

Delivery & Handing-Over Instructions....136

Operating Instructions....137

Spare Parts List....137

Warranty....137

Maintenance & Inspection Plan....138

22509392 (8-04) - Ingersoll-Rand ZX125 Crawler Excavator Operating & Maintenance Manual....143

TABLE OF CONTENTS....145

Introduction....149

General....150

Warranty....151

Notes on Using the Instruction Book....152

Environmental Requirements....152

Pictograms....153

Safety & Prevention of Accidents....157

Introductory Remarks....158

Proper Use....158

General Safety Notes....158

Operation....159

Danger Zone....160

Transport of Persons....160

Stability....160

Travel Operation....161

Operation....161

Guides....162

Danger of Falling Objects....162

Working in the Vicinity of Underground Power Lines....162

Working in the Vicinity of Overhead Power Lines....163

Operation in Closed Rooms....163

Work Stoppages....164

Crane Operations....164

Change of Work Attachments, Maintenance, Repair....165

Recovery, Loading & Transportation....166

Monitoring & Inspections....167

Fire Protection....168

Emergency Exit....168

Other Dangers....168

Failure of Hydraulic System....168

Technical Data....169

Engine....170

Electrical System....170

Travel Mechanism....171

Steering....171

Brakes....172

Hydraulic System....172

Lubricants....173

Filling Quantities....173

Fuel, Lubricant & Coolant Specifications....174

Alternative Recommendation for Other Temperature Ranges....175

Specific Ground Pressure....175

Sound Level Values & Vibration....176

Dimensions & Weights....176

Excavator Installation....177

Carrying Capacity....178

Work Attachments....179

Optional Equipment....180

Operation....181

Operator Controls....182

Instrument Panel....184

Description - Instrument Panel....185

Engine....186

Starting the Engine....186

Monitoring During Operation....188

Switching off the Engine....190

Driver's Seat....191

Heating / Ventilation / Air Conditioning....192

Heating....192

Ventilation....192

Air Conditioning....193

Front Window....194

Ventilation Position....194

Tracking & Steering....195

Tracking Forward or Reverse....195

Making Turns....195

Counter Rotation....195

Rubber Crawler Chains....197

Parking the Machine....199

Working Operation....201

General....202

Operation of Work Functions....203

Operation of Work Equipment....203

Operation - Articulation....205

Operation - Dozer Blade....206

Float Position....206