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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