Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Bobcat 825 Skid Steer Loader Service Repair Manual – PDF Download
$28.95
Bobcat 825 Skid Steer Loader Service Repair Manual
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Bobcat 825 Skid Steer Loader Service Repair Manual
FILE DETAILS:
Bobcat 825 Skid Steer Loader Service Repair Manual
LANGUAGE:ENGLISH
PAGES:176
DOWNLOADABLE:YES
FILE TYPE:PDF
BOBCAT 825 SKID STEER LOADER SERVICE REPAIR MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Bobcat 825 Skid Steer Loader Service Repair Manual
This manual provides instruction for proper routine service and adjustment of the Bobcat, and detailed overhaul instructions of the power train, loader hydraulic/hydrostatic system and general mainframe components.
Refer to the Owner’s Manual for general operating instructions (Starting Procedure, Daily Checks, Bucket Operation, Minor Maintenance, etc.).
A general inspection of the following items should be made whenever the machine has undergone service or repair:
1. Check hydraulic fluid level, engine oil level and fuel supply.
2. Inspect for any sign of fuel, oil or hydraulic fluid leaks.
3. Lubricate the machine.
4. Check battery condition, electrolyte level and cables.
5. Inspect air cleaner system for damage or leaks. Check element and make replacement, if necessary.
6. Check alternator drive belt for condition and tension.
7. Check for loose drive chains by lifting the rear of the machine and turning the rear wheels by hand.
8. Check tires for wear and pressure.
9. Check the Bob–Tach attachment for condition. Inspect the wedges for damage or wear.
10. Inspect safety items for condition (ROPS Guard, Seat Belt, Safety Treads, Lights, etc.).
11. Make a visual inspection for loose or broken parts or connections.
12. Operate the loader; checking all functions.
Advise the owner if any of the above items are in need of repair.
TABLE OF CONTENTS:
Bobcat 825 Skid Steer Loader Service Repair Manual
MAINTENANCE SAFETY...................................................... 3 CONTENTS................................................................ 5 FOREWORD............................................................ 5 PREVENTIVE MAINTENANCE.................................................. 7 INTRODUCTION........................................................ 9 Symbols......................................................... 9 Serial Number Identification.................................... 9 Loader Serial Number............................................ 9 Engine Serial Number............................................ 10 Pre-Delivery Inspection......................................... 10 30 Hour Inspection.............................................. 10 SERVICE SCHEDULE.................................................... 11 REAR GRILL.......................................................... 12 TILTING THE OPERATOR GUARD.......................................... 12 ROPS Tilt Motor................................................. 13 ENGINE MAINTENANCE.................................................. 13 Engine Oil...................................................... 13 Specifications.................................................. 13 ENGINE OIL AND FILTER REPLACEMENT................................... 15 ENGINE AIR INLET SYSTEM (AIR CLEANER)............................... 16 ENGINE COOLING SYSTEM............................................... 17 FAN BELT ADJUSTMENT................................................. 17 FLUSHING THE COOLING SYSTEM......................................... 17 FUEL SYSTEM......................................................... 18 FUEL SPECIFICATIONS................................................. 18 Water In The Fuel Tank.......................................... 18 TO SERVICE THE FUEL SYSTEM.......................................... 19 REMOVE THE AIR FROM THE FUEL SYSTEM................................. 19 ELECTRICAL SYSTEM MAINTENANCE....................................... 20 Electrical System............................................... 20 HYDRAULIC SYSTEM.................................................... 21 Hydraulic/Hydrostatic Transmission Fluid........................ 21 CHECKING AND ADDING HYDRAULIC FLUID................................. 21 HYDRAULIC FLUID FILTERS............................................. 21 Replacement Of The Suction (25 Micron) Filter .................. 22 Replacement Of The Return Line Filter (10 Micron)............... 22 DRAINING THE FLUID RESERVOIR........................................ 22 LEAKS............................................................... 23 OIL COOLER.......................................................... 23 CARE OF THE HYDROSTATIC TRANSMISSION................................ 23 Loader Start–Up................................................. 24 Cold Weather Start–Up........................................... 24 FINAL DRIVE CHAIN................................................... 24 TIRES............................................................... 24 TIRE MAINTENANCE.................................................... 25 TIRE ROTATION....................................................... 25 TIRE REPLACEMENT.................................................... 25 LUBRICATION......................................................... 25 WHEEL MOUNTING NUTS................................................. 25 BOB–TACH............................................................ 26 PARK BRAKE.......................................................... 26 HYDRAULIC SYSTEM........................................................ 27 HYDRAULIC / HYDROSTATIC SCHEMATICS.................................. 29 HYDRAULIC SYSTEM.................................................... 39 TUBELINES, HOSES, FITTINGS.......................................... 39 37° Flare Connection............................................ 39 Straight Thread O–Ring Fitting (Elbows, Adapter, Etc.).......... 40 Pipe Thread Fittings............................................ 40 Tubelines And Hoses............................................. 40 HYDRAULIC SYSTEM TROUBLESHOOTING.................................... 40 GEAR PUMP........................................................... 42 Testing......................................................... 42 Removal......................................................... 42 DISASSEMBLY OF GEAR PUMP............................................ 43 TO INSPECT PARTS FOR WEAR........................................... 43 General......................................................... 43 Gear Assembly................................................... 43 Front And Back Plates........................................... 43 Body............................................................ 44 Assembly Of Gear Pump........................................... 44 CONTROL VALVE....................................................... 44 Relief Valve Check.............................................. 44 Internal Leaks.................................................. 45 Control Valve Repair............................................ 45 Removal..................................................... 45 Disassembly................................................. 45 LIFT VALVE SPOOL (Float Detent)..................................... 46 Repair Of The Float Detent Of The Lift Spool................... 46 To Assemble The Detent Assembly................................. 46 Inspection, Repair And Assembly Of Control Valve................ 46 CONTROL PEDALS...................................................... 47 Adjustment...................................................... 47 Removal Of Pedal Assembly....................................... 48 HYDRAULIC CYLINDERS................................................. 48 Checking For Internal Leak (Lift Cylinder)...................... 48 Removal Of Lift Cylinder........................................ 48 Removal Of Tilt Cylinder........................................ 48 HYDRAULIC CYLINDER REPAIR........................................... 48 To Disassemble A Hydraulic Lift Or Tilt Cylinder................ 49 To Replace The Cylinder Seals................................... 49 To Assemble The Hydraulic Cylinder.............................. 49 OIL COOLER.......................................................... 50 Cleaning Of Grill............................................... 50 Removal Of Oil Cooler........................................... 50 By–Pass Valve................................................... 50 Cooler By-Pass Hose............................................. 50 HYDROSTATIC SYSTEM...................................................... 51 HYDROSTATIC DRIVE SYSTEM............................................ 53 Description..................................................... 53 HYDROSTATIC TRANSMISSION TROUBLESHOOTING............................ 53 CONTROL LINKAGE..................................................... 58 Adjustment Of Steering Linkage.................................. 58 ADJUSTMENT OF SPEED RANGE LINKAGE................................... 58 STEERING CONTROLLINKAGE............................................. 59 Removal......................................................... 59 CHECKING HYDROSTATIC SYSTEM......................................... 60 Test Kit........................................................ 60 Charge Pressure Check........................................... 62 Charge Pump Inlet Pressure...................................... 62 CHECKING RELIEF VALVES.............................................. 63 Charge Relief Valve............................................. 63 Filter Relief Valve............................................. 63 Charge Inlet Relief Valve....................................... 63 High Pressure Relief Valve...................................... 63 MICRON FINAL FILTER ELEMENT REPLACEMENT............................. 64 TEMPERATURE AND PRESSURE SWITCHES................................... 64 REMOVAL OF HYDROSTATIC PUMP ASSEMBLY................................ 65 INSTALLING HYDROSTATIC PUMP......................................... 65 REMOVAL OF HYDROSTATIC MOTOR........................................ 66 INSTALLING HYDROSTATICMOTOR......................................... 67 New Hydrostatic Pump & Motor.................................... 67 HYDROSTATIC PUMP OR MOTOR DISASSEMBLY .............................. 69 INSPECT PARTS FOR WEAR.............................................. 70 TO ASSEMBLE PUMP OR MOTOR........................................... 70 STARTING PROCEDURE, AFTER REPAIR.................................... 71 FINAL DRIVE SYSTEM...................................................... 73 FINAL DRIVE SYSTEM.................................................. 75 Description..................................................... 75 REMOVAL OF REDUCTION HOUSING........................................ 75 DISASSEMBLY OF REDUCTION HOUSING ................................... 75 Removal Of The Intermediate Gear (6)............................ 75 Removal Of Input Drive Gear (7)................................. 76 Removal Of Output Gear (14)..................................... 76 ASSEMBLY OF REDUCTION HOUSING....................................... 76 Installing The Output Shaft And Gear............................ 76 Installing Input Shaft And Gear................................. 76 Installing Intermediate Gear.................................... 76 Drive Chain Adjustment (Internal Adjustment Type)............... 76 Drive Chain Adjustment (External Adjustment Type)............... 77 Drive Chain Idler Removal (Internal Adjustment Type)............ 77 To Disassemble The Idler Gear (Internal)........................ 78 Drive Chain Idler Removal (External Adjustment Type)............ 78 REMOVAL OF DRIVE CHAIN.............................................. 79 INSTALLING DRIVE CHAIN.............................................. 79 REMOVAL OF AXLE..................................................... 80 Removal Of Rear Axle............................................ 80 Removal Of Front Axle........................................... 80 Installation Of The Axle........................................ 81 AXLE BEARING AND SEAL REPLACEMENT................................... 81 NSTALLATION OF AXLES PROCKET........................................ 82 PARK BRAKE REMOVAL.................................................. 82 MAIN FRAME.............................................................. 83 MAIN FRAME.......................................................... 85 Description .................................................... 85 REMOVAL OF ROPS..................................................... 85 PIVOT PIN AND BUSHING REPLACEMENT .................................. 85 BOB–TACH REMOVAL.................................................... 85 LIFT ARMS REMOVAL................................................... 86 FUEL TANK REMOVAL................................................... 86 Removing Fuel Tank On Loader S/N 16999 & Below ................. 86 Removing Fuel Tank On Loader S/N 17001 & Above.................. 86 ELECTRIC MOTOR FOR ROPS (Cab Tilt – S/N 19126 & Below).............. 86 Removal Of Tilt Mechanism....................................... 87 MECHANICAL TILT FOR THE ROPS (S/N 19127 & Above).................... 87 ELECTRICAL SYSTEM....................................................... 89 ELECTRICAL SCHEMATICS............................................... 93 ELECTRICAL CIRCUITRY................................................ 97 PROBLEM ANALYSIS.................................................... 97 FAN BELT............................................................ 99 TO CHECK ALTERNATOR OUTPUT.......................................... 99 TO CHECK THE REGULATOR.............................................. 99 ALTERNATOR SERVICE..................................................100 Removal (ROPS Must Be Tilted)...................................100 Disassembly.....................................................100 To Check Rotor..................................................100 To Check Stator ................................................100 To Check Diode Trio.............................................101 To Check Rectifier..............................................101 Assembly........................................................101 STARTER SERVICE.....................................................102 To Check The Starter............................................102 To Remove Starter...............................................102 Disassembly And Inspection......................................102 Assembly........................................................102 ENGINE SERVICE..........................................................103 INTRODUCTION........................................................105 Engine Parts....................................................105 Engine Number Location..........................................105 STARTING A NEW OR RECONDITIONED ENGINE..............................105 ENGINE OVERHAUL.....................................................105 Engine Removal..................................................105 Cylinder Head Maintenance.......................................106 To Remove The Valves............................................107 Combustion Chamber Inserts......................................107 Reconditioning Cylinder Heads...................................108 Cleaning........................................................108 Inspection......................................................108 Reconditioning Of Valves AndValve Seats.........................109 Valve Seat Inserts..............................................109 To Install Inserts..............................................109 To Disassemble The Rocker Shaft Assembly.......................110 To Assemble The Rocker Shaft Assembly..........................111 Push Rods.......................................................111 To Install The Valves...........................................111 INSTALLING CYLINDER HEAD............................................112 Cylinder Head Gasket............................................112 To Install The Cylinder Head...................................112 CONNECTING RODS AND PISTONS.........................................113 To Remove Pistons And Connecting Rods...........................113 To Remove Pistons And Rings From The Connecting Rods............114 Inspection......................................................114 To Install The Pistons To The Connecting Rods...................114 Installing The Piston Rings.....................................115 To Install Rings................................................115 To Install Piston And Connecting Rod Assemblies.................116 Installing New Pistons..........................................116 Cylinder Liners.................................................117 To Install New Cylinder Liners..................................117 CRANKSHAFT AND MAIN BEARINGS........................................117 Description.....................................................117 To Install Main Bearings And Thrust Washers.....................118 To Install Thrust Washers.......................................118 To Remove The Crankshaft........................................119 To Reinstall The Crankshaft.....................................120 Crankshaft Rear End Oil Seal....................................121 FLYWHEEL AND FLYWHEEL HOUSING.......................................121 To Remove The Flywheel..........................................121 To Replace The Flywheel Ring Gear...............................121 To Reinstall The Flywheel.......................................122 To Install The Flywheel Housing.................................122 TIMING CASE AND DRIVE...............................................122 To Remove The Timing Case Cover.................................122 Replacement Of The Crankshaft Front Oil Seal....................123 To Install The Timing Case Cover................................123 To Remove The Idler Gear And Hub................................123 To Install The Idler Gear And Hub...............................123 To Remove The Camshaft Gear.....................................124 To Install The Camshaft Gear....................................124 To Remove The Fuel Pump Gear....................................124 To Install The Fuel Pump Gear...................................124 To Remove The Fuel Pump Drive Hub...............................125 To Install The Fuel Pump Drive Hub..............................125 To Remove The Timing CaseBack Plate............................125 To Install The Timing Case Back Plate...........................126 To Remove The Camshaft And Tappets..............................126 To Install The Tappets And Camshaft.............................126 Timing Marks....................................................127 To Reset The Engine To The Original Timing......................127 Timing Pin......................................................128 Check Valve Timing..............................................128 Adjusting Valve Clearance.......................................129 Valve Adjustment Sequence.......................................129 LUBRICATION SYSTEM..................................................129 The Lubricating Oil Pump........................................129 To Remove The Sump..............................................129 To Install The Oil Pan..........................................129 To Remove The Oil Pump..........................................130 To Dismantle The Oil Pump.......................................130 Inspection......................................................130 To Assemble The Oil Pump........................................131 To Install The Oil Pump.........................................131 Oil Pressure Relief Valve.......................................131 To Dismantle The Oil Pressure Relief Valve......................132 To Assemble The Oil Pressure Relief Valve.......................132 COOLING SYSTEM......................................................132 Fan Belt........................................................132 Adjustment Of Fan Belt..........................................132 Water Pump......................................................133 Remove The Water Pump...........................................133 To Disassemble The Water Pump...................................133 Inspection......................................................133 To Assemble The Water Pump......................................134 To Install The Water Pump.......................................134 Thermostat......................................................134 To Remove The Thermostat........................................134 To Test The Thermostat.........................................135 Replacement Of The Thermostat...................................135 FUEL SYSTEM.........................................................135 To Test Fuel Lift Pump..........................................135 To Remove The Lift Pump.........................................135 Fuel Injection Pump.............................................136 To Remove The Fuel Injection Pump...............................136 To Install The Fuel Injection Pump..............................136 Checking Fuel Injection Pump Timing.............................136 Timing The fuel Injection Pump (Using Timing Tool MS 67123).....137 Checking The Timing Mark On The Flange Of The Injection Pump....139 Injector Problems...............................................140 Testing For Faulty Injector.....................................140 Injector Removal................................................140 Injector Installation...........................................140 Fuel Pipes (High Pressure)......................................140 Using C.A.V. Thermostart Units..................................141 Charging The Fuel System........................................142 SPECIFICATIONS..........................................................143 SPECIFICATIONS......................................................145 Cylinder Block..................................................145 Cylinder Liner (Cast Iron)......................................145 Pistons.........................................................145 Piston Rings....................................................145 Piston Pin Bushing..............................................145 Connecting Rod..................................................145 Connecting Rod Alignment........................................146 Crankshaft......................................................146 Crankshaft Thrust Washers.......................................146 Main Bearings...................................................146 Connecting Rod Bearings.........................................146 Camshaft........................................................147 Camshaft Thrust Plates..........................................147 Cylinder Head...................................................147 Combustion Chamber Inserts......................................147 Valve Guides (Inlet)............................................147 Valve Guides (Exhaust)..........................................147 Valves (Inlet)..................................................148 Valves (Exhaust)................................................148 Inner Valve Springs.............................................148 Outer Valve Springs.............................................148 Rocker Levers...................................................148 Valve Clearance.................................................148 Rocker Shaft....................................................148 Push Rods.......................................................148 Lifters.........................................................148 TIMING GEARS........................................................149 Injector Pump Gear..............................................149 Crankshaft Gear.................................................149 Timing Gear Backlash............................................149 LUBRICATION SYSTEM..................................................149 Lubricating Oil Pump............................................149 Pump Clearances.................................................149 Lubricating Oil Pump Drive Gear.................................149 Relief Valve (Lube Oil).........................................149 Lubricating Oil Filter..........................................149 COOLING SYSTEM......................................................149 Thermostat......................................................149 FUEL SYSTEM.........................................................149 Fuel Lift Pump..................................................150 Final Fuel Filter...............................................150 Fuel Injection Pump.............................................150 Injectors.......................................................150 Starting Aid....................................................150 SERVICE WEAR LIMITS.................................................150 DE–RATING FOR ALTITUDE..............................................151 TORQUE SPECIFICATIONS...............................................151 Hydrostatic Pump and Motor......................................151 High Pressure Relief Valves.....................................151 Loader Torque Specs.............................................151 STANDARD TORQUE SPECIFICATIONS FOR BOLTS............................152 DECIMAL AND MILLIMETER EQUIVALENTS..................................153 U.S. TO METRIC CONVERSION...........................................153 SPECIAL TOOLS.......................................................154 825 LOADER SPECIFICATIONS...........................................155 SPECIFICATIONS..................................................155 ENGINE..........................................................155 LOADER HYDRAULICS...............................................156 ELECTRICAL......................................................156 DRIVE SYSTEM....................................................156 CAPACITIES......................................................156 TIRES...........................................................156 ALPHABETICAL INDEX......................................................157 SERVICE BULLETINS.......................................................161 825-001.............................................................161 825-002.............................................................163 825-003.............................................................165 825-004.............................................................167 825-005.............................................................169 SERVICE MANUAL REVISIONS................................................161 825-1...............................................................171 825-2...............................................................173 825-3...............................................................175
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
