Bobcat 825 Skid-Steer Loader Repair Service Manual - 6549899

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This workshop repair service manual PDF download for the 825 Bobcat Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

Bobcat Loader 825 


TABLE OF CONTENTS :

PREVENTIVE MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC DRIVE SYSTEM
MECHANICAL TRANSMISSION
MAIN FRAME
ELECTRICAL SYSTEM
ENGINE SERVICE
SPECIFICATIONS
ALPHABETICAL INDEX
SERVICE BULLETINS
SERVICE MANUAL REVISIONS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6549899 (12–83)
Total Pages : 176


This 825 Bobcat Loader Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

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MAINTENANCE SAFETY
CONTENTS
    FOREWORD
    
PREVENTIVE MAINTENANCE
    INTRODUCTION
        Symbols
        Serial Number Identification
        Loader Serial Number
        Engine Serial Number
        Pre-Delivery Inspection
        30 Hour Inspection
    SERVICE SCHEDULE
    REAR GRILL
    TILTING THE OPERATOR GUARD
        ROPS Tilt Motor
    ENGINE MAINTENANCE
        Engine Oil
        Specifications
    ENGINE OIL AND FILTER REPLACEMENT
    ENGINE AIR INLET SYSTEM (AIR CLEANER)
    ENGINE COOLING SYSTEM
    FAN BELT ADJUSTMENT
    FLUSHING THE COOLING SYSTEM
    FUEL SYSTEM
    FUEL SPECIFICATIONS
        Water In The Fuel Tank
    TO SERVICE THE FUEL SYSTEM
    REMOVE THE AIR FROM THE FUEL SYSTEM
    ELECTRICAL SYSTEM MAINTENANCE
        Electrical System
    HYDRAULIC SYSTEM
        Hydraulic/Hydrostatic Transmission Fluid
    CHECKING AND ADDING HYDRAULIC FLUID
    HYDRAULIC FLUID FILTERS
        Replacement Of The Suction (25 Micron) Filter 
        Replacement Of The Return Line Filter (10 Micron)
    DRAINING THE FLUID RESERVOIR
    LEAKS
    OIL COOLER
    CARE OF THE HYDROSTATIC TRANSMISSION
        Loader Start–Up
        Cold Weather Start–Up
    FINAL DRIVE CHAIN
    TIRES
    TIRE MAINTENANCE
    TIRE ROTATION
    TIRE REPLACEMENT
    LUBRICATION
    WHEEL MOUNTING NUTS
    BOB–TACH
    PARK BRAKE
    
HYDRAULIC SYSTEM
    HYDRAULIC / HYDROSTATIC SCHEMATICS
    HYDRAULIC SYSTEM
    TUBELINES, HOSES, FITTINGS
        37° Flare Connection
        Straight Thread O–Ring Fitting (Elbows, Adapter, Etc.)
        Pipe Thread Fittings
        Tubelines And Hoses
    HYDRAULIC SYSTEM TROUBLESHOOTING
    GEAR PUMP
        Testing
        Removal
    DISASSEMBLY OF GEAR PUMP
    TO INSPECT PARTS FOR WEAR
        General
        Gear Assembly
        Front And Back Plates
        Body
        Assembly Of Gear Pump
    CONTROL VALVE
        Relief Valve Check
        Internal Leaks
        Control Valve Repair
            Removal
            Disassembly
    LIFT VALVE SPOOL (Float Detent)
         Repair Of The Float Detent Of The Lift Spool
        To Assemble The Detent Assembly
        Inspection, Repair And Assembly Of Control Valve
    CONTROL PEDALS
        Adjustment
        Removal Of Pedal Assembly
    HYDRAULIC CYLINDERS
        Checking For Internal Leak (Lift Cylinder)
        Removal Of Lift Cylinder
        Removal Of Tilt Cylinder
    HYDRAULIC CYLINDER REPAIR
        To Disassemble A Hydraulic Lift Or Tilt Cylinder
        To Replace The Cylinder Seals
        To Assemble The Hydraulic Cylinder
    OIL COOLER
        Cleaning Of Grill
        Removal Of Oil Cooler
        By–Pass Valve
        Cooler By-Pass Hose
        
HYDROSTATIC SYSTEM
    HYDROSTATIC DRIVE SYSTEM
        Description
    HYDROSTATIC TRANSMISSION TROUBLESHOOTING
    CONTROL LINKAGE
        Adjustment Of Steering Linkage
    ADJUSTMENT OF SPEED RANGE LINKAGE
    STEERING CONTROLLINKAGE
        Removal
    CHECKING HYDROSTATIC SYSTEM
        Test Kit
        Charge Pressure Check
        Charge Pump Inlet Pressure
    CHECKING RELIEF VALVES
        Charge Relief Valve
        Filter Relief Valve
        Charge Inlet Relief Valve
        High Pressure Relief Valve
    MICRON FINAL FILTER ELEMENT REPLACEMENT
    TEMPERATURE AND PRESSURE SWITCHES
    REMOVAL OF HYDROSTATIC PUMP ASSEMBLY
    INSTALLING HYDROSTATIC PUMP
    REMOVAL OF HYDROSTATIC MOTOR
    INSTALLING HYDROSTATICMOTOR
        New Hydrostatic Pump & Motor
    HYDROSTATIC PUMP OR MOTOR DISASSEMBLY 
    INSPECT PARTS FOR WEAR
    TO ASSEMBLE PUMP OR MOTOR
    STARTING PROCEDURE, AFTER REPAIR
    
FINAL DRIVE SYSTEM
    FINAL DRIVE SYSTEM
        Description
    REMOVAL OF REDUCTION HOUSING
    DISASSEMBLY OF REDUCTION HOUSING 
        Removal Of The Intermediate Gear (6)
        Removal Of Input Drive Gear (7)
        Removal Of Output Gear (14)
    ASSEMBLY OF REDUCTION HOUSING
        Installing The Output Shaft And Gear
        Installing Input Shaft And Gear
        Installing Intermediate Gear
        Drive Chain Adjustment (Internal Adjustment Type)
        Drive Chain Adjustment (External Adjustment Type)
        Drive Chain Idler Removal (Internal Adjustment Type)
        To Disassemble The Idler Gear (Internal)
        Drive Chain Idler Removal (External Adjustment Type)
    REMOVAL OF DRIVE CHAIN
    INSTALLING DRIVE CHAIN
    REMOVAL OF AXLE
        Removal Of Rear Axle
        Removal Of Front Axle
        Installation Of The Axle
    AXLE BEARING AND SEAL REPLACEMENT
    NSTALLATION OF AXLES PROCKET
    PARK BRAKE REMOVAL
    
MAIN FRAME
    MAIN FRAME
        Description 
    REMOVAL OF ROPS
    PIVOT PIN AND BUSHING REPLACEMENT 
    BOB–TACH REMOVAL
    LIFT ARMS REMOVAL
    FUEL TANK REMOVAL
        Removing Fuel Tank On Loader S/N 16999 & Below 
        Removing Fuel Tank On Loader S/N 17001 & Above
    ELECTRIC MOTOR FOR ROPS (Cab Tilt – S/N 19126 & Below)
        Removal Of Tilt Mechanism
    MECHANICAL TILT FOR THE ROPS (S/N 19127 & Above)
    
ELECTRICAL SYSTEM
    ELECTRICAL SCHEMATICS
    ELECTRICAL CIRCUITRY
    PROBLEM ANALYSIS
    FAN BELT
    TO CHECK ALTERNATOR OUTPUT
    TO CHECK THE REGULATOR
    ALTERNATOR SERVICE
        Removal (ROPS Must Be Tilted)
        Disassembly
        To Check Rotor
        To Check Stator 
        To Check Diode Trio
        To Check Rectifier
        Assembly
    STARTER SERVICE
        To Check The Starter
        To Remove Starter
        Disassembly And Inspection
        Assembly
        
ENGINE SERVICE
    INTRODUCTION
        Engine Parts
        Engine Number Location
    STARTING A NEW OR RECONDITIONED ENGINE
    ENGINE OVERHAUL
        Engine Removal
        Cylinder Head Maintenance
        To Remove The Valves
        Combustion Chamber Inserts
        Reconditioning Cylinder Heads
        Cleaning
        Inspection
        Reconditioning Of Valves AndValve Seats
        Valve Seat Inserts
        To Install Inserts
         To Disassemble The Rocker Shaft Assembly
         To Assemble The Rocker Shaft Assembly
        Push Rods
        To Install The Valves
    INSTALLING CYLINDER HEAD
        Cylinder Head Gasket
         To Install The Cylinder Head
    CONNECTING RODS AND PISTONS
        To Remove Pistons And Connecting Rods
        To Remove Pistons And Rings From The Connecting Rods
        Inspection
        To Install The Pistons To The Connecting Rods
        Installing The Piston Rings
        To Install Rings
        To Install Piston And Connecting Rod Assemblies
        Installing New Pistons
        Cylinder Liners
        To Install New Cylinder Liners
    CRANKSHAFT AND MAIN BEARINGS
        Description
        To Install Main Bearings And Thrust Washers
        To Install Thrust Washers
        To Remove The Crankshaft
        To Reinstall The Crankshaft
        Crankshaft Rear End Oil Seal
    FLYWHEEL AND FLYWHEEL HOUSING
        To Remove The Flywheel
        To Replace The Flywheel Ring Gear
        To Reinstall The Flywheel
        To Install The Flywheel Housing
    TIMING CASE AND DRIVE
        To Remove The Timing Case Cover
        Replacement Of The Crankshaft Front Oil Seal
        To Install The Timing Case Cover
        To Remove The Idler Gear And Hub
        To Install The Idler Gear And Hub
        To Remove The Camshaft Gear
        To Install The Camshaft Gear
        To Remove The Fuel Pump Gear
        To Install The Fuel Pump Gear
        To Remove The Fuel Pump Drive Hub
        To Install The Fuel Pump Drive Hub
         To Remove The Timing CaseBack Plate
        To Install The Timing Case Back Plate
        To Remove The Camshaft And Tappets
        To Install The Tappets And Camshaft
        Timing Marks
        To Reset The Engine To The Original Timing
        Timing Pin
        Check Valve Timing
        Adjusting Valve Clearance
        Valve Adjustment Sequence
    LUBRICATION SYSTEM
        The Lubricating Oil Pump
        To Remove The Sump
        To Install The Oil Pan
        To Remove The Oil Pump
        To Dismantle The Oil Pump
        Inspection
        To Assemble The Oil Pump
        To Install The Oil Pump
        Oil Pressure Relief Valve
        To Dismantle The Oil Pressure Relief Valve
        To Assemble The Oil Pressure Relief Valve
    COOLING SYSTEM
        Fan Belt
        Adjustment Of Fan Belt
        Water Pump
        Remove The Water Pump
        To Disassemble The Water Pump
        Inspection
        To Assemble The Water Pump
        To Install The Water Pump
        Thermostat
        To Remove The Thermostat
         To Test The Thermostat
        Replacement Of The Thermostat
    FUEL SYSTEM
        To Test Fuel Lift Pump
        To Remove The Lift Pump
        Fuel Injection Pump
        To Remove The Fuel Injection Pump
        To Install The Fuel Injection Pump
        Checking Fuel Injection Pump Timing
        Timing The fuel Injection Pump (Using Timing Tool MS 67123)
        Checking The Timing Mark On The Flange Of The Injection Pump
        Injector Problems
        Testing For Faulty Injector
        Injector Removal
        Injector Installation
        Fuel Pipes (High Pressure)
        Using C.A.V. Thermostart Units
        Charging The Fuel System
        
SPECIFICATIONS
    SPECIFICATIONS
        Cylinder Block
        Cylinder Liner (Cast Iron)
        Pistons
        Piston Rings
        Piston Pin Bushing
        Connecting Rod
        Connecting Rod Alignment
        Crankshaft
        Crankshaft Thrust Washers
        Main Bearings
        Connecting Rod Bearings
        Camshaft
        Camshaft Thrust Plates
        Cylinder Head
        Combustion Chamber Inserts
        Valve Guides (Inlet)
        Valve Guides (Exhaust)
        Valves (Inlet)
        Valves (Exhaust)
        Inner Valve Springs
        Outer Valve Springs
        Rocker Levers
        Valve Clearance
        Rocker Shaft
        Push Rods
        Lifters
    TIMING GEARS
        Injector Pump Gear
        Crankshaft Gear
        Timing Gear Backlash
    LUBRICATION SYSTEM
        Lubricating Oil Pump
        Pump Clearances
        Lubricating Oil Pump Drive Gear
        Relief Valve (Lube Oil)
        Lubricating Oil Filter
    COOLING SYSTEM
        Thermostat
    FUEL SYSTEM
        Fuel Lift Pump
        Final Fuel Filter
        Fuel Injection Pump
        Injectors
        Starting Aid
    SERVICE WEAR LIMITS
    DE–RATING FOR ALTITUDE
    TORQUE SPECIFICATIONS
        Hydrostatic Pump and Motor
        High Pressure Relief Valves
        Loader Torque Specs
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS
    DECIMAL AND MILLIMETER EQUIVALENTS
    U.S. TO METRIC CONVERSION
    SPECIAL TOOLS
    825 LOADER SPECIFICATIONS
        SPECIFICATIONS
        ENGINE
        LOADER HYDRAULICS
        ELECTRICAL
        DRIVE SYSTEM
        CAPACITIES
        TIRES
        
ALPHABETICAL INDEX

SERVICE BULLETINS
    825-001
    825-002
    825-003
    825-004
    825-005
    
SERVICE MANUAL REVISIONS
    825-1
    825-2
    825-3
    
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