BOBCAT BL-275 B Series Ingersoll Rand Service Manual SN 572411001 PDF DOWNLOAD

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BOBCAT BL-275 B Series Ingersoll Rand Service Manual SN 572411001 PDF DOWNLOAD

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BOBCAT BL-275 B Series Ingersoll Rand Service Manual SN 572411001 PDF DOWNLOAD

Language : English
Pages :754
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

BOBCAT BL-275 B Series Ingersoll Rand Service Manual SN 572411001 PDF DOWNLOAD

ALPHABETICAL INDEX……………………………………… 5
CONTENTS………………………………………………. 7
FOREWORD…………………………………………… 8
SAFETY INSTRUCTIONS…………………………………. 11
Before Operation………………………………… 11
Fire Prevention…………………………………. 13
SERIAL NUMBER LOCATION………………………………. 14
Loader Backhoe Serial Number……………………… 14
Engine Serial Number…………………………….. 14
DELIVERY REPORT…………………………………….. 14
INGERSOLL-RAND IDENTIFICATIONS……………………….. 15
SAFETY & MAINTENANCE……………………………………. 17
LIFTING AND BLOCKING THE LOADER BACKHOE……………….. 19
Procedure………………………………………. 19
APPROVED LIFT ARM SUPPORT DEVICE……………………… 21
Installing The Approved Lift Arm Support Device…….. 21
Removing The Approved Lift Arm Support Device………. 22
ENGINE COVER……………………………………….. 23
TRANSPORTING THE LOADER BACKHOE………………………. 25
Procedure………………………………………. 25
TOWING THE LOADER BACKHOE……………………………. 27
Procedure………………………………………. 27
AXLE TOE-IN………………………………………… 29
Adjustment……………………………………… 29
SERVICE SCHEDULE……………………………………. 31
Chart………………………………………….. 31
AIR CLEANER SERVICE…………………………………. 33
Replacing The Filter…………………………….. 33
ENGINE COOLING SYSTEM……………………………….. 35
Coolant Replacement……………………………… 35
FUEL SYSTEM………………………………………… 37
Fuel Specifications……………………………… 37
Filling The Fuel Tank……………………………. 37
Fuel Filter…………………………………….. 37
Removing Air From The Fuel System…………………. 38
ENGINE LUBRICATION SYSTEM……………………………. 39
Checking Engine Oil……………………………… 39
Oil Chart………………………………………. 39
Replacing The Oil And Filter……………………… 39
HYDRAULIC/HYDROSTATIC SYSTEM…………………………. 41
Checking And Adding Fluid………………………… 41
Cleaning The Cooler……………………………… 42
Replacing Hydraulic/Hydrostatic Filter…………….. 42
Replacing Hydraulic Fluid………………………… 43
REAR AXLE………………………………………….. 45
Checking Oil Level………………………………. 45
Draining Oil……………………………………. 45
FRONT AXLE…………………………………………. 45
Checking Oil Level………………………………. 45
Draining Oil……………………………………. 45
BOOM LOCK PIN………………………………………. 47
Engaging And Disengaging The Pin………………….. 47
BOB-TACH…………………………………………… 49
Inspection And Maintenance……………………….. 49
ALTERNATOR BELT…………………………………….. 51
Adjusting The Alternator Belt…………………….. 51
LUBRICATING THE LOADER BACKHOE……………………….. 53
TIRE MAINTENANCE……………………………………. 59
Wheel Nuts……………………………………… 59
Tire Mounting…………………………………… 59
Tire Pressure…………………………………… 59
SWING LOCK PIN……………………………………… 61
Engaging The Swing Lock Pin………………………. 61
HYDRAULIC SYSTEM……………………………………….. 63
HYDRAULIC/HYDROSTATIC SCHEMATICS……………………… 67
HYDRAULIC SYSTEM INFORMATION…………………………. 71
Troubleshooting…………………………………. 75
Description…………………………………….. 76
ARM CYLINDER……………………………………….. 77
Checking……………………………………….. 77
Removal And Installation…………………………. 78
Parts Identification…………………………….. 81
Disassembly…………………………………….. 82
Assembly……………………………………….. 84
BOOM CYLINDER………………………………………. 87
Checking……………………………………….. 87
Removal And Installation…………………………. 89
Parts Identification…………………………….. 92
Disassembly…………………………………….. 93
Assembly……………………………………….. 95
SWING CYLINDER……………………………………… 97
Checking……………………………………….. 97
Removal And Installation…………………………. 98
Parts Identification……………………………..100
Disassembly……………………………………..101
Assembly………………………………………..103
Bushing Removal And Installation…………………..105
BUCKET CYLINDER……………………………………..107
Checking………………………………………..107
Removal And Installation………………………….109
Parts Identification……………………………..112
Disassembly……………………………………..113
Assembly………………………………………..115
STABILIZER CYLINDER………………………………….117
Checking………………………………………..117
Removal And Installation………………………….118
Parts Identification……………………………..121
Disassembly……………………………………..122
Assembly………………………………………..126
SIDE SHIFT LOCK CYLINDER……………………………..129
Removal And Installation………………………….129
Parts Identification……………………………..131
Disassembly……………………………………..132
Assembly………………………………………..133
TILT CYLINDER……………………………………….135
Checking………………………………………..135
Removal And Installation………………………….136
Parts Identification……………………………..138
Disassembly……………………………………..139
Assembly………………………………………..141
LIFT CYLINDER……………………………………….143
Checking………………………………………..143
Removal And Installation………………………….144
Parts Identification……………………………..146
Disassembly……………………………………..147
Assembly………………………………………..149
STEERING CYLINDER (FRONT)…………………………….151
Removal And Installation………………………….151
Parts Identification……………………………..155
Disassembly And Assembly………………………….156
Inspection………………………………………159
STEERING CYLINDER (REAR)……………………………..161
Removal And Installation………………………….161
Parts Identification……………………………..164
Disassembly And Assembly………………………….165
Inspection………………………………………168
MAIN RELIEF VALVE……………………………………171
Testing The Main Relief Valve……………………..171
Adjustment………………………………………172
PORT RELIEF VALVE (BACKHOE CONTROL VALVE)………………173
Testing And Adjusting (Arm Control)………………..173
Testing And Adjusting (Boom Control)……………….175
Testing And Adjusting (Boom Swing Control)………….177
PORT RELIEF VALVE (LOADER CONTROL VALVE)……………….179
Testing And Adjusting (Bucket Tilt)………………..179
Testing And Adjusting (Front Auxiliary)…………….181
LOADER CONTROL VALVE…………………………………183
Removal And Installation………………………….183
Parts Identification……………………………..185
Disassembly And Assembly………………………….186
Inlet/Outlet Valve Section………………………..187
Lift Arm Valve Section……………………………189
Tilt Valve Section……………………………….192
Auxiliary Valve Section…………………………..196
BACKHOE CONTROL VALVE………………………………..201
Removal And Installation………………………….201
Parts Identification……………………………..203
Disassembly And Assembly………………………….204
Inlet/Outlet Valve Section………………………..205
Arm Valve Section………………………………..208
Tilt Valve Section……………………………….211
Right Stabilizer Valve Section…………………….214
Left Stabilizer Valve Section……………………..217
Boom Valve Section……………………………….221
Boom Swing Valve Section………………………….224
Outlet Valve Section……………………………..227
HYDRAULIC FLUID RESERVOIR…………………………….229
Removal And Installation………………………….229
Strainer Removal And Installation………………….231
HYDRAULIC FILTER HOUSING……………………………..233
Removal And Installation………………………….233
Disassembly……………………………………..234
Assembly………………………………………..235
GEAR PUMP…………………………………………..237
Removal And Installation………………………….237
Parts Identification……………………………..238
Disassembly And Assembly………………………….239
Inspection………………………………………241
STEERING PUMP……………………………………….243
Removal And Installation………………………….243
Parts Identification……………………………..244
Disassembly……………………………………..245
Inspection………………………………………254
Assembly………………………………………..254
TRAVEL PEDAL………………………………………..263
Removal And Installation………………………….263
Parts Identification……………………………..264
Disassembly And Assembly………………………….265
STEERING VALVE………………………………………271
Removal And Installation………………………….271
Adjustment………………………………………272
SAPR BRAKE CYLINDER………………………………….273
Removal And Installation………………………….273
Parts Identification……………………………..275
Disassembly……………………………………..276
Assembly………………………………………..278
SAPR BRAKE CONTROL VALVE……………………………..281
Removal And Installation………………………….281
Parts Identification……………………………..282
Disassembly And Assembly………………………….283
HYDROSTATIC SYSTEM………………………………………285
HYDROSTATIC SYSTEM INFORMATION………………………..287
Troubleshooting Chart…………………………….287
Replenishing Valve Function……………………….288
OIL COOLER………………………………………….289
Removal And Installation………………………….289
Parts Identification……………………………..290
HYDROSTATIC DRIVE MOTOR………………………………291
Removal And Installation………………………….291
Parts Identification……………………………..292
Disassembly……………………………………..293
Inspection………………………………………297
Assembly………………………………………..299
HYDROSTATIC PUMP…………………………………….305
Removal And Installation………………………….305
Parts Identification……………………………..308
Disassembly……………………………………..310
Inspection………………………………………326
Assembly………………………………………..328
HYDROSTATIC TESTING………………………………….343
Pump Adjustment………………………………….343
DRIVE SYSTEM……………………………………………347
PARKING BRAKE……………………………………….349
Lever Removal And Installation…………………….349
Cable Removal And Installation…………………….350
Adjustment………………………………………352
PARKING BRAKE……………………………………….353
Lever Removal And Installation…………………….353
Cable Removal And Installation…………………….354
Adjustment………………………………………356
REAR AXLE…………………………………………..357
Removal…………………………………………357
Installation…………………………………….360
AXLE AND DIFFERENTIAL (REAR)………………………….363
Drive Axle Parts Identification……………………369
Drive Axle Disassembly……………………………370
Troubleshooting Chart…………………………….363
General Information………………………………364
Wheel Hub/Spindle Parts Identification……………..364
Wheel Hub/Spindle Disassembly……………………..365
Steering Knuckle Parts Identification………………373
Steering Knuckle Disassembly………………………374
Differential Parts Identification………………….377
Differential Disassembly………………………….378
Differential Inspection…………………………..384
Pinion Group Parts Identification………………….385
Pinion Group Disassembly………………………….386
Pinion Group Inspection…………………………..389
Pinion Group Assembly…………………………….390
Differential Assembly…………………………….397
Steering Knuckle Assembly…………………………406
Drive Axle Assembly………………………………409
Wheel Hub/Spindle Assembly………………………..412
STEERING ANGLE ADJUSTMENT (REAR AXLE)………………….417
Adjustment………………………………………417
FRONT AXLE………………………………………….419
Removal…………………………………………419
Installation…………………………………….421
AXLE AND DIFFERENTIAL (FRONT)…………………………423
Troubleshooting Chart…………………………….423
General Information………………………………424
Wheel Hub/Spindle Parts Identification……………..424
Wheel Hub/Spindle Disassembly……………………..425
Drive Axle Parts Identification……………………429
Drive Axle Disassembly……………………………430
Steering Knuckle Parts Identification………………433
Steering Knuckle Disassembly………………………434
Differential Parts Identification………………….437
Differential Disassembly………………………….438
Differential Inspection…………………………..444
Pinion Group Parts Identification………………….445
Pinion Group Disassembly………………………….446
Pinion Group Inspection…………………………..449
Pinion Group Assembly…………………………….450
Differential Assembly…………………………….457
Steering Knuckle Assembly…………………………466
Drive Axle Assembly………………………………469
Wheel Hub/Spindle Assembly………………………..472
STEERING ANGLE ADJUSTMENT (FRONT AXLE)…………………477
Adjustment………………………………………477
DRIVESHAFT………………………………………….479
Removal And Installation………………………….479
DROP BOX……………………………………………481
Removal And Installation………………………….481
Parts Identification……………………………..484
Disassembly……………………………………..485
Inspection………………………………………492
Assembly………………………………………..492
MAIN FRAME……………………………………………..497
OPERATOR CAB………………………………………..499
Not Available At Time Of Printing………………….499
ENCLOSED CAB………………………………………..501
Removal And Installation………………………….501
Cab Mount Removal And Installation…………………508
OPERATOR SEAT……………………………………….509
Removal And Installation………………………….509
FLOOR PANELS………………………………………..511
Left Front Panel Removal And Installation…………..511
Right Front Panel Removal And Installation………….511
Rear Panel Removal And Installation………………..512
GRILL………………………………………………513
Removal And Installation………………………….513
GRILL FRAME…………………………………………515
Removal And Installation………………………….515
ENGINE SIDE COVERS…………………………………..517
Removal And Installation………………………….517
FENDER……………………………………………..519
Removal And Installation………………………….519
ENGINE COVER………………………………………..521
Removal And Installation………………………….521
FUEL TANK…………………………………………..523
Removal And Installation………………………….523
Fuel Fill Screen Removal And Installation…………..524
LIFT ARMS…………………………………………..525
Removal And Installation………………………….525
BOB-TACH……………………………………………529
Removal And Installation………………………….529
Bob-Tach Lever And Wedge………………………….531
Pivot Pin Bushing Removal And Installation………….533
ARM………………………………………………..535
Removal And Installation………………………….535
Arm Pivot Bushing Removal And Installation………….537
BOOM……………………………………………….539
Removal And Installation………………………….539
Boom Pivot Bushing Removal And Installation…………540
SWING FRAME…………………………………………541
Removal And Installation………………………….541
Bushing Removal And Installation…………………..543
X-CHANGE™…………………………………………..545
Removal And Installation………………………….545
BUCKET……………………………………………..547
Backhoe Bucket Teeth Removal And Installation……….547
Loader Bucket Teeth Removal And Installation………..547
STABILIZER FRAME…………………………………….549
Removal And Installation………………………….549
FRONT AXLE PIVOT FRAME……………………………….553
Removal…………………………………………553
Installation…………………………………….554
Bushing Removal And Installation…………………..555
REAR WINDOW…………………………………………557
Removal And Installation………………………….557
CAB DOOR……………………………………………561
Removal And Installation………………………….561
ELECTRICAL SYSTEM AND ANALYSIS……………………………563
ELECTRICAL SCHEMATICS………………………………..565
ELECTRICAL SYSTEM INFORMATION…………………………569
Troubleshooting Chart…………………………….569
Description……………………………………..570
Fuse Location……………………………………570
BATTERY…………………………………………….571
Removal And Installation………………………….571
Servicing The Electrical System……………………572
Using A Booster Battery (Jump Starting)…………….573
ALTERNATOR………………………………………….575
Adjusting The Alternator Belt……………………..575
Description……………………………………..575
Tests…………………………………………..576
Alternator Output Test……………………………576
Full Field Test………………………………….577
Alternator Regulator Test…………………………577
Alternator Regulator Test With Voltmeter……………578
Removal And Installation………………………….579
Parts Identification……………………………..580
Pulley Removal And Installation……………………581
Disassembly And Assembly………………………….582
Rotor Continuity Test…………………………….585
Stator Continuity Test……………………………585
Rectifier Continuity (Diode) Test………………….586
Brush Length…………………………………….586
STARTER…………………………………………….587
Removal And Installation………………………….587
Checking The Starter In The Loader…………………587
Parts Identification……………………………..589
Disassembly……………………………………..590
Inspection And Repair…………………………….595
No Load Test…………………………………….599
Assembly………………………………………..600
FRONT LIGHTS………………………………………..607
Bulb Removal And Installation……………………..607
Housing Removal And Installation…………………..609
TURN INDICATOR LIGHTS (FRONT)…………………………611
Bulb Removal And Installation……………………..611
TURN INDICATOR LIGHTS (REAR)………………………….613
Bulb Removal And Installation……………………..613
CAB LIGHTS………………………………………….615
Bulb Removal And Installation……………………..615
Housing Removal And Installation…………………..617
FUEL LEVEL SENDER……………………………………619
Removal And Installation………………………….619
INSTRUMENT PANEL…………………………………….621
Removal And Installation………………………….621
FRONT WIPER…………………………………………623
Removal And Installation………………………….623
REAR WIPER………………………………………….627
Removal And Installation………………………….627
ENGINE SERVICE………………………………………….629
TROUBLESHOOTING……………………………………..633
Chart…………………………………………..633
ENGINE SPEED CONTROL…………………………………635
Removal And Installation………………………….635
Cable Removal And Installation…………………….636
MUFFLER…………………………………………….637
Removal And Installation………………………….637
AIR CLEANER…………………………………………639
Removal And Installation………………………….639
RADIATOR……………………………………………641
Removal And Installation………………………….641
ENGINE COMPONENTS AND TESTING…………………………643
Checking Engine Compression……………………….643
Checking Glow Plugs………………………………644
Glow Plug Removal And Installation…………………645
Fuel Shut-Off Solenoid Removal And Installation……..646
Checking Fuel Injection Pump………………………647
Fuel Injection Pump Removal And Installation………..648
Fuel Injection Pump Timing………………………..650
Fuel Injector Nozzles Removal And Installation………651
Checking Fuel Injector, Nozzles……………………653
Thermostat Removal And Installation………………..654
Water Pump Removal And Installation………………..655
ENGINE……………………………………………..657
Removal And Installation………………………….657
Mount Replacement………………………………..661
RECONDITIONING THE ENGINE…………………………….663
Timing Gear Case Cover Removal And Installation……..663
Oil Pump Removal And Installation………………….665
Crankshaft Front Seal Removal And Installation………667
Engine Speed Control Plate Removal And Installation….668
Idle Limit And Fuel Limit Adjustment……………….669
Exhaust Manifold Removal And Installation…………..669
Valve Cover Removal And Installation……………….670
Rocker Arm Removal And Installation………………..671
Push Rod Removal And Installation………………….672
Tappet Removal And Installation……………………673
Water Flange Removal And Installation………………673
Cylinder Head Removal And Installation……………..674
Checking Piston Top Clearance……………………..675
Cylinder Head Disassembly And Assembly……………..676
Servicing The Cylinder Head……………………….677
Combustion Chamber Removal And Installation…………680
Idler Gear Removal And Installation………………..681
Camshaft Removal And Installation………………….682
Fuel Camshaft Removal And Installation……………..684
Oil Pan Removal And Installation…………………..686
Governor Shaft Removal And Installation…………….687
Governor Fork Lever Removal And Installation………..690
Piston Removal And Installation……………………692
Checking The Piston And Connecting Rod……………..692
Connecting Rod Alignment………………………….693
Piston Ring Gap………………………………….693
Piston Ring Installation………………………….694
Connecting Rod Installation……………………….695
Checking Engine Cylinder Bore……………………..695
Crankshaft Removal And Installation………………..696
Checking Crankshaft Journal And Block Bearing……….698
Checking Crankshaft Journal And Main Bearing………..699
Connecting Rod Journal……………………………700
Checking The End Play Of The Crankshaft…………….701
Crankshaft Alignment……………………………..701
Engine Timing Installation………………………..702
Timing Gear Backlash, Idler Gear And Crankshaft……..702
Idler Gear And Camshaft Gear………………………703
Idler Gear And Fuel Camshaft Gear………………….703
Fuel Camshaft Gear And Governor Shaft Gear………….703
FLYWHEEL HOUSING…………………………………….705
Removal And Installation………………………….705
FLYWHEEL……………………………………………707
Removal And Installation………………………….707
Ring Gear Removal And Installation…………………707
RUBBER DRIVE COUPLER…………………………………709
Removal And Installation………………………….709
Disassembly……………………………………..709
TURBOCHARGER………………………………………..711
Checking………………………………………..711
Description……………………………………..711
Removal And Installation………………………….711
HEATER…………………………………………………715
COMPONENTS………………………………………….717
Identification…………………………………..717
HEATER FAN………………………………………….719
Removal And Installation………………………….719
HEATER UNIT…………………………………………721
Removal And Installation………………………….721
Parts Identification……………………………..723
Disassembly And Assembly………………………….724
SPECIFICATIONS………………………………………….727
LOADER BACKHOE SPECIFICATIONS…………………………729
Loader Backhoe Dimensions…………………………729
Backhoe Rated Load Capacity (Per SAE J31)…………..730
Performance……………………………………..731
Controls………………………………………..731
Engine………………………………………….731
Hydraulic System…………………………………732
Electrical………………………………………732
Drive System…………………………………….733
Capacities………………………………………733
Tires…………………………………………..733
ENGINE SPECIFICATIONS………………………………..735
Engine Compression……………………………….735
Fuel Injection Nozzles……………………………735
Fuel Injection Pump………………………………735
Cylinder Head……………………………………735
Valves………………………………………….735
Valve Springs……………………………………736
Rocker Arms……………………………………..736
Camshaft………………………………………..736
Cylinders……………………………………….736
Piston Rings…………………………………….737
Pistons…………………………………………737
Crankshaft………………………………………737
Oil Pump………………………………………..738
Thermostat………………………………………738
Grinding Specifications for the Crankshaft………….739
LOADER BACKHOE TORQUE………………………………..741
Specifications…………………………………..741
TORQUE SPECIFICATIONS FOR BOLTS……………………….743
Torque For General Metric Bolts……………………743
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS……………..745
Specifications…………………………………..745
CONVERSIONS…………………………………………747
Decimal And Millimeter Equivalents…………………747
U.S. To Metric Conversion…………………………747
SMR……………………………………………………749
Revision No: BL275-1…………………………………749
Revision No: BL275-2…………………………………751
Revision No: BL-275-3………………………………..753

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DESCRIPTION:

BOBCAT BL-275 B Series Ingersoll Rand Service Manual SN 572411001 PDF DOWNLOAD

FOREWORD
This manual is for the Ingersoll-Rand loader mechanic. It provides necessary servicing and
adjustment procedures for the loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, Starting procedure, daily checks, etc.

SAFETY INSTRUCTIONS (CONT’D)
Fire Prevention

• The machines and some attachments have components that are at high temperatures under normal operating conditions. The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks.
• Flammable debris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it can cause a fire hazard. Clean often to avoid this accumulation. Flammable debris in the engine compartment is a potential fire hazard.

PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
• You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
• Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted

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