Bobcat Crawler Excavator ZX75 ZX125 Series - Service Repair Manual - Owners

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BOBCAT CRAWLER EXCAVATOR (ZX75 ZX125 SERIES) - SERVICE AND OWNERS MANUAL

- Service Manual And Owners Manual, to Bobcat Crawler Excavator ZX75 ZX125 Series.



CONTENTS:


ZX75 22990683 SM 10-06
 
- CONTENTS
- FOREWORD
- SAFETY INSTRUCTIONS
- Fire Prevention
- SERIAL NUMBER LOCATIONS
- Excavator Serial Number
- Engine Serial Number
- DELIVERY REPORT
- INGERSOLL RAND EXCAVATOR IDENTIFICATION
- MAINTENANCE SAFETY
- SPECIFICATIONS
- HYDRAULIC EXCAVATOR SPECIFICATIONS
- Machine Dimensions
- Performance
- Controls
- Engine
- Electrical
- Hydraulic System
- Hydraulic System
- Hydraulic Cycle Times
- Swing System
- Hydraulic Cylinders
- Drive System
- Brakes
- Undercarriage
- Track
- Capacities
- Digging Force
- EXCAVATOR BOLT TORQUE
- Specifications
- TORQUE SPECIFICATIONS FOR BOLTS
- Torque For General SAE Bolts
- Torque For General Metric Bolts
- HYDRAULIC FLUID SPECIFICATIONS
- Specifications
- FUEL, COOLANT AND LUBRICANTS
- Chart
- CONVERSIONS
- Decimal And Millimeter Equivalents
- U.S. To Metric Conversion
- SAFETY AND MAINTENANCE
- LIFTING AND BLOCKING THE EXCAVATOR
- Procedure
- LIFTING THE EXCAVATOR
- Procedure
- OPERATOR CAB
- Description
- Entering And Exiting The Excavator
- Raising And Lowering The Left Console
- Emergency Exit
- TRANSPORTING THE EXCAVATOR
- REAR COVER
- Opening And Closing The Rear Cover
- RIGHT SIDE COVER
- Opening And Closing The Right Side Cover
- SERVICE SCHEDULE
- AIR CLEANER
- Daily Check
- Replacing The Filters
- FRESH AIR FILTER
- Removal And Installation
- FRESH AIR FILTER
- Removal And Installation
- FUEL SYSTEM
- Fuel Specifications
- Filling The Fuel Tank
- Pre-Filter Removal And Installation
- Fuel Filter Removal And Installation
- Draining The Fuel Tank
- ENGINE LUBRICATION SYSTEM
- Checking Engine Oil
- Replacing Oil And Filter
- HYDRAULIC SYSTEM
- Checking And Adding Hydraulic Oil
- Replacing The Hydraulic Oil
- Hydraulic Filter Removal
- Hydraulic Filter Installation
- Hydraulic Filter Removal
- Hydraulic Filter Installation
- Hydraulic Filter Installation
- Diagnostic Couplers
- LUBRICATION OF THE EXCAVATOR
- TRAVEL MOTOR
- Checking Oil Level
- Draining The Travel Motor
- ALTERNATOR BELT
- Adjusting Belt Tension
- FAN/FUEL PUMP BELT
- Adjusting Belt Tension
- AIR CONDITIONING COMPRESSOR BELT
- Adjusting Belt Tension
- CAB TILT PROCEDURE
- Installing The Cab Tilt Hinges
- Tilting The Cab
- HYDRAULIC SYSTEM
- HYDRAULIC SYSTEM INFORMATION
- Troubleshooting Chart
- Description
- BOOM CYLINDER
- Testing
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- ARM CYLINDER
- Testing
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- BOOM OFFSET CYLINDER
- Testing
- BOOM OFFSET CYLINDER
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- BUCKET CYLINDER
- Testing
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- BLADE CYLINDER
- Testing
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- RELIEF VALVES
- Description
- Testing The Three Spool Control Valve Main Relief Valve
- Adjusting The Three Spool Control Valve Main Relief Valve
- PORT RELIEF VALVES
- Adjustment Procedure
- PRESSURE REDUCING VALVE
- Description
- Testing
- PRESSURE REDUCING VALVE
- Adjustment
- DUMP VALVE
- Description
- Testing
- Adjustment
- Removal And Installation
- Parts Identification
- Disassembly And Assembly
- SIX SPOOL HYDRAULIC CONTROL VALVE
- Removal And Installation
- Control Valve Identification
- Disassembly And Assembly
- Left Travel And Right Travel Valve Section Disassembly And Assembly
- Boom, Arm, Bucket And Auxiliary Valve Section Disassembly And Assembly
- Inlet Valve Section Disassembly And Assembly
- THREE SPOOL HYDRAULIC CONTROL VALVE
- Removal And Installation
- Parts Identification
- Disassembly And Assembly
- Boom Offset And Blade Valve Section Disassembly And Assembly
- Inlet/Upperstructure Swing Valve Section Disassembly And Assembly
- HYDRAULIC PISTON PUMP

- Hydraulic Pump Work Sheet
- HYDRAULIC PISTON PUMP
- Testing Information
- Pump Testing
- Removal And Installation
- Coupler Removal And Installation
- Torque Limiter Valve Parts Identification
- Torque Limiter Valve Removal and Installation
- Torque Limiter Valve Disassembly
- Torque Limiter Valve Assembly
- Initial Torque Limiter Valve Setting
- Pump Control Parts Identification
- Pump Control Removal And Installation
- Pump Control Disassembly And Assembly
- Parts Identification
- Disassembly
- Assembly
- HYDRAULIC GEAR PUMP
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- ACCUMULATOR
- Description
- Removal And Installation
- TRAVEL MOTOR
- Removal And Installation

- Parts Identification
- Disassembly
- Assembly
- SWIVEL JOINT
- Removal And Installation
- Parts Identification
- Disassembly And Assembly
- SWING MOTOR
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly

- SWING MOTOR DRIVE CARRIER
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- SWING BRAKE VALVE
- Removal And Installation
- Parts Identification
- Disassembly And Assembly
- SWING BRAKE RELEASE VALVE
- Removal And Installation
- Parts Identification
- Disassembly And Assembly
- JOYSTICK CONTROL PATTERN SELECTOR VALVE
- Removal And Installation
- Parts Identification
- Disassembly And Assembly
- JOYSTICK LOCKOUT/TWO SPEED VALVE
- Removal And Installation
- Parts Identification
- Disassembly And Assembly
- RIGHT CONTROL LEVER (JOYSTICK)
- Testing
- Handle Removal And Installation
- Removal And Installation
- Parts Identification
- Disassembly And Assembly
- LEFT CONTROL LEVER (JOYSTICK)
- Testing
- Handle Removal And Installation
- Removal And Installation
- Parts Identification
- Disassembly and Assembly
- TRAVEL LEVER/FOOT PEDAL VALVE
- Left Travel Lever/Foot Pedal Valve Removal And Installation
- Right Travel Lever/Foot Pedal Valve Removal And Installation
- Parts Identification
- Disassembly And Assembly
- HYDRAULIC FILTER MOUNT
- Removal And Installation
- HYDRAULIC RESERVOIR
- Removal And Installation
- SECONDARY FRONT AUXILIARY VALVE
- Removal And Installation
- Parts Identification
- Disassembly And Assembly
- HYDRAULIC BREAKER APPLICATION VALVE
- Removal And Installation
- Parts Identification
- Disassembly And Assembly
- AUXILIARY HYDRAULIC FLOW CONTROL VALVE
- Removal And Installation
- Parts Identification
- Disassembly And Assembly
- AUXILIARY HYDRAULIC FLOW CONTROL/HYDRAULIC BREAKER APPLICATION VALVE
- Removal And Installation
- Parts Identification
- Disassembly And Assembly
- BLADE VALVE
- Removal And Installation
- Parts Identification
- Disassembly And Assembly
- BLADE FLOAT VALVE
- Removal And Installation
- Parts Identification
- Disassembly And Assembly
- BOOM OFFSET VALVE
- Removal And Installation
- Parts Identification
- Disassembly And Assembly
- BOOM LOAD HOLDING VALVE
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- OIL TEMPERATURE REGULATOR
- Description
- Removal And Installation
- AUXILIARY HYDRAULICS SELECTOR VALVE
- Removal And Installation
- HYDRAULIC PISTON PUMP DRIVE COUPLER
- Removal And Installation
- UNDERCARRIAGE
- BLADE
- Removal And Installation
- TRACKS
- Track Lug Height
- Rubber Track Clearance
- Steel Track Clearance
- Track Adjustment
- Rubber Track Removal And Installation
- TRACK FRAME
- Disassembly And Assembly
- Drive Sprocket Removal And Installation
- TRACK IDLER
- Parts Identification
- Disassembly
- Assembly
- UPPER TRACK ROLLER
- Parts Identification
- Disassembly
- Assembly
- LOWER TRACK ROLLER
- Parts Identification
- Disassembly
- Assembly
- GREASE CYLINDER
- Parts Identification
- Disassembly
- Assembly
- TRACK DAMAGE IDENTIFICATION
- Cutting Of Steel Cords
- Abrasion Of Embedded Metals
- Separation Of Embedded Metals
- Separation Of Embedded Metals Due To Corrosion
- Cuts On The Lug Side Rubber
- Cracks On The Lug Side Rubber Due To Fatigue
- Lug Abrasion
- Cracks And Cuts On The Lug Side Rubber

- Abrasion Of The Track Roller Side
- Cuts On The Edges Of Track Roller Side
- UPPERSTRUCTURE & SWING SECTION
- UPPERSTRUCTURE
- Removal And Installation
- Swing Bearing Removal And Installation
- CAB
- Removal And Installation
- Door Removal And Installation
- Front Window Removal And Installation
- Front Window Disassembly And Assembly
- Front Window Gas Strut Removal And Installation
- Front Window Pivot Frame Removal And Installation
- Lower Front Widow Removal And Installation
- Door, Left Side, Right Side And Rear Window Removal
- Door, Left Side, Right Side And Rear Window Installation
- Cab Visor Removal And Installation
- Top Window Removal And Installation
- SEAT AND SEAT MOUNT
- Removal And Installation
- RIGHT CONSOLE
- Description
- LEFT CONSOLE
- Removal And Installation
- Disassembly And Assembly
- Console Lockout Switch Removal And Installation
- ENGINE SPEED CONTROL
- Removal And Installation
- Disassembly And Assembly
- CONTROL LEVERS
- Description
- FUEL TANK
- Removal And Installation
- HORN
- Removal And Installation
- SWING FRAME
- Removal And Installation
- Bushing Removal And Installation
- FLOOR MAT
- Removal And Installation
- BOOM
- Removal And Installation
- ARM
- Removal And Installation
- BUCKET
- Removal And Installation
- REAR COVER
- Removal And Installation
- RIGHT SIDE COVER
- Removal And Installation
- COUNTERWEIGHT
- Removal And Installation
- ELECTRICAL SYSTEM AND ANALYSIS
- ELECTRICAL SYSTEM INFORMATION
- Troubleshooting Chart
- Description
- Fuse And Relay Location
- BATTERY
- Servicing
- Removal And Installation
- Using A Booster Battery (Jump Starting)
- ALTERNATOR
- Removal And Installation
- Parts Identification
- Alternator Identification
- Charging System Check
- STARTER
- Removal And Installation (S/N 522311001 & Above)
- Parts Identification (All Models)
- FRONT CAB LIGHT
- Removal And Installation
- Disassembly And Assembly
- TWO SPEED SWITCH
- Removal And Installation
- FUEL LEVEL SENDER
- Removal And Installation
- WIPER MOTOR
- Removal And Installation
- BATTERY DISCONNECT SWITCH
- Removal And Installation
- INSTRUMENT PANEL
- Removal And Installation
- E-Prom Information
- ENGINE SERVICE
- TROUBLESHOOTING
- Chart
- MUFFLER
- Removal And Installation
- AIR CLEANER
- Removal And Installation
- ENGINE
- Removal And Installation
- RADIATOR/OIL COOLER
- Removal And Installation
- Hydraulic Check Valve Removal And Installation
- Hydraulic Check Valve Disassembly And Assembly
- FLYWHEEL
- Removal And Installation
- Flywheel Ring Gear
- HEATING, VENTILATION, AIR CONDITIONING
- EVAPORATOR/HEATER UNIT
- Removal And Installation
- Disassembly And Assembly
- HEATER/AC FAN
- Removal And Installation
- Resistor Removal And Installation
- AIR CONDITIONING SYSTEM FLOW
- Principles
- Chart
- COMPONENTS
- Identification
- SAFETY
- Safety Equipment
- REGULAR MAINTENANCE
- Heater Air Filter
- Air Conditioning Compressor Belt
- Cleaning The Condenser
- BASIC TROUBLESHOOTING
- Poor A/C Performance
- Compressor Drive Belt Inspection
- Cleaning The A/C Evaporator Coil & Heater Coil
- Cleaning The A/C Evaporator Coil & Heater Coil (S/N 528911001 & Above And 528611001 & Above)
- Checking The Electrical System
- Engine Coolant By-Passing The Heater Valve
- GENERAL AIR CONDITIONING SERVICE GUIDELINES
- Compressor Oil
- Compressor Oil Check
- Component Replacement And Refrigeration Leaks
- SYSTEM TROUBLESHOOTING CHART
- Blower Motor Does Not Operate
- Gauge Pressure Related Troubleshooting
- TEMPERATURE/PRESSURE
- Chart
- SYSTEM CHARGING AND RECLAMATION
- Reclamation Procedure
- COMPRESSOR
- Removal And Installation
- Compressor Clutch Disassembly And Assembly
- CONDENSOR
- Removal And Installation
- RECEIVER/DRYER
- Removal And Installation
- PRESSURE SWITCH
- Removal And Installation
- AIR CONDITIONING SYSTEM
- Evaporator Unit Removal And Installation
- Disassembly And Assembly
- Thermostat Removal And Installation
- Evaporator Removal And Installation
- Fan Removal And Installation
- ALPHABETICAL INDEX

ZX75-ZX125 22856462 SM 3-06
 
- TABLE OF CONTENTS ZX75
- TABLE OF CONTENTS ZX125
- Load Excavator ZX75
- Load Excavator ZX75
- Diesel Engine
- Electrical System
- Transmission
- Travel Range
- Working Hydraulics
- Pressure and Setting Values (Working)
- Slew Drive
- Lubricants
- Maintenance Parts
- Capacities
- Hydraulic System
- Electrical System
- Power Supply
- Horn
- Check Module
- Load Warning Sensor
- Load Warning Device
- Joystick, Right
- Working Floodlights
- Reach Limitation
- Control Module
- Charge Indicators
- Oil Pressure Indicators
- Air Filter Indicators
- Hydraulic Oil Filter Indicators
- Hydraulic Oil Level
- Working Hydraulics
- Breaker
- Fast Travel
- Float Position
- Swing Brake
- Additional Control Circuit I
- Additional Control Circuit II
- Inspection Plan
- Operator Controls
- Instrument Panel
- Working Equipment Parallel to Tracks
- Cabin Suspension
- Instructions for Tilting the Cabin
- Load Excavator ZX125
- Load Excavator ZX125
- Diesel Engine
- Electrical System
- Transmission
- Travel Range
- Working Hydraulics
- Pressure and Setting Values (Travel)
- Slew Drive
- Lubricants
- Maintenance Parts
- Capacities
- Hydraulic Installations
- Setting Instructions
- Function
- Power Control Valve
- Description of Function
- Test and Pressure Setting
- Rexroth Valve Bank SX 18
- Start-Up
- Brakes (Downhill)
- Electrical System
- Power Supply
- Horn
- Check Module
- Hydraulic Oil Level
- Load Warning Device
- Working Hydraulics
- Joystick, Left
- Restriction of Reach
- Working Floodlights
- Check Module
- Inspection Plan
- Operator Controls
- Instrument Panel

ZX75 22509384 OM 8-04

- TABLE OF CONTENTS
- Introduction
- General
- Warranty
- Notes on Using the Instruction Book
- Environmental Requirements
- Pictograms
- Safety & Prevention of Accidents
- Introductory Remarks
- Proper Use
- General Safety Notes
- Operation
- Danger Zone
- Transport of Persons
- Stability
- Travel Operation
- Operation
- Guides
- Danger of Falling Objects
- Working in the Vicinity of Underground Power Lines
- Working in the Vicinity of Overhead Power Lines
- Operation in Closed Rooms
- Work Stoppages
- Crane Operations
- Change of Work Attachments, Maintenance, Repair
- Recovery, Loading & Transportation
- Monitoring & Inspections
- Fire Protection
- Emergency Exit
- Other Dangers
- Technical Data
- Diesel Engine
- Electrical System
- Crawler Unit
- Steering
- Brakes
- Hydraulic System
- Hydraulic Pumps
- Lubricants
- Filling Quantities
- Fuel, Lubricant & Coolant Specifications
- Alternative Recommendation for Other Temperature Ranges
- Specific Ground Pressure
- Sound Level Values, Vibration
- Dimensions & Weights
- Excavator Installation
- Work Attachments
- Optional Equipment
- Operation
- Operator Controls
- Instrument Panel
- Engine
- Starting the Engine
- Monitoring During Operation
- Switching off the Engine
- Driver's Seat
- Heating/Ventilation/Air Conditioning
- Heating
- Ventilation
- Air Conditioning (Option)
- Front Window
- Ventilation Position
- Tracking and Steering
- Tracking Forward or Reverse
- Taking Bends
- Spot - Turning
- Turning Over One Crawler
- Rubber Crawler Chains
- Parking the Machine
- Working Operation
- General
- Operation of Work Functions
- Operation of Work Equipment
- Operation - Articulation
- Operation - Dozer Blade
- Float Position
- Operation - Additional Control Circuit
- Rock Breaker Operations
- Grab Operations, Swing Bucket, etc.
- Changing Work Attachments
- General
- Assembly of Work Attachments
- Procedure for Changing Work Attachments
- Clamshell Grab
- Changing Procedure
- Hydraulic Rock Breaker
- Attachment
- Working with the Hydraulic Rock Breaker
- Maintenance
- Using the Machine for Load Hook Applications
- Overload Warning Device
- Using the Machine for Load Hook Applications
- Possible Forms of Attachment, Attaching Loads
- Attaching and Guiding Loads
- Checking the Overload Warning Device
- Work Equipment - Monobloc and Boom
- Tiedown & Transport
- Tiedown of the Machine
- Loading the Machine by use of a Crane
- Transport of the Machine
- Care & Maintenance
- General Notes
- Intervals
- Regular Oil Analysis
- Advantages of an Oil Analysis
- Oil Analysis Intervals
- Warranty

- Inspection Parts & Aids
- Lubricants
- Care & Cleaning
- Notes for Winter Operation
- Hydraulic Oil
- Engine Oil
- Coolant
- Battery Charge
- Fuel
- Checking, Maintenance & Inspection Plans
- Initial Inspection (Delivery/Handing-Over Inspection)
- Daily and Weekly Tasks
- Daily
- Weekly
- Overview of Lubricating Points
- Inspection Plan
- Inspection & Maintenance Work
- Engine Oil
- Checking the Engine Oil Level
- Engine Oil Change
- Engine Oil Filter
- Engine Oil Cooling System/Hydraulic Oil Cooler
- Fuel System
- Fuel Level
- Draining Water from the Fuel Filter
- Fuel Filter
- Fuel Tank
- Air Filter, Air Intake
- Dust Ejection Valve
- Air Intake
- Cartridge Maintenance Interval
- Air Filter - Main Cartridge
- Air Filter Safety Cartridge
- Cartridge Replacement
- Main Cartridge
- Safety Cartridge
- V-Belts
- Checking the V-Belt Tension
- Checking the V-Belt Tension without a Measuring Device
- Tensioning V-Belts
- Replacing V-Belts
- Checking the Valve Lash
- Checking & Adjusting
- Hydraulic Oil Tank
- Checking the Hydraulic Oil Level
- Changing the Hydraulic Oil
- Hydraulic Oil Return Filter
- Cartridge Maintenance Interval
- Breather of Hydraulic Oil Tank
- Crawler Gear Units
- Checking the Oil Level in the Crawler Gear Unit
- Oil Change
- Crawler Chains
- Checking the Crawler Chain Tension
- Rubber Crawler Chain
- Steel Crawler Chain
- Tensioning the Crawler Chain
- Releasing the Crawler Chain Tension
- Replacing Track Shoes
- Replacement
- Swing Gear
- Swing Bearing
- Lubrication of Toothing
- Lubrication of Bearing Races
- Checking the Fastening
- Dust Filter for Cab Ventilation
- Removal
- Re-installation
- Windshield Washer System
- Electrical Equipment
- Battery
- Disconnecting the Battery
- Installing the Battery
- Lighting & Warning Equipment
- Shutdown
- Preservation (Temporary Shutdown)
- During Shutdown
- After Shutdown
- Trouble-Shooting
- General
- Engine
- Appendix
- Immobilizer
- Activating the system
- The Immobilizer is Self-Activating
- Deactivating the System
- Operating Malfunctions
- Possible Sources of Malfunction
- Damaged or Lost Code Keys
- Delivery & Handing-Over Instructions
- Operating Instructions
- Spare Parts List
- Warranty
- Maintenance & Inspection Plan

ZX125 22509392 OM 8-04

- TABLE OF CONTENTS
- Introduction
- General
- Warranty
- Notes on Using the Instruction Book
- Environmental Requirements
- Pictograms
- Safety & Prevention of Accidents
- Introductory Remarks
- Proper Use
- General Safety Notes
- Operation
- Danger Zone
- Transport of Persons
- Stability
- Travel Operation
- Operation
- Guides
- Danger of Falling Objects
- Working in the Vicinity of Underground Power Lines
- Working in the Vicinity of Overhead Power Lines
- Operation in Closed Rooms
- Work Stoppages
- Crane Operations
- Change of Work Attachments, Maintenance, Repair
- Recovery, Loading & Transportation
- Monitoring & Inspections
- Fire Protection
- Emergency Exit
- Other Dangers
- Failure of Hydraulic System
- Technical Data
- Engine
- Electrical System
- Travel Mechanism
- Steering
- Brakes
- Hydraulic System
- Lubricants
- Filling Quantities
- Fuel, Lubricant & Coolant Specifications
- Alternative Recommendation for Other Temperature Ranges
- Specific Ground Pressure
- Sound Level Values & Vibration
- Dimensions & Weights
- Excavator Installation
- Carrying Capacity
- Work Attachments
- Optional Equipment
- Operation
- Operator Controls
- Instrument Panel
- Description - Instrument Panel
- Engine
- Starting the Engine
- Monitoring During Operation
- Switching off the Engine
- Driver's Seat
- Heating / Ventilation / Air Conditioning
- Heating
- Ventilation
- Air Conditioning
- Front Window
- Ventilation Position
- Tracking & Steering
- Tracking Forward or Reverse
- Making Turns
- Counter Rotation
- Rubber Crawler Chains
- Parking the Machine
- Working Operation
- General
- Operation of Work Functions
- Operation of Work Equipment
- Operation - Articulation
- Operation - Dozer Blade
- Float Position
- Operation - Additional Control Circuit
- Additional Control Circuit I (25/17)
- Rock Breaker Operations
- Grapple Operations (Swing Bucket, etc.)
- Additional Control Circuit Il (25/2)
- Changing Work Attachments
- General
- Assembly of Work Attachments
- Procedure for changing work attachments
- Clamshell Grapple
- Changing Procedure
- Hydraulic Rock Breaker
- Attachment
- Working with the Hydraulic Rock Breaker

AND MORE...