Bobcat 825 Skid Steer Loader 6549899 (6-12) (Preview)
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
– 825-4
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