Академический Документы
Профессиональный Документы
Культура Документы
2
Service
Manual
1 of 176
2 of 176
Dealer Copy -- Not for Resale
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
3 of 176
4 of 176
Dealer Copy -- Not for Resale
FORWARD PREVENTIVE
This manual provides instruction for proper routine service and adjustment of the Bobcat, and
MAINTENANCE
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.). HYDRAULIC
SYSTEM
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.
HYDROSTATIC
2. Inspect for any sign of fuel, oil or hydraulic fluid leaks. DRIVE SYSTEM
7. Check for loose drive chains by lifting the rear of the machine and turning the rear wheels
MAIN
by hand. FRAME
9. Check the Bob–Tach attachment for condition. Inspect the wedges for damage or wear.
ELECTRICAL
10. Inspect safety items for condition (ROPS Guard, Seat Belt, Safety Treads, Lights, etc.). SYSTEM
SPECIFICATIONS
CONTENTS
825 Loader
5 of 176 –1––3– Service Manual
Dealer Copy -- Not for Resale
825 Loader
6 of 176 –1––2– Service Manual
PREVENTIVE MAINTENANCE PREVENTIVE
MAINTENANCE
Paragraph Page
Number Number
BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–30 1–16
DRAINING THE FLUID RESERVOIR . . . . . . . . . . . . . . . . . . 1–19 1–12
ELECTRICAL SYSTEM MAINTENANCE . . . . . . . . . . . . . . . 1–15 1–10
ENGINE AIR INLET SYSTEM (Air Cleaner) . . . . . . . . . . . . . . 1–7 1–6
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8 1–7
ENGINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 1–4
ENGINE OIL AND FILTER REPLACEMENT . . . . . . . . . . . . . 1–6 1–5
FAN BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9 1–7
FINAL DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23 1–14
FLUSHING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . 1–10 1–7
FUEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 1–8
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11 1–8
FUEL SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13 1–9
HYDRAULIC FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17 1–11
HYDRAULIC FLUID FILTERS . . . . . . . . . . . . . . . . . . . . . . . . 1–18 1–11
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16 1–11
HYDRAULIC SYSTEM LEAK CHECKS . . . . . . . . . . . . . . . . 1–20 1–13
HYDROSTATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 1–22 1–13
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 1–1
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–28 1–15
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–21 1–13
825 Loader
7 of 176
Revised Feb. 82 –1––1– Service Manual
Dealer Copy -- Not for Resale
825 Loader
8 of 176 –1–0– Service Manual
INTRODUCTION
1–1.1 Symbols Serial Number
Plate
WARNING
Instructions are necessary
before operating or servicing
machine. Read Operation &
Maintenance Manual,
Handbook and signs (decals)
on machine. Follow warnings
and instructions in the
manuals when making repairs,
adjustments or servicing.
Check for correct function
after adjustments, repairs or B–02969R
service. Failure to follow Fig. 1–1 Loader Serial Number Plate
instructions can cause injury
or death [A].
W–2003–0797
4970 A 1001 M
Plant Location
Production Sequence
Lot Code
Model, Engine Version
All items on the 30–hour inspection form (Fig. 1–4) must be completed by the
mechanic according to specification in this manual.
When the 30 hour inspection has been completed, the form must be signed by the
mechanic that completed the inspection, dealer person and owner or operator.
One copy of the completed form is for the owner of the loader. Another copy is to
be sent to the attention of Service Department, Melroe Division. The remainder Fig. 1–4 30 Hour Inspection Form
copy is for the dealer.
825 Loader
10 of
Revised Feb. 82176 –1–2– Service Manual
SERVICE SCHEDULE
Maintenance work must be done at regular intervals. Failure
to do so will result in damage to the Bobcat loader or the
engine. The SERVICE SCHEDULE is a guide for correct
maintenance of the Bobcat loader. DO NOT change this
SERVICE SCHEDULE unless you increase the frequency of
service when the Bobcat loader is operated in very hot, cold, Never go under or reach under lift arms or a lift
dusty or corrosive conditions. cylinder without an approved lift arm stop
installed, or you could be crushed.
W–2060–0887
NOTE: Check the torque of the cylinder head bolts during the 30 hour inspection. Adjust valve tappets after
making torque adjustment.
825 Loader
11 of 176 –1–3– Service Manual
Revised Feb. 82
1–3 REAR GRILL
825ServiceManual#6549899–PreventiveMaintenanceSectionPages1–4
Grill
The rear grill is opened by pulling forward Handle
and up on the rubber fastener (Fig. 1–5).
Lift up the engine cover, pull up on the
handle to release the grill. Pull the grill
open (Fig. 1–6).
1–4 TILTING THE OPERATOR GUARD Latch
NOTE: Always install the retaining nuts after ROPS is lowered and before
operating Bobcat.
2. Put the lift arms all the way down or hold the lift arms up with a LIFT ARM
STOP. The LIFT ARM STOP must be installed by a second person while the
operator is in the operator seat.
4. Remove the nuts on each side of the operator guard at the rear corners (Fig.
1–7).
5. The hex bolt for the mechanical tilt is located on the right side of the loader B–01796
between the wheels (Fig. 1–8A). Use a rachet and socket (Fig. 1–8a) and Fig. 1–7 ROPS Retaining Nuts
tilt the operator guard into the full forward position (Fig. 1–9).
NOTE: DO NOT exceed 50 ft–lbs. (68 Nm) torque on the hex bolt used to
raise or lower the operator guard. Raise
WARNING
Tilt
DO NOT raise or lower the Switch
operator’s guard with the
engine running.
W–2303–0298
825 Loader
12 of
Revised Feb. 82176 –1–4– Service Manual
1–4.1 ROPS Tilt Motor
To seal out water from the ROPS tilt
motor, clean the area (Fig. 1–9a, Item
1). Seal electric wire opening the R.T.V.
(Room Temperature Vulcanizing) type
compound. 1
3. Oil level must always be kept between the Min and Max marks on the dipstick
(Fig. 1–10 & 1–11).
Max.
Min.
A–01528
Fig. 1–10 Dipstick
Fill Pipe
Dipstick
B–01789
Fig. 1–11 Engine Oil Dipstick/Fill Locations
825 Loader
13 of 176
Revised Feb. 82 –1–4a– Service Manual
825ServiceManual#6549899–PreventiveMaintenanceSectionPages4a–4b
825 Loader
14 of 176 –1–4b– Service Manual
NOTE: Do not use synthetic lubricating oils.
Use oil of correct SAE viscosity for expected temperature conditions at the time
of starting, not for the highest temperature expected during the working day.
SAE 40 or 20W–50
SAE 10W–30/40
SAE 15W–40
SAE 5W–30
SAE 30W
SAE 20W/20
SAE 10W
F°–30 –20 –10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +110 +120 +130 +140
Replacement of oil filter element. (Allow warm engine to set for a few minutes
before removing the oil to prevent spillage when the filter element is removed).
1. Use a filter wrench to remove the spin–on filter element from the lower right
hand side of engine.
2. Clean the filter head thoroughly, removing all oil, sludge, dirt, etc.
Drain Plug
3. Put oil on seal and turn new element on to filter head. Tighten the element
until hand tight.
Start the engine and run it for a few minutes, and check for leaks at the filter. Stop
the engine, check the oil level and add oil if necessary. Fill to the full mark on the
dipstick. Do not overfill, as this causes oil foaming, oil consumption, high engine
temperature and oil leaks at the engine seals.
A–02275
Fig. 1–12 Engine Oil Drain Plug
825 Loader
15 of 176
Revised Feb. 82 –1–5– Service Manual
1–7 ENGINE AIR INLET SYSTEM (AIR
CLEANER)
Correct maintenance of air inlet system Dust Cap
is necessary for long engine life. A small
leak in the system can destroy an
engine in a few minutes. Set up a
schedule for inspection and follow it
regularly. To service the filter, follow
these steps:
3. Before installing the new cartridge, wipe all foreign material from the filter
housing.
4. Install clean cartridge carefully to be sure of good seal. Be sure that the Reset Button
cartridge gasket is in good condition and the new plastic washer is correctly
5. Press the reset button on the condition indicator to reset the red ring.
Window
Air cleaners must be inspected regularly for leaks or damage. A damaged air
cleaner can badly effect the performance of an engine.
The following air cleaner service procedures can be taken when the engine is to
be serviced in the field:
1. Check all connections for tightness, making sure that the air cleaner outlet
pipe and air inlet hose are complete. Indicator
2. If the air cleaner has been damaged, check all connections immediately.
Check the internal cartridge seal areas. Make replacement of the air cleaner A–02291
body if necessary. Fig. 1–14 Condition Indicator
Element
4. Inspect the intake manifold gasket
for damage or looseness which
can cause dirty air to enter the
engine.
B–01791
Fig. 1–15 Removing Air Cleaner Element
825 Loader
16 of 176
Revised August 79 –1–6– Service Manual
1–8 ENGINE COOLING SYSTEM Radiator
Cap
Correct coolant level must be kept to cool the engine or overheating will result.
Check the coolant level in the radiator daily and fill to 2.0 inches below the filler
neck when level is low (Fig. 1–16). Remove radiator cap carefully, after engine has
cooled. The cooling system is under pressure. The pressure rating of the cap is
7 PSI. During freezing temperatures, a correct mixture of Ethylene Glycol and
water must be used to protect coolant from freezing. The capacity of the cooling
system is 10 U.S. quarts (9.46 liters).
The radiator grill area must be kept free from debris for good cooling. Use an air
or water pressure nozzle and blow from the outside to remove foreign material.
Remove the oil cooler if necessary to remove debris deposits between the engine
radiator and oil cooler (Fig. 1–17).
B–01808
Fig. 1–16 Checking Radiator Level
1. Loosen the generator adjustment lever bolt (Fig. 1–18, Item 1).
A–02289
Fig. 1–17 Cleaning Engine Radiator
2. Loosen the generator bracket fastening bolt above the generator (Item 2).
3. Move the generator towards or away from the engine to either loosen or
tighten the belt. Make adjustment of belt tension to give 0.375 inch of play Mounting
at the middle point between the pulleys (Item 3). Bolt
4. When belt tension is correct, tighten the adjustment bolt and fastening bolt.
A–02287
Fig. 1–18 Adjusting Fan Belt
825 Loader
17 of 176
Revised January 77 –1–7– Service Manual
1–11 FUEL SYSTEM
WRONG
B–01794R
Fig. 1–20 Fuel Fill Pipe Location
3. Regularly remove the fuel tank plug (Fig. 1–21), and remove water.
B–01811
B–01812
Fig. 1–21 Fuel Tank Drain
825 Loader
18 of
Revised Feb. 82176 –1–8– Service Manual
1–13 TO SERVICE THE FUEL
SYSTEM 3
1
The engine is equipped with two fuel
filters; a filter which holds water and a Secondary
secondary filter (Fig. 1–22). The filter Filter
element (Fig. 1–22, Item 1) must be
replaced every 250 hours of operation.
Clean the water filter (sediment bowl)
(Fig. 1–22, Item 2) at regular intervals
(See SERVICE SCHEDULE).
2
Loosen
5. Install the new filter element in
position and install the bolt. Do not
over–tighten the bolt.
2
1. Loosen the plug at the top of the injector pump housing (Fig. 1–23, Item 1).
2. Loosen the plug at the side of the injector pump housing (Fig. 1–23, Item 2). 1
3. Loosen the bolt (Fig. 1–24, Item 1) on the top of the final fuel filter.
Loosen
B–01798R
Fig. 1–24 Fuel Filter Bolt
825 Loader
19 of 176
Revised Feb. 82 –1–9– Service Manual
4. Operate the lever on the fuel lift pump (Fig. 1–25) pushing the fuel and air
through the vent plugs.
NOTE: If the lift pump will not pump fuel, rotate the engine a small amount.
5. When solid flow of fuel flows from the vent plugs (no air bubbles), tighten all
the vent plugs in the following order:
(a) Final fuel filter bolt (Fig. 1–24, Item 1).
(b) Injector pump housing side plug (Fig. 1–23, Item 2).
(c) Injector pump housing top plug (Fig. 1–23, Item 1).
6. Loosen the fittings on the high pressure lines of the injectors (Fig. 1–26).
7. Move the throttle to half open position. Turn the engine with the starter until B–03873
no air bubbles show at the fittings of the injectors. Tighten all the high Fig. 1–25 Fuel Lift Pump
pressure fittings.
1. Check battery electrolyte level and fill as needed with distilled water.
2. Check battery cables for corrosion. Remove acid corrosion with soda and
water solution. Cover connections with grease to prevent corrosion deposit.
3. Check alternator drive belt tension. Adjust for 0.375 inch play at the middle
point between pulleys (Fig. 1–18).
4. Check the condition of the wiring to the warning indicators (Alt., Trans–Hot, Sender
Wire
Trans–Fit, Eng–Hot and Eng–Oil). Check the Trans–Hot and Eng–Hot
indicators regularly to see if they are in working condition. The Trans–Hot
sender switch is located at the top of the oil cooler and the Eng–Hot sender
switch is located on the engine head beside the thermostat housing. To
check these warning indicators, turn the ignition switch at the dash panel to
ON, remove the wire from the sender switch and put it against the frame. The
indicator must light when the wire is in contact with frame (Fig. 1–27). The
other warning lights must always light up whenever the ignition switch is
turned on and go out after the engine has started. Warning lights that still
have light while engine is running are an indication of a malfunction in the
system. If this happens, stop the engine immediately and troubleshoot.
A–02288
Fig. 1–27 Grounding Sender Wire
825 Loader
20 of
Revised Feb. 82176 –1–10– Service Manual
1–16 HYDRAULIC SYSTEM
1–16.1 Hydraulic/Hydrostatic Transmission Fluid
Use Clark hydraulic/hydrostatic transmission fluid (P/N 6563328). This fluid is
available at Chicago Central Parts. 10W–30 or 10W–40 SAE Motor Oil API Class
SE or SF can also be used. Dipstick
4. Lower the ROPS cab, set the throttle at about 1/2 throttle, set steering
controls in neutral and start the engine.
5. With the engine running, check the filter housing area for any indication of
leaks.
6. Slowly move the steering levers to activate the transmission. Drive forward
and backward at slow intervals. Continue to drive the loader until all
indication of air is out of the system.
825 Loader
22 of 176 –1–12– Service Manual
Regularly (depending on humidity and/or
temperature change) lift the rear of the
loader and let stand overnight. Loosen
the drain plug to allow water, if any, to run
out. A large quantity of water in the sump
may cause permanent damage to the
hydraulic and transmission system.
1–20 LEAKS
Regular inspection must be made to find
leaks at tube fittings, hose connections,
lift and tilt cylinders, filters, etc. A leak in
the hydraulic system must not be
permitted. Even a small leak can amount
to a large loss of fluid in a short period of
time. Most leaks are easily repaired.
Sometimes, tightening a fitting or hose
clamp is all that is necessary. Do not over
tighten tube fittings, as this can cause a
greater leak. A tube fitting that still leaks B–01803
after it has been properly tightened must Fig. 1–33 Cleaning The Oil Cooler
be disconnected and checked for foreign
particles or damaged joint. If the seat is
cracked or has deep scratches, the part
must have replacement made.
2. Use an air nozzle or water spray and blow from the outside of the cooler (Fig.
1–33).
3. Use a thin soft (plastic or wood) rod to help remove material. Also clean the
engine radiator.
A high temperature warning switch is installed at the top of the oil cooler. If the
hydraulic system overheats, the switch closes and lights the Trans–Hot indicator
on the dash panel. Be sure the wire is correctly connected to the switch.
1–22 CARE OF THE HYDROSTATIC TRANSMISSION
Good preventive maintenance practice is an important item in adding to the life
of the transmission. When adding fluid to the reservoir, be sure that the fluid is very
clean. Do not let dirt fall into the reservoir, fill pipe, and be sure to install the filler
cap. Use only correct oil when filling the reservoir. (See Transmission Fluid, page
1–11).
825 Loader
23 of 176
Revised January 77 –1–13– Service Manual
1–22.1 Loader Start–Up
Follow these procedures when starting
the loader, after servicing:
C–01759
Fig. 1–34 Checking Drive Chain Freeplay
1–22.2 Cold Weather Start–Up
Allow additional warm–up time during low temperature conditions. Run the engine
at low RPM and activate the cylinders and control valves for several minutes until
the oil is warm to the touch.
1. Lift the Bobcat until all four wheels are off the ground.
2. Take hold of one of the wheels and turn it back and forth (Fig. 1–34). If there
is more than 0.250 inch of free play measured at the tire tread, the chain
needs adjustment. Check the free play at each side of the loader. See
Section 4 for drive chain adjustment.
1–24 TIRES
Several types of tires are available to fit the use of the Bobcat. It is very important
that the Bobcat be equipped with the correct tires for its use. The following basic
tires are recommended for use indicated:
8:25 x 15 – 6 ply, standard . . . . . . . . . . Standard, regular construction loading,
excavation, quarry, mine
12:00 x 16.5 – 6 ply, flotation, . . . . . . . . . . . Flotation and traction, mud, swamp,
coal mine, bar lug tread sand
825 Loader
24 of 17677
Revised January –1–14– Service Manual
NOTE: Do not use ballast in tires.
A–01250
Fig. 1–35 Tire Rotation
1–27 TIRE REPLACEMENT
The tires on the Bobcat Loader are
specially designed for it. Exchanging
them with any other tire tread, or size, CODE FOR SYMBOLS
1–28 LUBRICATION
Refer to the SERVICE SCHEDULE for
lubrication intervals. Figure 1–36 shows
the location of grease fittings on the 825
Bobcat. There are 15 lubrication points.
Use a good multipurpose lithium base
grease when making lubrication of the
Bobcat, and add grease until it shows. In
addition to the grease fittings shown in
Figure 1–36, put lubricant on the engine
door hinges, engine cover hinge and
engine throttle pivot. Use medium
engine oil for this purpose. Also remove (Early)
the seat and put grease on the seat rails
to keep them working smoothly. (Current)
825 Loader
25 of 176
Revised Feb. 82 –1–15– Service Manual
1–30 BOB–TACH
825ServiceManual#6549899–PreventiveMaintenanceSectionPages5–16
Unlocked
Check the Bob–Tach locking lever
and wedges for wear or damage. The
lever springs must compress enough
to hold the levers in over–centered
(lock) position when the levers are
pushed down (Fig. 1–37, 1–38).
Spring tension adjustment is Locked
possible. Check the wedges for
condition and move locking levers to
see that the wedges move far enough
to correctly engage a bucket or
attachment. Bent or broken wedges
must have replacement made.
If new style Bob–Tach is to be
installed on a Bobcat with old style
cylinder, (Serial Number 12000 & Wedges
Below) it will be necessary to cut off
0.625 inch from each end of the rod B–01508
end trunnion (Fig. 1–38a). Fig. 1–37 Bob–Tach (Old Style)
Tighten
Lock
0.625” 0.625”
A–02427 A–02464
Fig.1–38a Cutting Old Style Cylinder Rod Fig.1–39 Park Brake
825 Loader
26 of 176
Revised August 79 –1–16– Service Manual
HYDRAULIC SYSTEM
Paragraph Page
Number Number
CONTROL PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9 2–9
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7 2–6 HYDRAULIC
GEAR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4 2–4 SYSTEM
GEAR PUMP DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5 2–4
HYDRAULIC CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10 2–10
HYDRAULIC CYLINDER REPAIR . . . . . . . . . . . . . . . . . . . . . 2–11 2–10
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 2–1
HYDRAULIC SYSTEM TROUBLESHOOTING . . . . . . . . . . . 2–3 2–2
INSPECT PARTS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . 2–6 2–5
LIFT VALVE SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8 2–8
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12 2–12
TUBELINES, HOSES, FITTINGS . . . . . . . . . . . . . . . . . . . . . . . 2–2 2–1
825 Loader
27 of 176 –2––1– Service Manual
Dealer Copy -- Not for Resale
825 Loader
28 of 176 –2–0– Service Manual
29 of 176
Dealer Copy -- Not for Resale
30 of 176
Dealer Copy -- Not for Resale
31 of 176
Dealer Copy -- Not for Resale
32 of 176
Dealer Copy -- Not for Resale
33 of 176
Dealer Copy -- Not for Resale
34 of 176
Dealer Copy -- Not for Resale
35 of 176
Dealer Copy -- Not for Resale
36 of 176
Dealer Copy -- Not for Resale
37 of 176
Dealer Copy -- Not for Resale
38 of 176
Dealer Copy -- Not for Resale
2–1 HYDRAULIC SYSTEM
Description: The hydraulic system is made up of a 25 micron filter, gear type
implement pump, control valve, hydraulic cylinders and the oil cooler. See the
color flow chart PI–2511 for full description of the hydraulic system.
825 Loader
39 of 176
Revised Feb. 82 –2–1– Service Manual
Fitting Size Rotate No. of Hex Flats Mark a Line on Nut
and Adapter Before Torquing
1/2 inch 2
5/8 inch 1–1/2 – 2
3/4 inch 1
7/8 inch 3/4 – 1
1 inch 3/4 – 1 Misalignment of Marks Shows
Amount to Tighten
(See Chart)
1. Tighten the nut hand tight with a wrench until it contacts the seat.
2. Mark a line on the length of the nut and the adapter (Fig. 2–2).
3. Use a wrench to rotate the nut to tighten to the amount shown in the chart.
If the fitting leaks after tightening, disconnect it and inspect the seat area for A–01897
damage. Make replacement of the part if it is damaged. Fig. 2–2 Tightening Flared Fittings
A–01852
Fig. 2–3 Straight Thread Seal
825 Loader
40 of 176 –2–2– Service Manual
CHART A
NO OR SLOW HYDRAULICS
Check Check If
Check Check Defect Make Repair
Suction If Pump If Pedal Or
Fluid Level Output Linkage
And Type Side Fittings Is Replacement
(Of Pump) Good Page 2–4 Good Page 2–9 Of Linkage
Found
If Output If No Defect
Is Still Low Is Found
Check Check If
Pump Release Pressure Make Repair
If Output If Pressure
Is Still Low Is Correct
If
Make Repair Defect Make Repair
Check Valve Or
Or Assembly
Replacement Is Replacement
Page 2–6 Of Valve
Of Pump Found
CHART B CHART C
ROUGH ACTION OR NO ACTION NO LIFT, NO TILT OR NO AUXILIARY
OF HYDRAULIC CYLINDERS
Check If No If No
Check If Check Defect Check Defect Check
Fluid Level Suction Side Cylinder Seals Linkage Rods Valve Section
And Type Of Pump For Page 2–11 Page 2–9 Page 2–6
Correct Air Leaks Is Is
Found Found
825 Loader
41 of 176 –2–3– Service Manual
2–4 GEAR PUMP
2–4.1 Testing
NOTE: With the tester connected this way, there is no relief valve in the
hydraulic circuit. Closing the pressure control valve fast can cause
very high pressure and damage the pump. Turn the knob very
slowly as the pressure begins to increase. Do not go over 2200 PSI.
9. Turn the pressure control valve slowly until the pressure is 2100 PSI. Correct
flow is 12.5 GPM.
10. If an indication of 12.5 GPM and/or 2100 PSI is not present, check for air
leaks. If, after checking for air leaks, there is still not 12.5 GPM at 2100 PSI,
remove and make pump repairs.
16 5
Reverse the above procedure to install.
Tighten the fastening bolts to 33 ft–lbs. C–01090
torque. Fig. 2–6 Gear Pump Breakdown
825 Loader
42 of
Revised Feb. 81176 –2–4– Service Manual
2–5 DISASSEMBLY OF GEAR PUMP (Fig. 2–6)
1. Clean outside of pump thoroughly.
2. Clamp pump in vise, shaft down.
3. Remove four tie bolts (Item 1).
4. Remove two tie bolts (Item 2).
5. Use a sharp tool to mark across front place, body and back plate. This will
aid in correct assembly.
6. Remove the pump from the vise. Hold the pump in both hands and hit the
shaft against a wooden block to separate the front plate (Item 3) from the
back plate (Item 4). The body (Item 5) will hold to either the front plate or the
back plate.
7. To separate the body from the section it is with, put drive gear (Item 6) in the
bearing and hit the end with a plastic hammer.
8. Remove the O–ring (Item 7) from the back plate assembly.
9. Remove the diaphragm (Item 8) from the front plate by using a sharp tool.
10. Remove the springs (Item 9), two each, and steel balls (Item 10), two each,
from the front plate.
NOTE: Some pumps only have one spring (Item 9) and ball (Item 10). Make
sure they are installed in the correct location (pressure side of the
gears).
12. Lift the diaphragm seal (Item 13) from the front plate.
13. Remove the shaft seal (Item 14) from the front plate.
2–6 TO INSPECT PARTS FOR WEAR
2–6.1 General
1. Clean and dry all parts.
2. Use an emery cloth to remove scratches from all parts.
825 Loader
43 of 176
Revised Feb. 81 –2–5– Service Manual
3. Bearings in front plate must be flush with lands in groove pattern.
4. Check for wear on face of back plate – if wear is more than 0.0015 inch, back
plate needs replacement.
2–6.3 Body
1. Check inside gear pockets for wear.
2. Body needs replacement if I.D. of gear pocket is more than 1.719 inch.
3. Press protector gasket (Item 12) and back–up gasket (Item 11) into
diaphragm seal.
4. Put steel balls (Item 10) into respective seats and put springs (Item 9) over
balls.
7. Put gear assemblies into oil and install in front plate bearings.
9. Apply a thin amount of thick grease to both machined faces of body. Slide
body over gears onto front plate – half moon shaped openings in body must
face away from front plate (note small drilled hole in one of openings). This
hole must be on pressure side of pump.
11. Slide back plate over gear shafts until dowel pins are engaged.
12. Install bolts (Items 1 & 2) and tighten evenly to 23 ft.–lbs. torque.
13. Install shaft seal over drive gear shaft taking care not to cut rubber sealing
lip. (Put oil on seal before assembly.)
15. Rotate pump shaft by hand or with pliers. Pump will have small amount of
resistance, but will turn freely after short period of use.
4. Activate auxiliary pedal and check flow meter to see if tester hoses are
correctly connected. Hydraulic
Tester
5. Increase engine to full RPM. C–01823
Fig. 2–7 Testing Relief Pressure
825 Loader
44 of 176 –2–6– Service Manual
6. Activate auxiliary pedal so
pressure goes over relief
setting. 4
3
7. Correct pressure is 2100–2150
PSI.
5. If a valve section is to be
disassembled, place it in a vise. Be B–01511R
careful not to clamp the machine
surface in the vise jaws. Fig. 2–10 Hydraulic Control Valve Breakdown
6. Remove the die cast bonnet from the back of the section (Fig. 28, Item 2).
NOTE: When disassembling the lift valve section, remove the snap ring
from the float detent rod at the end of the bonnet before removing
the bonnet. The detent rod must be with the spool assembly or the
four steel balls will fall out of their holes. A restrictor is also located
in the B (rear) tubeline opening, on top of the valve section (Fig. 2–8,
7. Remove the spool by pulling it out the rear of the valve section.
8. Remove the front seal plate and O–ring. Remove the rear seal retainer and
O–ring.
9. Remove the large hex plugs (load check valves) (Fig. 2–8, Item 4) located
above the spool bore on each end of the valve section. Carefully remove the
spring and poppet (Fig. 2–8, Item 1).
10. Wash all the parts in solvent and place them on a clean surface.
825 Loader
46 of 176 –2–8– Service Manual
NOTE: Install the rear O–ring seals
and seal retainer on the spool
before installing spool in the Valve Section
valve section. Push the spool
into the rear of the valve
section (Fig. 2–12). Retaining Washer
7. Install new O–rings into the counterbores on the sides of the valve sections.
9. After all the control valve sections have been assembled, install the thru bolts
and the nuts. Tighten the nuts to 20 ft.–lbs. torque. Do not overtighten.
10. With the control valve clamped in a vise, check the operation of each spool
for free movement and centering.
If any spool restriction is noted and spool does not displace properly, try rotating
the spool 180°. If this does not help, loosen the three thru bolt nuts and check spool
movement. If spool movement is now normal, use care in tightening the thru bolt
nuts. To install the valve back into the machine, reverse the removal procedure.
A–01924
Fig. 2–13 Reassembly Of Valve
STEP 4
NOTE: Make adjustment to fit
operator.
STEP 1
Remove
Pin
0.250”
STEP 2
Loosen Nut
D–01170 A–02385
Fig. 2–14 Adjustment Of Control Pedals
825 Loader
47 of 176 –2–9– Service Manual
2.9.2 Removal Of Pedal Assembly
1. Lift the lift arms and install cylinder stops.
4. No more than four drops per minute must come out of opening.
1. Lift the lift arms and hold with a Fig. 2–15 Brake Lever Removal
support or hoist.
2. Disconnect hydraulic hoses and
protect ends with plastic bags. Pin
2
3. Remove pivot pins. 1
4. Remove cylinder.
To install, reverse removal procedure.
3
2–10.3 Removal Of Tilt Cylinder (Fig.
2–17)
1. Tilt Bob–Tach forward to the floor.
5. Remove cylinder.
825 Loader
48 of 176
Revised March 1978 –2–10– Service Manual
2. Pin holes at either of the cylinder fittings can cause external leakage.
Pinholes can be welded shut by gas or electric arc welding. When welding Stone
the cylinders at the pivot (base) end, the shaft must be extended to prevent
heating and weakening the piston seals. When welding cylinders at the head
(rod) end, the cylinder must be disassembled to prevent damage to the head
seals.
3. A bent cylinder case can cause the piston to be worn flat and result in internal
leakage.
If a cylinder case has been bent and the piston worn flat, make replacement
of the cylinder.
4. Foreign material on the cylinder case can cause damage to the cylinder wall PI–01221B
and result in internal leakage. Use caution when opening hydraulic lines or
making replacement of the filter element. Do not allow dirt to get into the Fig. 2–18 Removing Scratches
system, as it will circulate through the system and cause wear to the
hydraulic pump, control valve and cylinders.
Cylinder
2–11.1 To Disassemble A Hydraulic Lift Or Tilt Cylinder Head
1. Remove the cylinder from the machine (To remove the lift cylinder, remove
both pivot pins first, move the cylinder forward and remove the hydraulic
lines).
2. Use a special spanner wrench to remove the head from the cylinder (Fig.
2–19).
NOTE: If the piston comes loose from the cylinder rod, it can have the Spanner Wrench
A–01896
wrong piston or nut. The piston should be made of aluminum, not
zinc. The nut should be 0.625 inch (16 mm) thick (Fig. 2–19.1) Fig. 2–19.1 Locking Nuts
1. File or grind a bevel on the shoulder at the piston end of the cylinder shaft,
if it does not have one (Fig. 2–20). This will allow the seals to be installed over
the shoulder without damaging them. Remove all scratches from the shaft
(Fig. 2–18). Do not use a power grinder or file for removing scratches.
2. Put the Teflon piston seal in warm oil or water for several minutes before
installing it. This will make it softer and easier to install.
A–02425
Fig. 2–19.1 Locking Nuts
2–11.3 To Assemble The Hydraulic Cylinder
825 Loader
49 of 176
Revised Feb. 81 –2–11– Service Manual
2–12 OIL COOLER
825ServiceManual#6549899–HydraulicSystemSection
825 Loader
50 of
Revised Feb. 81176 –2–12– Service Manual
HYDROSTATIC SYSTEM
Paragraph Page
Number Number
ADJUSTMENT OF SPEED RANGE LINKAGE . . . . . . . . . . . 3–4 3–6
CHECKING HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . 3–6 3–8
CHECKING RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7 3–9
CONTROL LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3 3–6
HYDROSTATIC DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 3–1 3–1
HYDROSTATIC MOTOR INSTALLATION . . . . . . . . . . . . . . . 3–13 3–12
HYDROSTATIC MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . 3–12 3–12 HYDROSTATIC
HYDROSTATIC PUMP INSTALLATION . . . . . . . . . . . . . . . . 3–11 3–11 SYSTEM
HYDROSTATIC PUMP & MOTOR ASSEMBLY . . . . . . . . . . 3–16 3–14
HYDROSTATIC PUMP & MOTOR DISASSEMBLY . . . . . . 3–14 3–13
HYDROSTATIC PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . 3–10 3–11
HYDROSTATIC TRANSMISSION
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 3–1
INSPECT PARTS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . 3–15 3–14
STARTING PROCEDURE, AFTER REPAIR . . . . . . . . . . . . 3–17 3–15
STEERING CONTROL LINKAGE . . . . . . . . . . . . . . . . . . . . . . 3–5 3–7
TEMPERATURE & PRESSURE SWITCHES . . . . . . . . . . . . . 3–9 3–10
10 MICRON FINAL FILTER REPLACEMENT . . . . . . . . . . . . 3–8 3–10
825 Loader
51 of 176 –3––1– Service Manual
Dealer Copy -- Not for Resale
825 Loader
52 of 176 –3–0– Service Manual
3–1 HYDROSTATIC DRIVE SYSTEM
3–1.1 Description
The hydrostatic system is made up of a charge pump (geroter), two hydrostatic
pumps and two hydrostatic motors. See the colored Flow Charts PI–02512,
PI–02513 and System Operation description for the full operation the Hydrostatic
System.
PROBLEM PROBLEM
ANALYSIS CHART
No Drive On Either Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
.................................................................... B
.................................................................... C
Drive With Warning Lights On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D
No Drive On One Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E
Loader Pulls To One Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F
Loader Operates Only One Direction – One Side . . . . . . . . . . . . . . . . . . . . . . . . G
System Overheats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H
825 Loader
53 of 176 –3–1– Service Manual
CHART A– NO DRIVE
SYSTEM PRE–CHECK
Turn On If Check If Light
Check If Ignition & Light Start Engine TransFilt Light Will Operate
Oil Check & Run At (Max. 5 Sec. Lift Arm
Level Correct TransFilt Is 1/2 Throttle For Light To Not Control
Light On Go Out) Go Out
Go To
Chart B
CHART B – NO DRIVE
GEAR PUMP CHECK
Check If
Output Of Gal/Min Go To
Implement Chart C
Pump Is
Page 2–4 Correct
If Gal/Min
Is Low
Make If
Replacement Of Gal/Min Check
25 Micron Filter Pump If Pressure
& Recheck Pressure Is Low
Is
Gal/Min Correct
If Gal/Min If Pressure
Is Low Is Correct
825 Loader
54 of 176
Revised March 1976 –3–2– Service Manual
CHART C
NO DRIVE
Check If If Inspect If
Pressure Check Stroked Pressure Defect
Charge Charge Pressure Components Install New
Pressure Page 3–8 & Case Drain Component
Page 3–8 Is Correct Is Low Page 3–14 Is Found
If No Defect
Is Found
Check Install
Charge Internal
10 Micron
CHART D
DRIVE WITH WARNING LIGHT ON
If Pressure
Is Correct
If System
Now Operates
If Pressure Correctly If Pressure
Is Correct Return To Is Correct
Service
825 Loader
55 of 176 –3–3– Service Manual
CHART E
NO DRIVE ON ONE SIDE
If No If
Inspect Defect Check Stroked Pressure Inspect
Control Is Charge Pressure Is Drive
Linkage Found Page 3–8 Correct Chain
If Flow Is Large In
Motor Or Pump
CHART F
LOADER PULLS TO ONE SIDE
825 Loader
56 of 176 –3–4– Service Manual
CHART G
LOADER OPERATES ONLY ONE DIRECTION – ONE SIDE
CHART H
SYSTEM OVERHEATING
Make Make
Add Or Make Repair Make
Replacement Repair
Or Of Belt Repair
Of Oil Clean
If In High If Defect
Range Is Found
Make
Operate In Repair Or
Low Range Install
New Valve
825 Loader
57 of 176 –3–5– Service Manual
3–3 CONTROL LINKAGE
3–3.1 Adjustment Of Steering
Linkage
1. Lift and block loader so all
wheels are off floor, or pull out
transmission gear box levers
(Fig. 3–10). Lever
4. Lower ROPS.
825 Loader
58 of80
Revised April 176 –3–6– Service Manual
To remove speed–range linkage:
825ServiceManual#6549899–HydrostaticSystemSectionPages1–7
C–01826
6. Disconnect linkage.
Steering
7. Loosen the support nuts (Fig. Lever
3–7).
B–02209 B–02207
8. Slide left hand shaft over to Fig. 3–6 Removing Steering Lever Fig. 3–7 Steering Lever Support Nuts
welded bracket.
Control Lever
Shaft
B–01906
Fig. 3–8 Removing Control Lever Assembly
825 Loader
59 of 176
Revised Feb. 81 –3–7– Service Manual
100 – 120 ft.–lbs.
(136 – 162 Nm)
25 – 28 ft.–lbs. 50 – 70 ft.–lbs.
(34 – 38 Nm) (68 – 94 Nm)
25 – 28 ft.–lbs.
(34 – 38 Nm)
NOTE: Put LOCTITE sealant on the threads of the bolts for the pintle levers
during assembly.
Use the above procedure in reverse order to install the steering linkage. See figure
3–8.1 for the correct torque.
NOTE: All 825 Bobcat loaders between serial number B–1000 and C–1000
have a spacer inside the steering levers (Fig. 3–8.2, Item 1). The
spacers must be in place or the levers will not operate correctly.
825 Loader
60 of 176
Revised Feb. 82 –3–7a– Service Manual
825ServiceManual#6549899–HydrostaticSystemSectionPage7a–7b
825 Loader
61 of 176 –3–7b– Service Manual
3–6.2 Charge Pressure Check
Steering Levers In Neutral Position:
1. Remove the oil sender unit from the right rear of the tank (Fig. 3–11, Item 1). Pull Out
4. Lower the ROPS. Position the hose so it will not be damaged (pinched) when
lowering the ROPS.
5. Fasten the gauge to the side of the ROPS so it can be seen when operating
the Bobcat.
7. Operate the machine under load at full RPM and check pressure on the
gauge. 100 PSI (689 kPa) is the minimum acceptable reading. B–02949R
Fig. 3–10 Trans. Disengagement Lever
3–6.3 Charge Pump Inlet Pressure
Steering Levers in Neutral Position:
B–02167
Fig. 3–11 Checking Inlet Pressure To Charge Pump
825 Loader
62 of
Revised Feb. 82176 –3–8– Service Manual
3–7 CHECKING RELIEF VALVES
Cup
3–7.1 Charge Relief Valve
NOTE: See Bobcat Technical Information Bulletin #162 for more
information on the Charge Relief Valve.
Spring
To check condition of charge relief valve it must be removed from unit and visual
inspection made as follows:
825 Loader
63 of 176
Revised Feb. 82 –3–9– Service Manual
3–8 10 MICRON FINAL FILTER
ELEMENT REPLACEMENT (Fig.
3–16)
1. Lift the lift arms and install
cylinder stop on lift cylinder
(Fig. 3–14).
C–01828
Fig. 3–17 Removing Pump Suction Hose
825 Loader
64 of 176 –3–10– Service Manual
The charge pump inlet switch (2) is set
to activate when pressure goes below
4 PSI.
The temperature inlet switch is set to
activate when temperature goes
above 210°F (99°C).
C–01829
Fig. 3–19 Disconnecting Steering Linkage
825 Loader
65 of 176
Revised January 77 –3–11– Service Manual
3. Connect steering linkage to
pump control arms.
825ServiceManual#6549899–HydrostaticSystemSectionPages8–12
4. Connect hoses.
3–12 REMOVAL OF
HYDROSTATIC MOTOR
Remove
Bolts
Rear
Motor
B–01905
C–01819
Fig. 3–22 Removing Speed–Range
Linkage Fig. 3–23 Hydrostatic Motor
825 Loader
66 of 176
Revised August 79 –3–12– Service Manual
3–13 INSTALLING HYDROSTATIC
MOTOR
825 Bobcats 14001 & Up have new hydrostatic pumps and motors. Old style pump
and motors are no longer available. Conversion kits are available to change the
old units to the new, better units and are listed in the 825 Parts Book. Check to see
which unit you have by checking the letters on the pump (Fig. 3–23b).
When hydrostatic units have been changed they must be marked to show the
change.
ID. No.
Front
Pump
Motor
Rear
ID. No. Pump ID. No.
B–02670
Fig. 3–23b Checking Hydrostatic Units
825 Loader
67 of 176
Revised Feb. 82 –3–12a– Service Manual
825ServiceManual#6549899–HydrostaticSystemSectionPages12a–12b
825 Loader
68 of 176 –3–12b– Service Manual
3–14 HYDROSTATIC PUMP OR
MOTOR DISASSEMBLY (Fig. 3–24)
The inner parts of hydrostatic pumps
and motors are similar. The following
procedure for pump disassembly can be 23
used for disassembly and assembly of 22
22A*
motor. (Do not do the steps which belong 21
to pump disassembly.) 18 19 20
To disassemble the pump, begin by: 14
12 24 25
1. Remove pump assembly from the 10
transmission housing. Put plugs in 13
all fluid openings to keep out dirt. 11 10
12 38 48
2. Separate pump from the 39 14
7 45 50
assembly. 49
5 11
3 8 9 15
To disassemble motor, begin by: 1 35 44 41
33 40
1. Remove the motor from the 4
transmission housing. 6 34 50
4
2 33 43
2. Remove the back plate from the
motor.
34
Continue to disassemble the pump or
4. Use a plastic hammer and hit the adaptor (Item 43) to loosen it, then pull the
adaptor straight up until it is free.
5. Remove the outer gerotor gear (Item 41), the inner gerotor gear (Item 40)
and the key (Item 39) from the pump shaft.
6. Use a plastic hammer and hit the back plate (Item 32) to loosen it, then pull
the back plate straight out. Remove the gasket (Item 30).
7. Remove the relief valves (Item 35) from the back plate (Item 32).
8. Lift the piston block (Item 23) from the pump housing.
9. If the pistons (Item 20) did not come out with the piston block, remove them,
the spider (Item 21) and the wave washer (Item 22A [motor only]).
10. The piston block assembly (Item 23) must not be disassembled.
12. Remove the snap ring (Item 1), shaft seal (Item 2) and the washer (Item 3)
from the housing.
14. To remove the camplate (Item 19) from the housing, remove the two snap
rings (Item 14) from the side of the housing. Remove the two covers (Items
13 and 15), the two O–rings (Item 12), the one inner race (Item 11) and the
two bearings (Item 10). The camplate can now be pushed to one side and
removed. The two camplate pivot bearings are a loose fit into the housing.
3. Inspect the gerotor chamber inside the charge pump housing (Item 43) for damage.
4. Inspect the needle bearing (Item 49) inside the charge pump adaptor housing, if the needles are free of loose play
and are in the bearing cage there is no need to make replacement of the bearing. (Later Model pumps do not use
this bearing, See BTIB #162).
5. Inspect the check ball assembly (Item 38). Make sure the ball seat is in good condition and the ball is free to move.
6. Inspect the flat surfaces of the back plate (Item 32), the finish on the gerotor side must show no damaged surface.
The finish on the piston block side must be smooth and free of grooves or metal deposit. The back plate will need
replacement if it shows any wear above. The cam stop must be tight in the back plate.
7. The pistons (Item 20) must move freely in the piston block bore. If they are tight in the bore, inspect the bore for
damage.
8. Inspect the outside diameter of the pistons for finish condition. They must not show wear or deep scratches. The
shoes must fit well on the ball end of the pistons with no more than 0.003 inch (0,076 mm) end play. The flat surfaces
of the shoes must be flat, smooth and show no sign of loose metal or metal deposit. The minimum thickness of the
shoe can not be less than 0.148 inch (3,759 mm). Do not machine the piston shoes.
9. Inspect the spider (Item 21). It must be flat, no cracks and no signs of wear in the pivot area.
11. Inspect the camplate (Item 19) for the condition of the finish of the shoe surface. It must show no signs of scratches.
12. Inspect the shaft for wear or damage in the bearing and the spline areas.
13. Inspect the thrust bearing (Item 6) and washers (Item 5) for wear.
14. Inspect the needle bearing (Item 8) in the housing assembly. If the needles are free of loose play and are in the bearing
cage, there is no need for replacement of the bearing.
2. The following procedure must be used when you assemble the adapter plate to the pump housing.
(a) Put a soft material (such as wood) on the jaws of the vise, then put the drive shaft of the front pump in the vise
with the drive shaft down.
(b) Install the adapter plate and the four bolts. Tighten the four bolts with your hand only.
(c) Install the connector (for the drive shaft), then install the rear pump and fasten with two bolts.
(d) Tighten the four bolts to 27–31 ft.–lbs. (37–42 Nm) torque.
(e) Tighten the two bolts to 90–100 ft.–lbs. (122–136 Nm) torque.
3. Install a new O–ring (Item 18) on the camplate trunnion. Put camplate into housing (Item 9). Put the needle bearings
(Item 10) and the bearing inner races (Item 11) over the shaft and slide into the housing. The chamfered inside
diameter of the race must be inward.
4. Install new O–rings (Item 12) around the outside diameter of the cam pivot bearings. Install sleeve cover (Item 13)
and fasten with snap ring (Item 14).
5. Install trunnion cover (Item 15) and fasten with snap ring (Item 14).
6. Install snap ring (Item 4) on shaft (Item 7). Install the thrust washer (Item 5), thrust bearing (Item 6) and second thrust
washer (Item 5). Fasten with second snap ring (Item 4).
825 Loader
70 of 82
Revised Feb. 176 –3–14– Service Manual
7. Install shaft in housing and install washer (3), shaft seal (2) and hold with
snap ring (1).
8. Clamp this assembly in a vise with the open end of the housing up.
9. Compress the pin keep (24) and install the spline. Install the three pins (25)
with the head to the inside of the block. Install the wave washer (Fig. 3–24.1).
Install pins in the special grooves of the piston block spline.
10. Install the pivot (22), spider (21) and the piston assemblies (20) in the piston
block. Install this assembly in the housing assembly, the piston shoes must
be in contact with the camplate. Be sure all the parts are in their correct
position.
B–02648
11. Install and tighten the back plate to give a preload to the wave washer. Fig. 3–24.1 Install Wave Washer (Motor)
Remove the back plate (motor only).
14. Install new O–ring (36) and back–up washer (37) on the check valve
assembly (38). Install O–ring next to the roll pin. Install in back plate (32) with
roll pin in back plate.
15. Install key (39) on the shaft and install the inner geroter gear (40) over the
shaft. Use oil to lubricate the gear.
17. Install a new O–ring (34) on the relief valve assemblies (35) and install seats
(33) and relief valves in the back plate (32).
1. Remove the pressure line from the implement pump. Install a hose from the
implement pump to the hydraulic reservoir.
2. With the throttle in the OFF position, turn the engine with the starter until oil
flows from the pump.
825 Loader
71 of 176
Revised Feb. 82 –3–15– Service Manual
3. Connect the pressure line to the
implement pump.
825ServiceManual#6549899–HydrostaticSystemSectionPages13–16
Temperature
Sender
To clean and charge the system, use the
following procedure:
1. Put the gearboxes in neutral
position by removing the nut and
pulling out on the gearbox levers
(Fig. 3–25).
3. Remove the temperature sender from the oil cooler (Fig. 3–26) and install
a 1–100 PSI (0–700 kPa) gauge.
5. Loosen and disconnect the tubeline (Item 2) from the 25 micron filter. Turn
the tubeline away from the filter. Put a cap (Item 3) on the filter fitting where
the tubeline was removed. Connect a hose (Item 4) from the tubeline to the
reservoir filler tube.
6. Remove the hydraulic pressure
sender from the right side of the 5
loader. Install a 0–200 PSI (0–400
kPa) gauge at this location (Item 5).
825 Loader
72 of
Revised Feb. 82176 –3–16– Service Manual
FINAL DRIVE SYSTEM
Paragraph Page
Number Number
AXLE BEARING & SEAL REPLACEMENT . . . . . . . . . . . . . . 4–8 4–6
AXLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7 4–5
DRIVE CHAIN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 4–6 4–4
DRIVE CHAIN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5 4–4
FINAL DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 4–1
REDUCTION HOUSING ASSEMBLY . . . . . . . . . . . . . . . . . . . 4–4 4–2
REDUCTION HOUSING DISASSEMBLY . . . . . . . . . . . . . . . . 4–3 4–1
REDUCTION HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . 4–2 4–1
MECHANICAL
TRANSMISSION
825 Loader
73 of 176 –4––1– Service Manual
Dealer Copy -- Not for Resale
825 Loader
74 of 176 –4–0– Service Manual
4–1 FINAL DRIVE SYSTEM Front Of Loader
Final Drive
4–1.1 Description (Fig. 4–1) Reduction Chain Axle (Front)
Gearcase
The final drive system is made up of
a 3–step reduction gearcase, a 100
H.E. final drive chain, axles and idler
assemblies.
4–2 REMOVAL OF REDUCTION
HOUSING
1. Tilt or remove the ROPS
enclosure (See Section 5). Idler Assembly
Clean the transmission area
thoroughly.
Axle (Rear)
2. Lift the lift arms and install the
cylinder stops (Fig. 4–2).
3. Remove the fluid from the C–01842
reservoir.
Fig. 4–1 Final Drive Chain System
4. Remove the transmission
covers, hydrostatic pump
assembly and motor (See
Section 3) and the final drive
chain. Remove the lever for
engaging the drive gears (Fig.
C–01820 B–02143
Fig. 4–4 Removing Gearcase Bolts Fig. 4–5 Removing Reduction Housing
825 Loader
75 of 176
Revised Feb. 82 –4–1– Service Manual
5. Remove the shaft from the housing.
3. Remove the gear (14), shaft (16), snap rings (19, 20) and bearings (17, 18).
825 Loader
76 of 17677
Revised January –4–2– Service Manual
3. Tilt or remove ROPS enclosure
(See Section 5–2).
4. Clean area thoroughly.
5. Remove foot pedal assembly Idler Fastening
(See Section 2). Nuts
6. Remove the floor plate.
7. Loosen idler fastening bolts and
turn the adjustment bolt (Fig.
4–9).
8. Turn the large bolt and tighten
the idler bracket until no
freeplay is present at the wheel
on the tightest place on the
sprocket. Check at several
places on the circumference of
the sprocket to prevent over Adjustment
tightening (Fig. 4–10). Tighten Bolt
the drive chain when freeplay at
the wheel reaches 0.500 inch
maximum.
9. Tighten the idler fastening
bolts.
10. Install a new gasket under the
floor plate.
825 Loader
77 of 176
Revised Feb. 82 –4–3– Service Manual
6. Remove the 10 micron (internal) filter assembly.
7. Separate the chain and remove links until end clears idler assembly.
8. Loosen the reduction gear housing fastening bolts and move the gear
housing away from the side wall of the transmission housing.
9. Remove the two fastening nuts on the idler assembly (Fig. 4–11).
12. Remove the sprocket from the chain. Do not turn the sprocket or bearing
cups and races will not match.
825 Loader
78 of
Revised Feb. 81176 –4–4– Service Manual
4–5 REMOVAL OF DRIVE CHAIN
1. Lift the loader and put on safe
blocks.
2. Remove ROPS (cab).
3. Lift loader lift arms and install
cylinder stops.
4. Steam clean the loader
thoroughly.
5. Remove the front transmission
cover.
6. Remove pedal assembly and
floor plate.
7. Loosen the chain idler bracket
(Fig. 4–9).
8. Remove from sprocket lock bolt B–02949R
and nut.
Fig. 4–14 Drive Gear Lever
9. Put reduction housing gears in
neutral. (Lever on outside of
transmission housing (Fig.
4–14).
10. Rotate drive chain until master
connector link (white) is in
825 Loader
79 of 176
Revised Feb. 82 –4–5– Service Manual
6. When chain tension is correct,
tighten the fastening nuts on tighter.
7. Install chain guide (Fig. 4–18).
Axle
Nut
4–7 REMOVAL OF AXLE
4–7.1 Removal Of Rear Axle
11. Put reduction housing gear in neutral (Fig. 4–14). (Remove nut and pull out
on lever.)
12. Rotate drive chain until master connector link is in position for removal.
825 Loader
80 of 176
Revised August 79 –4–6– Service Manual
4–7.3 Installation Of The Axle
Bearing
Reverse the above steps to install axles. Puller
Replace the gasket between the axle
and the transmission case if damaged.
When installing the axle housing, tighten
the upright bolts (Item 3) to 240–280 Axle
ft.–lbs. (326–380 Nm) torque (Fig.
4–21). Tighten fastening bolts (Item 8) to
the frame to 125–140 ft.–lbs. (170–190
Nm) torque.
Bearing
B–02177
Fig. 4–21 Installing Axle Housing
NOTE: If repairs are being done on loaders (S/N 15640 & Below) used in
heavy work conditions or when solid tires are used also weld the
axle housing to the loader main frame (Fig. 4–20a). The welds
shown in Figure 4–20a are all that are needed. Any more than this B–01909
will cause axle housing distortion and removal will not be possible. Fig. 4–22 Removing Outer Axle Bearing
4–8 AXLE BEARING AND SEAL REPLACEMENT
1. Remove the axle assembly (axle
with housing) from the loader.
2. Remove the inner bearing and axle
825 Loader
81 of 176
Revised Feb. 81 –4–7– Service Manual
4–9 INSTALLATION OF AXLE
SPROCKET
825ServiceManual#6549899–FinalDriveSystemSection
3
Install the axle sprockets after the axle 125 – 140 ft.–lbs.
is installed in the loader. (170–190 Nm) Torque
1
To install the axle sprockets:
2
1. Install the axle sprocket (Fig.
4–27, Item 1).
1. Lift the lift arms and install cylinder stops (Fig. 4–2).
5. Before removal of the left brake, remove the steering linkage. Brake linkage
rod and hydraulic oil pickup tube.
Before removal of the right brake, remove steering linkage and steering arm
from the pump. Remove the brake linkage rod.
B–02651
6. Remove shoulder screws from the case and lift out brake assembly. Use Fig. 4–28 Removing Brake Assembly
caution not to drop the actuator lever from the bottom of the brake assembly
(Fig. 4–28).
825 Loader
82 of
Revised Feb. 81176 –4–8– Service Manual
MAIN FRAME
Paragraph Page
Number Number
BOB–TACH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4 5–1
ELECTRIC MOTOR FOR ROPS . . . . . . . . . . . . . . . . . . . . . . . 5–7 5–2
FUEL TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6 5–2
LIFT ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5 5–2
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 5–1
PIVOT PIN & BUSHING REPLACEMENT . . . . . . . . . . . . . . . 5–3 5–1
ROPS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 5–1
MAIN
FRAME
825 Loader
83 of 176 –5––1– Service Manual
Dealer Copy -- Not for Resale
825 Loader
84 of 176 –5–0– Service Manual
5 MAIN FRAME
5–1.1 Description (Fig. 5–1) ROPS
2. Stop the engine and engage the tilt pedal to release the hydraulic pressure
on the system.
3. Remove the tilt cylinder pivot pins (rod end).
4. Remove the Bob–Tach lower pivot pin.
5. Remove the Bob–Tach.
6. Reverse the above steps to install.
825 Loader
85 of 176
Revised Feb. 81 –5–1– Service Manual
5–5 LIFT ARMS REMOVAL (Fig.
5–3)
D–01172
5–6 FUEL TANK REMOVAL Fig. 5–2 ROPS (Cab) Tilting Mechanism (Electric)
825 Loader
86 of
Revised Feb. 82176 –5–2– Service Manual
5–7.1 Removal Of Tilt Mechanism
B–02419
5. Reverse to install. Fig. 5–5 Cab Tilt Motor
If the jack is repaired or replaced, make sure the ROPS is supported by a chain
hoist.
The ROPS fastening bolts must be tightened to 120 – 150 ft.–lbs. (163 – 203 Nm)
torque.
B–03626
Fig. 5–7 Raising & Lowering the ROPS
825 Loader
87 of 176
Revised Feb. 82 –5–3– Service Manual
825ServiceManual#6549899–MainFrameSection
825 Loader
88 of 176 –5–4– Service Manual
ELECTRICAL SYSTEM
Paragraph Page
Number Number
ALTERNATOR OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4 6–3
ALTERNATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6 6–4
ELECTRICAL CIRCUITRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 6–1
FAN BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3 6–3
PROBLEM ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2 6–1
REGULATOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5 6–3
STARTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7 6–6
825 Loader
89 ofFeb.
Revised 176 82 –6––1– Service Manual
Dealer Copy -- Not for Resale
825 Loader
90 of 176 –6–0– Service Manual
91 of 176
Dealer Copy -- Not for Resale
92 of 176
Dealer Copy -- Not for Resale
93 of 176
Dealer Copy -- Not for Resale
94 of 176
Dealer Copy -- Not for Resale
95 of 176
Dealer Copy -- Not for Resale
96 of 176
Dealer Copy -- Not for Resale
6 ELECTRICAL SYSTEM
6–1 ELECTRICAL CIRCUITRY
There are two basic circuits in the
electrical system:
1. Charging circuit.
2. Starting circuit.
IMPORTANT
E–01108
When working on the Fig.6–1 Electrical System
electrical circuitry, first
remove the ground (negative)
cable from the battery.
I–2155–1297
Check
Check Condition Charging
If If Check If Check If Output System
Generator Of Wiring Output
Drive Belt Good Good Good Works
Battery & (Page 6–3) (Page 6–3) Is Correct
Cable Correctly
Remove
Make If No And
Repair As Make Make Check Defect
Repair As Repair As Regulator Inspect
Needed Is Generator
(Page 6–3) Needed Needed (Page 6–4) Found (Page 6–4)
If Defect
Is Found
CHART B
STARTER WILL NOT TURN ENGINE OVER
Check Wiring,
Check Check Ignition
For If Engine Condition If Check If
Starter Switch &
Engine Of Battery Good Good Circuit
Seizure Is Good & Cables (Page 6–6)
Breaker
If Engine If Defect
Has Defect Is Found
Remove
Correct And Make
Engine Repair As
Problem Needed
(Page 6–6)
825 Loader
Revised January
98 of 176 77 –6–2– Service Manual
6–3 FAN BELT
Mounting
Check the drive belt for correct tension. A loose belt can cause charging problems. Bolt
Correct tension is 0.375 inch (10 mm) play at the midway point (Fig. 6–2).
1. It is worn narrow.
0.375”
2. It has cracks or is separating.
A–02287
To check wiring: Fig. 6–2 Fan Belt Adjustment
1. Turn the ignition switch on. Connect a voltmeter from chassis to: (Fig. 6–3)
No. 1 alternator connection
B–02113
Fig. 6–3 Alternator
825 Loader
99 of 176
Revised Feb. 82 –6–3– Service Manual
2. Lower the electric charge in battery. (Turn engine with starter, connect lights, Test Hole
etc.)
3. With the engine running at full throttle, connect the alternator field to chassis
with a small screwdriver or wire (Fig. 6–4).
3. Remove the two bolts that hold alternator in place and lift alternator from the
Bobcat.
2. Remove the pulley from the shaft. Fig. 6–5 Separating Alternator Housing
5. Remove the nuts which hold the three stator wires to the frame. Remove the
stator.
1. Connect a test light from the middle wire connection to one of the outside
wire connections. If the light doesn’t come on, there is a defect in the stator.
2. Connect the test light from the middle connection to the other outside
connection. If the light doesn’t come on, there is a defect in the stator.
3. Connect the test light from one of the connections to the frame of the stator.
If the light comes on, there is a defect in the stator.
Ohmmeter
(Check for Grounds) B–02108
Fig. 6–6 Checking Stator Coil Wires
825 Loader
10082
Revised Feb. of 176 –6–4– Service Manual
a
6–6.5 To Check Diode Trio (Fig. 6–8)
Insulated
1. Connect a D.C. test light from one Half
of the three connections to the
single connection. Then, reverse
the connections. The light must
come on when connected one
way, but not when connected the
other way.
A–02382
3. Connect the test light from the middle connection to each outside
connection. If the light comes on, there is a defect in the diode trio.
3. Connect the test light from one connection, to the insulated heat sink. Then,
reverse the connections. The light should come on when connected one
way, but not when connected the other way.
4. Connect the test light from the grounded heat sink to the same connection.
Then, reverse the connections. The light must come on when connected
one way, but not when connected the other way.
5. Repeat Steps 3 and 4 on both the other connections. If any of the tests are
bad, complete rectifier replacement is necessary.
B–02128
Fig. 6–10 InsulationWashers And Spacers
6–6.7 Assembly
Assembly is basically the reverse of disassembly.
If the regulator is removed, make sure the insulation washers and spacers are in
good condition on the two regulator screws (Fig. 6–10).
To install the rotor, put a piece of straight wire through the case to hold the brushes
in place (Fig. 6–11).
B–02097
Fig. 6–11 Holding Brushes
825 Loader
101 of 176 –6–5– Service Manual
a
6–7 STARTER SERVICE Jumper Wire
825ServiceManual#6549899–ElectricalSystemSection
1. Lift the Bobcat on safe blocks. Keep the ignition switch off. Be sure the Bat
S
battery has full charge and the connections are clean and tight. M
3. Connect the jumper from the Batt connection on solenoid to the M terminal
on starter (Fig. 6–13). If the starter will turn rapidly, the defect is in the A–01991
solenoid. If starter does not turn, the defect is in the starter. Fig.6–12 Checking Solenoid
Jumper Wire
6–7.2 To Remove Starter
Solenoid
1. Disconnect negative battery cable.
Bat
S
M
2. Disconnect the wires from starter connections.
3. Remove the bracket which holds the rear of the starter. Remove the three Cranking
nuts which hold the starter in place, and lift it out.
A–01992
6–7.3 Disassembly And Inspection Fig. 6–13 Checking Operation
1. Remove the three screws which hold the solenoid in place. Twist the
solenoid 1/4 turn and slide it off. Armature
2. Remove the thru bolts and the shift lever bolt. The starter will now come
apart.
3. Check the armature by connecting a test light from the outside of the
armature to the commutator (Fig. 6–14). If the light comes on, the defect is
in the armature.
6–7.4 Assembly
Assembly is the reverse of
disassembly.
A–01994 B–02122
Fig. 6–15 Armature Testing (Shorts) Fig. 6–16 Checking Field Coil Wires
825 Loader
102 of 176 –6–6– Service Manual
ENGINE SERVICE
Paragraph Page
Number Number
CONNECTING RODS AND PISTONS . . . . . . . . . . . . . . . . . . 7–5 7–9
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–10 7–28
CRANKSHAFT AND MAIN BEARINGS . . . . . . . . . . . . . . . . . 7–6 7–13
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3 7–1
FLYWHEEL AND FLYWHEEL HOUSING . . . . . . . . . . . . . . . . 7–7 7–17
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–11 7–31
INSTALLING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 7–4 7–8
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 7–1
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9 7–25
STARTING ENGINE AFTER
RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2 7–1
TIMING CASE AND DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8 7–18
825 Loader
103 of 176 –7––1– Service Manual
Dealer Copy -- Not for Resale
825 Loader
104 of 176 –7–0– Service Manual
7–1 INTRODUCTION
7–1.1 Engine Parts
Whenever engine parts are ordered, be sure that all information is given. Always
quote the engine serial number, engine part number and description.
7–1.2 Engine Number Location
The engine number is stamped on the fuel pump mounting flange as shown in
Figure 1–2.
NOTE: The oil passages and the rocker arm shaft will need a little time to
fill with oil. Once the oil flow to the rocker arms is satisfactory, the
rocker arm cover and the air cleaner can be installed.
4. Run the engine at idle (1200 – 1500 RPM) for 10 – 15 minutes to let it warm
up.
5. After the engine has been warmed up thoroughly it must be stopped and
825 Loader
105 of Feb.
Revised 176 82 –7–1– Service Manual
7–3.2 Cylinder Head Maintenance
The number of hours run has no
effect on when to overhaul the
cylinder head on the 4.108 diesel
engine, since carbon beyond a small
quantity does not form and gather in
the combustion chambers and on the
pistons as in gasoline engines.
Easy starting and performance
should be the determining factors
and the cylinder head removed only
when it becomes absolutely
necessary.
Before starting to overhaul the
cylinder head, make sure that all
gaskets and any other parts
expected to be required are
available.
Remove any external foreign matter
from the area of the cylinder head
cover, injectors and fuel pump.
Remove the cylinder head as follows:
1. Completely empty the cooling
825 Loader
10677
Revised Jan. of 176 –7–2– Service Manual
12. Remove the low pressure fuel
pipes between the fuel filter and
the fuel pump, remove the fuel
filter after disconnecting the feed
pipe from the lift pump, plug all
pipes and openings to prevent
entry of foreign particles.
13. Remove the four high pressure
fuel pipes from the fuel pump to the
injectors. Plug fuel pump outlet
ports.
14. Remove the injector fastening
nuts and carefully remove the
injectors. Plug the exposed
openings on the injectors.
15. Remove the alternator adjusting
arm.
16. Remove the cylinder head C–01810
fastening nuts and lift off the
cylinder head completely with Fig. 7–3 Lifting Cylinder Head
intake and exhaust manifolds (Fig.
7–3).
NOTE: During this final operation do not pry with a screwdriver or any
other sharp instrument between the cylinder head and block faces.
Once the head has been removed it must be placed on a flat surface,
such as wood, to prevent any damage to the machined face.
NOTE: Cracks are easier to see by checking the inside face of the insert.
A–02681
7–3.5 Cleaning Fig. 7–7a Pre–CombustionInserts (Good)
Plug all openings, oil ways, etc., where the entry of foreign matter could cause
damage to the working parts. Remove any carbon carefully from the tops of
pistons (a ring of grease between the piston and cylinder wall can help catch loose
carbon particles).
Clean the cylinder head face, being careful not to scratch the machined surface.
If the water jacket within the cylinder head shows signs of excessive scale, then
a special cleaning solution must be used. The cylinder head should be tested for A A
B
water leakage after this cleaning.
Clean all the studs on top of the cylinder head and those in the top face of the
NOTE: Studs and nuts are phosphate coated. Be sure that only genuine
parts are used as replacements.
7–3.6 Inspection
After the cylinder head has been disassembled and cleaned, the following
components should be inspected as follows:
1. Valve springs
Valve springs become weak because of the combined effects of heat and the
normal working of the springs.
It is best to install new valve springs whenever the engine undergoes an
overhaul. Where a top overhaul only is being done, the springs should be B–01887
inspected, paying special attention to squareness of ends and pressures at Fig. 7–8 Valve Guide Removal
specific lengths. The details can be found on page 8–4.
2. Valve Guides
The valve guides should be inspected for wear and if necessary replaced by
new ones.
The worn guides should be removed either by press or the valve guide
removal tool shown in Figure 7–8, being careful not to damage the bores
during their removal.
Before installing new guides, remove any burrs from the cylinder head parent
bores, then coat the bores with clean oil and either press in the new guides
or pull them in by means of the tool shown in Figure 7–9 until the guide
protrusion above the head top face is 0.800–0.815 inch.
825 Loader
108 of 176
Revised August 79 –7–4– Service Manual
3. Valves and Valve Seats
The valves should be checked in
their guides for wear and
replacement made if worn. Be
sure that the wear is on the valve
stem and not in the guide bore
before making a replacement.
B–01858 A–01653
Fig. 7–10 Refacing Valve Seats Fig. 7–11 Checking Valve Head Depth
825 Loader
109 of 176 –7–5– Service Manual
4. Using the valve guide bore as a
pilot once again press the insert Valve Valve
in with the insert driver, this tool is Inlet Exhaust
shown fully dimensioned in
Figure 7–13. Steady pressure
should be given with either a
hand or a hydraulic press. The
purpose of the insert driver is to
get squareness when the insert is
being pressed in.
1. Remove the snap rings from each end of the rocker shaft.
K
2. Withdraw the rocker levers, springs and support brackets from the rocker E
shaft.
3. Unscrew the oil feed pipe from the connector and remove the connector. C H
(When refitting this feed pipe, it should be noted that the end of the pipe
locates the connector position on the shaft.) J
G Rad.
After disassembly, thoroughly wash all parts in clean solvent. Inspect the rocker
A
bushings and shaft for wear. The rocker levers should be an easy fit on the rocker
B
shaft without loose side play.
If any rocker lever bushings have bad seizure onto the rocker shaft, the bushings
will have worked loose in their locations. Each rocker lever should be checked and
if any looseness is present, make a replacement of both lever and bushing.
New rocker levers are supplied complete with bushing fitted and reamed to size. F
D
B–02016
Fig. 7–13 Insert Driver
825 Loader
110 of 176 –7–6– Service Manual
NOTE: When fitting new bushings, see that the oil feed holes are in Align Oil Feed
alignment before pressing in, and when pressed fully in see that the Holes
holes are in alignment (Fig. 7–14).
1. Install the oil feed connection and locate with the feed pipe.
2. Install the rocker levers, springs and support brackets in the opposite order
to which they were removed. Lightly oil the components during re–assembly
and ensure that each rocker lever does not bind on the shaft. The assembly
should now be as shown in figure 7–15.
A–02352
Fig. 7–14 Rocker Arm Bearing
7–3.12 Push Rods
Make a replacement of any bent push
rods.
Replacement of push rods may be
made without removing the rocker
shaft, as follows:
1. Ensure that the valve is closed.
2. Loosen the valve adjusting screw
until the rocker lever can be moved
NOTE: This procedure does not apply to No. 5 rocker lever as the connector
prevents the side movement. Nos. 1 and 8 rocker levers may be
removed after removal of the snap ring and push rod replacement.
1. Ensure that the cylinder head and all parts are clean.
2. Put oil on the valve stems to provide the initial lubrication.
3. Insert each valve into its correct guide.
4. Locate the spring seat washers, valve springs and spring caps in position.
NOTE: The valve springs have a damper coil, when correctly installed this 5
coil is nearest the cylinder head top face. See note on spring caps 3
on page 8–4. Inner
Valve
5. Use a valve spring compressor, as 2 Spring
shown in Figure 7–16, to compress
the valve springs and locate the
retaining semi–conical collets. Outer
Valve
Spring
NOTE: Inlet valve stems are fitted 1
with rubber O–ring seals.
They fit inside the valve
spring cap bore and must
align with groove on the valve
stem. Assembly of the inlet 4
valve assemblies should be
carried out as follows: (Fig.
7–17). B–01862 A–02340
Fig. 7–16 Valve Spring Compression Fig. 7–17 Valve Assembly
825 Loader
111 of 176 –7–7– Service Manual
6. Put spring seating washer in
position (Item 1).
7. Position the valve springs
correctly on the seating washer
(Item 2).
8. Put the valve spring cap in position
(Item 3).
9. Compress with the valve spring
compressor until the valve stem is
through the cap enough to install
the O–ring seal.
10. Install the O–ring over the valve
stem and slide it down until it
locates in the groove (Item 4).
11. Install the collets (Item 5).
NOTE: If the oil feed pipe nut is tightened before the rocker shaft bracket
fastening nuts, there will be stress on the pipe.
6. Adjust the valve clearances to 0.012 inch (0,3 mm) as described on page
7–25.
7. Replace the alternator adjusting link and adjust the fan belt tension.
8. Install the injectors (refer to page 7–34) but do not tighten the holding nuts. B–01861
9. Install the leak off pipe assembly and four high pressure fuel pipes to the Fig. 7–20 Rocker Oil Line
injectors. Tighten the holding nuts.
10. Install the fuel oil filter and the low pressure fuel pipes between filter and lift
pump and filter and fuel pump.
11. Connect the electrical wire and fuel line to the starting aid.
12. Install the muffler onto the manifold.
13. Connect the water outlet connection at the front of the cylinder head.
14. Fill the cooling system with clean water. Check for water leaks.
15. Vent the air from the fuel system as described on page 7–35.
NOTE: Any ridges or carbon deposits around the top of the cylinder bores
must be removed with a suitable ridge reamer before piston
removal.
3. Rotate the crankshaft until one pair of big ends are at bottom dead center,
then remove the connecting rod cap bolts.
4. Remove the connecting rod caps and bearing shells (Fig. 7–21).
B–01989
Fig. 7–22 Removing Pistons
NOTE: If the bearing shells are to be used again, they should be marked to
identify them to their original locations. Identification marks should
be made on the steel (back) face.
5. Push the pistons and connecting rods carefully out through the top of the
block and remove as shown in figure 7–22.
6. Rotate the crankshaft through 180° to bring the other pair of big ends to
bottom dead center and remove them.
When piston removal has been done, keep each piston and rod assembly
separate, each to each as marked. Mark the pistons on the crown (before
removing the piston pin) to indicate the Front marking on the connecting rods.
825 Loader
113 of 176 –7–9– Service Manual
7–5.2 To Remove Pistons And Rings From The Connecting Rods
1. Remove the piston rings from each piston, using a piston ring tool, as shown
in figure 7–23.
NOTE: The laminated pieces fitted in the fourth ring groove should be
removed by hand.
7–5.3 Inspection
1. Thoroughly clean all the disassembled components.
NOTE: All ring gaps, ring groove clearances, etc., are given in the Technical
Data Section on page 8–1.
4. Check the gaps of the piston rings at the bottom of the bore.
5. Check the fit of the piston pin in the bushing. If worn, make replacement of
the bushing.
6. To make replacement of bushing, remove the old one with a press. The bore
should be cleaned and any burrs which are present should be removed.
Press in the new bushing, making sure that the oil holes are in alignment
when fitted. Ream out the new bushing to fit the piston pin (refer to the details
given on page 8–1), then check the rod for angle and twist (Refer to page B–01987
8–2). Fig. 7–24 Piston And Rod Numbering
7. Inspect the rod bearing inserts for signs of wear or pitting. Also inspect the
crankpins and, if out of round, remove the crankshaft from the engine for a
complete dimensional check, to determine whether grinding or a
replacement crankshaft is necessary. For details of crankshaft removal, See
Page 7–15.
7–5.4 To Install The Pistons To The
Connecting Rods
If the original pistons are to be fitted, they
must be assembled to the same
connecting rods, i.e., No. 1 piston to No.
1 connecting rod assembly. Refer to
Figures 7–24 and 7–25 for location of
piston and rod numbering. Any new
components fitted must be numbered
the same as the old components.
825 Loader
11482
Revised Feb. of 176 –7–10– Service Manual
2. Position No. 1 piston on its head, noting the position of the F mark indicating
Front. (When there is no mark, pistons can be installed either way.)
3. Hold No. 1 connecting rod with the small end between the piston pin bores
so that the word Front on the rod is towards the same side.
4. Push the piston pin into the piston to hold the connecting rod in position.
5. Install the two retaining snap rings making sure that they fit correctly in their
recesses (Fig. 7–26).
NOTE: If the engine has been in use for a long time, install new snap rings,
even if the old ones are not damaged. B–01878
Fig. 7–26 Piston Pin Retainer
6. Repeat this procedure for the other three pistons and connecting rods.
1. Slotted oil control – below the piston pin (fifth groove) (Item 1).
2. Slotted oil control – above the piston pin (fourth groove) (Item 2). 5 4
3. Internally stepped compression (third groove) (Item 3).
825 Loader
115 of 176 –7–11– Service Manual
When all the rings have been fitted, they must be as shown in Figure 7–28.
7–5.7 To Install Piston And Connecting Rod Assemblies
Before installing the piston and connecting rod assemblies in their respective
cylinder bores, thoroughly clean and wash each bore with clean engine oil.
1. Turn the engine until the crankpins of numbers 1 and 4 cylinders are at
bottom dead center.
2. Use a ring clamp of the type shown in Figure 7–29 carefully compress the
rings on No. 1 piston and hold in this position.
3. With the word Front on the connecting rod facing the front of the engine,
insert the rod carefully into No. 1 cylinder bore.
NOTE: The cylinders are numbered 1, 2, 3 & 4 starting from the (water
pump) end of the engine. It is important that these components
(marked as shown in figures 7–24 and 7–25) are installed in their
original locations.
4. The piston head may be hit lightly with the shaft of a hammer as shown in
figure 7–29 until all the rings have entered the cylinder bore.
5. Pull the rod towards the crankshaft, put the top half bearing shell in position
with the tag in the machined slot and add oil lubricant. Pull the rod fully onto
the crank pin.
7. Fit the two connecting rod fastening bolts and tighten evenly to 38 ft.–lbs.
(5,8 kgf/m) torque.
8. Use the same procedure for No. 4 piston and connecting rod assembly.
9. Rotate the crankshaft to bring numbers 2 and 3 crank pins to bottom dead
center.
825 Loader
116 of 176 –7–12– Service Manual
7–5.9 Cylinder Liners
The cylinder liners are made of cast alloy iron, they are an interference fit in the
cylinder block and are of the thinwall dry type.
Boring of these liners to a larger size is not possible and new liners must be fitted
when liners have become worn.
Dimensional checks of the cylinder bore is best done with an inside micrometer.
When checking liners each one should be measured in three positions – top,
center and bottom; the readings being taken parallel and at right angles to the
center line of the cylinder block, giving six readings for each cylinder bore.
When checking the internal bore of a new installed liner, first let the liner settle for
a period of time.
7–5.10 To Install New Cylinder Liners
1. Remove all the components from the cylinder block. (Refer to the specific
sections for details of their removal.)
2. Remove the cylinder head studs from the cylinder block top face.
3. Use a liner removal tool to pull the liners carefully out through the top of the
cylinder block (Fig. 7–30).
4. Clean the bore thoroughly and remove any burrs which may be present.
5. Thoroughly clean and dry the liner after the removal of any grease or
preservative.
8. Press the liner into the bore making sure that it enters squarely, check for
squareness with a machinists square.
9. Press the liner into the bore evenly until it contacts the solid washer.
A–02314
10. Follow same procedure for other liners.
Fig. 7–30 Liner Removal
11. Bore and hone the liners to the dimensions quoted on page 8–1.
NOTE: The liner height may make boring difficult where boring equipment
is mounted on the top face of the cylinder block. This may be
overcome by making a parallel plate to fit between the boring bar
and cylinder block face. Such a plate must be thicker than 0.027 inch
(0,686 mm) and have holes bored in it to give clearance around the
liners.
12. Assemble the engine components to the cylinder block. (Refer to the specific
sections for assembly of these components.)
825 Loader
117 of 176 –7–13– Service Manual
The main bearing caps are not interchangeable and must always be kept as a set
and regarded as an integral part of the block. The main bearing shells are located
in position in the same manner as the connecting rod bearing shells by means of
tabs, which locate in machined slots in the bearing housings.
NOTE: Before renewal of the main bearings is attempted, make sure that
the correct replacement parts are available.
2. Loosen the six capscrews which hold the main bearing caps.
3. Remove completely one of the main bearing caps and remove the bearing
shell from the cap.
4. Remove the top half of the bearing shell by pushing it, on the side opposite
to the one having the locating tab, using a strip of wood and rotating it on the
crankshaft as shown in Figure 7–32.
5. Inspect the bearing shells and if replacements are necessary, add light
lubricant and insert the new top half bearing shell, plain end first, into the side
having the tab location.
NOTE: To remove the rear main bearing cap, first remove the two oil seal
housing bolts as shown in Figure 7–33.
10. Finally, tighten the main bearings to 85 ft.–lbs. (11,5 kgf/m) torque.
NOTE: When both thrust washers and main bearing shells are being
installed, both operations would normally be done with the main
bearing cap removed.
3. Remove the rear main bearing cap and from it the two lower half thrust
washers (Fig. 7–34).
4. Remove the single upper half thrust washer by rotating it with a thin piece
of wood until it can be lifted out of its position.
NOTE: The new thrust washers should have a light lubrication with oil
before fitting. The steel faces of the lower thrust washers should
face towards the bearing cap (Fig. 7–35), the steel face of the upper
thrust washer should also face towards the cap.
5. Position the upper thrust washer half as shown in Figure 7–36, put the lower
halves on either side of the rear main bearing cap as described and install
the cap. B–01865
Fig. 7–32 Removing Bearing Insert
825 Loader
118 of 176 –7–14– Service Manual
6. Tighten the bolts evenly to 85
ft.–lbs. (11,5 kgf/m) torque.
2. Remove the crankshaft front pulley, timing case cover, timing gears and fuel B–01869
pump drive hub. (Refer to page 7–19.)
Fig. 7–35 Thrust Washer Position
3. Remove the fastening bolts (also any studs fitted) and remove the timing
case back plate.
4. Remove the oil pan and lubricating oil pump, complete with suction and
delivery pipes. (Refer to page 7–25.)
5. Remove all the connecting rod bolts, connecting rod caps and bearing shells.
(Refer to page 7–9.)
NOTE: All the bearing shells must be marked (on the steel face) to indicate
Top or Bottom and number of the rod assembly.
825 Loader
119 of 176 –7–15– Service Manual
7–6.5 To Reinstall The Crankshaft
1. First clean the crankshaft and
check that all the oilways are clear.
2. Clean the bearing housings, put
the three top bearing shells in
position then give them lubrication
with clean engine oil.
5. Clean the bore in the main bearing caps, fit the three lower bearing shells,
then give them lubrication with oil.
7. Check the main bearing bolts before installing for signs of stretch or thread
damage. When damaged, use new bolts.
8. Install bolts and tighten them evenly to 85 ft.–lbs. (11,5 kgf/m) torque.
9. Check that the crankshaft can be rotated freely. Check the crankshaft end
play with a feeler gauge as shown in Figure 7–37. If it is not within the limits
specified on page 8–2, then install oversize thrust washers to give the
necessary adjustment. (Refer to page 8–2.)
10. Install new seal strips to the rear main bearing oil seal housings and install
the housings as described under Crankshaft Rear End Oil Seal on page
7–17.
11. Put oil on the crank pins, install the connecting rod bearing shells, making
sure their positions are correct, then install the connecting rod caps as
described on page 7–12. The crankcase should now be as shown in Figure
7–38.
12. Install the lubricating oil pump complete with suction and delivery pipes.
(Refer to page 7–25.)
13. Install the oil pan using new seals and gaskets. (Refer to page 7–25.)
14. Install the timing case back plate, fuel pump drive hub, timing gears, timing
cover and crankshaft front pulley. (Refer to page 7–21 for their reassembly.)
15. Install and make correct alignment of the flywheel housing as described on
page 7–18.
825 Loader
120 of 176 –7–16– Service Manual
7–6.6 Crankshaft Rear End Oil Seal
The seal assembly location is in two half
housings bolted around the rear of the
crankshaft.
2. Press about 1.0 inch (25 mm) of the strip, at each end, into the ends of the
groove making sure that each end of the strip goes 0.010/0.020 inch
(0,25/0,50 mm) beyond the half housing face.
4. Fit the sealing strip to the other half housing, using same method.
5. Remove all of the old gasket from the cylinder block rear face and fit a new
gasket treated with a good sealing material.
7. Put graphite grease over the inside diameter surface of the strip.
8. Assemble the half housings around the crankshaft rear journal and fasten
together by the two bolts (See Fig. 7–40).
9. Turn the complete seal housing on the shaft to seal in the strips, and to make
sure that the assembly turns on the crankshaft.
10. Bolt the seal housing in position on the block and the rear main bearing cap B–01864
then tighten the bolts to block.
Fig. 7–40 Rear Main Seal Installation
7–7 FLYWHEEL AND FLYWHEEL HOUSING
7–7.1 To Remove The Flywheel
1. Remove the transfer chaincase and clutch housing from the flywheel
housing.
2. Straighten the locking tabs on the flywheel fastening bolts.
3. Remove the bolts and carefully remove the flywheel from the crankshaft
flange.
7–7.2 To Replace The Flywheel Ring Gear
1. The flywheel ring gear is a shrink fit on the flywheel. It can be removed by
cutting partway through the gear with a hacksaw and chisel cutting it from
the flywheel. Another method is to heat the ring gear to expand it enough to
hit it loose with a hammer, evenly, from the flywheel.
825 Loader
121 of 176 –7–17– Service Manual
2. The outer face of the flywheel should be thoroughly cleaned to give a smooth
fit when the new ring gear is installed.
3. Clean, then heat the new ring gear to a temperature not more than 480°F
(250°C).
4. Fit the ring gear over the flywheel with the lead on the teeth facing uppermost
(facing away from the engine when the flywheel is installed). Rotate the gear
quickly on its location as soon as it is fitted to make sure that it is laying flat,
then let cool.
3. Install a dial indicator with the base against the rear face of the flywheel
4. When the flywheel is correctly aligned, lock the bolts with the tab washers.
1. Make sure that the rear face of the cylinder block and the face of the flywheel
housing are clean and free from burrs, etc. Check dowel location in block and
housing.
2. Position the flywheel housing carefully on the two dowels and install the
fastening bolts.
1. Loosen the alternator fastening bolts, remove the adjusting arm bolt and
remove the fan belt.
3. Remove the crankshaft pulley holding bolt and washer and use a puller tool
to remove the pulley. (Keyed fit on the crankshaft.)
4. Remove the bolts and nuts from the timing case and carefully remove the
cover, being careful not to catch the rubber lip of the oil seal on the crankshaft
pulley locating key.
825 Loader
122 of 176 –7–18– Service Manual
7–8.2 Replacement Of The Crankshaft Front Oil Seal
1. Use a press to remove the oil seal from the timing case cover by pushing out
through the front.
2. Put the new seal in position so that the lip faces inwards.
3. Press in the new seal from the front until it is lightly against the seal holding
lip.
1. Thoroughly clean the faces of the timing case front cover and the timing case
back plate. B–01880
Fig. 7–42 Idler Gear
2. Using a new gasket with a light application of sealing material, put the front
cover in position being careful not to damage the rubber lip of the oil seal on
the crankshaft key.
5. Install the crankshaft pulley holding bolt and washer and tighten to 150
ft.–lbs. (20,5 kgf/m) torque.
2. Straighten the locking tabs and unturn the two idler hub holding bolts.
3. The bolts, idler gear and hub may now be removed together as shown in
Figure 7–42.
4. Clean and thoroughly inspect the gear and hub for signs of heavy wear,
cracks, etc.
NOTE: Clearance is given in the bolt holes of the idler gear hub, so that it
may be moved slightly to give the necessary backlash adjustment
for the timing gears.
4. Make adjustment of the idler gear until gear play between both crankshaft
gear/idler gear and camshaft gear/idler gear is within the range given on
page 8–5 with the gears held together. Gear play can be checked with a
feeler gauge as shown in Figure 7–44.
5. When the gear play has correct adjustment, tighten the idler gear hub bolts
to 32 ft.–lbs. (4,4 kgf/m) torque.
6. Check the idler gear end play as shown in Figure 7–45, the limits are given
on page 8–5. C–01812
Fig. 7–45 Idler Gear End Play
825 Loader
123 of 176 –7–19– Service Manual
7. Lock the idler gear hub bolts with
the tab washers.
3. Install the gear to the camshaft making sure the D marks on the gear and D Marks
camshaft hub are in alignment as shown in Figure 7–47.
4. Install the three bolts and tighten to a torque of 19–21 ft.–lbs. (2,6–2,9
kgf/m)*.
NOTE: Only the round (not–slotted) holes in the camshaft gear are to be
used and these will make alignment with the tapped holes on the
camshaft hub when the D marks are in alignment.
5. Install the idler hub and gear, timing case front cover, etc., as described
earlier in this section.
B–01884
7–8.7 To Remove The Fuel Pump Gear Fig. 7–47 Camshaft Gear
1. Remove the timing case front cover as described earlier in this section.
2. Remove the idler gear and hub as described earlier in this section. Timing
Marks
3. Remove the three bolts and carefully pull the gear from its location on the
fuel pump drive hub.
4. Clean and thoroughly inspect the gear for signs of wear, cracks, pitting, etc.
825 Loader
124 of 176 –7–20– Service Manual
3. Install the idler gear and hub, timing case front cover, etc., as previously
detailed in this section.
*Tightening these bolts to the correct torque is more easily done after the idler gear
and hub have been installed.
7–8.9 to Remove The Fuel Pump Drive Hub
1. Remove the timing case front cover as described earlier in this section.
3. Remove the low and high pressure fuel pipes from the fuel (injection) pump
and plug the openings.
4. Remove the fuel pump fastening bolts and remove the pump.
5. Remove the drive hub snap ring with a pair of snap ring pliers (Fig. 7–50).
7. Clean and examine the drive hub and the bearing for signs of wear, surface
cracks, pitting, etc.
NOTE: The bearing is a tight fit in the cylinder block and replacement must
be made with a puller, or press if the block is completely stripped.
Install the new one in the reverse method.
1. Install the drive hub in the bearing and locate with the snap ring as shown Snap Ring
in Figure 7–50. Hub
2. Check the drive hub end play with feeler gauges placed between the front
face of the bearing and the rear face of the drive hub. The end play limits are
given on page 8–5.
4. Install the low and high pressure fuel pipes to the fuel pump.
5. Install the fuel pump drive gear, idler gear and hub, timing case front cover,
etc., as described earlier in this section. B–01882
Fig. 7–49 Pump Drive Hub
825 Loader
125 of 176 –7–21– Service Manual
7–8.12 To Install The Timing Case
Back Plate Thrust
Plate
1. Make sure that both the cylinder
block and timing case back plate
faces are clean. Install the timing
case back plate to the cylinder
block using a new gasket and
sealing material.
1. Remove the cylinder head cover, rocker shaft and push rods.
NOTE: If it is not possible to turn the engine block over, then remove the
side cover and lift the tappets to the top of their locations and hold
them with clips.
5. Remove the oil pan and lubricating oil pump assembly. (Refer to page 7–26
for details of their removal.)
NOTE: The camshaft cannot be removed with the oil pump in position.
6. Remove the timing cover back plate as described earlier, this will show the
camshaft and thrust plates as illustrated in Figure 7–51.
7. Pull the camshaft out from the block and catch the two thrust plates as they
come out of their recess in the cylinder block.
8. Pull out the camshaft as shown in Figure 7–52 taking the weight of the
camshaft and exercising great care to ensure that the cams and journals are
not damaged during this operation.
9. If desired, the tappets may now be removed by lifting them out of their
locations (Fig. 7–53).
10. Thoroughly clean the camshaft and tappets, then inspect for signs of wear,
surface cracks, pitting, etc.
825 Loader
126 of 176 –7–22– Service Manual
3. Before the camshaft is pushed
fully in, locate the two thrust
plates (Fig. 7–54) (one of which
locates on the dowel in the
recess) in position, either side Thrust Plate
of the camshaft hub, when
correctly located the camshaft
can be pushed fully in and will
appear as in Figure 7–51.
If the cylinder head assembly is still in Fig. 7–56 Alignment Of Timing Marks
position, it is best to remove the
injectors and rocker shaft to make
timing easier.
825 Loader
127 of 176 –7–23– Service Manual
3. Install the fuel pump gear on to the fuel pump drive hub, making sure that
the stamped timing marks align as shown in figure 5–58. Fasten with the
three bolts. Timing
Marks
4. Install the idler gear so that the double dots on the idler gear are in alignment
to the single dot on the crankshaft gear and single line (or dot) on the
camshaft gear, with the single dot on the idler gear in alignment with the
double dots on the fuel pump gear. These timing marks when correctly
positioned will appear as shown in Figure 7–56.
5. Put the idler gear with the hub and install the two retaining screws using a
new washer.
1. Turn the crankshaft until the valves of No. 4 cylinder are both moving (Page
7–25).
2. In this position set the valve clearance of No. 1 inlet valve to 0.039 inch (1,0
mm).
Timing Pin
3. Turn the engine slowly in the normal direction of rotation until the clearance
of No. 1 inlet valve is just taken up. (In this condition it will be possible to rotate B–01872
No. 1 inlet valve push rod between the thumb and the forefinger.) Fig.7–59 Timing Pin
4. Nos. 1 and 4 pistons will now be at T.D.C. if the timing has been correctly set.
NOTE: If valve timing is incorrect and the camshaft gear has been correctly
fitted to the camshaft hub, the error will probably be due to wrong
alignment of the original timing marks on the drive gears (Check as
detailed on page 7–23).
When valve timing is originally set and checked during production a timing
tolerance of plus or minus 2–1/2 (flywheel) degrees is available for item (4) above.
When the timing has been correctly set, do not forget to reset No. 1 inlet valve
clearance to the correct figure also to return the timing pin to its correct location
if it has been used to check T.D.C.
825 Loader
128 of 176 –7–24– Service Manual
7–8.18 Adjusting Valve Clearance
825ServiceManual#6549899–EngineServiceSectionPart1of4
Following the firing order sequence (1, 3, 4, 2) turn the engine so that the valves
of No. 1 cylinder are in the position of valve overlap (the period between the
opening of the inlet valve and the closing of the exhaust valve). In this position,
make adjustment for clearances of the No. 4 cylinder; then with No. 3 cylinder
valves in the valve overlap, make adjustment of valves of No. 2 cylinder; with No.4
3. Remove the oil pan fastening screws and remove the pan carefully.
Thoroughly clean the pan before installing.
1. Remove all pieces of the gasket from the pan and crankcase faces and
pieces of cork strip from around the front and rear main bearing caps.
2. Put a light application of gasket compound on the crankcase and pan faces
and position the gasket so that all the holes are in alignment.
NOTE: When the gaskets are being put in position, it is important that the
shaped ends go right up into the recesses in the front and rear main
bearing caps.
3. Put a light application of gasket compound on the cork strips, then press
these strips into the grooves in the main bearing caps.
4. Put the pan in position and install all of the fastening screws. Tighten them
evenly.
5. Install the dipstick and pan drain plug, then fill with clean new oil of correct
grade to the full level. Do not overfill.
825 Loader
129 of 176 –7–25– Service Manual
7–9.4 To Remove The Oil Pump
Remove
2. Remove the drive gear with a
puller.
7–9.6 Inspection
B–01888
Fig. 7–62 Lube Oil Pump Removal
825 Loader
130 of 176 –7–26– Service Manual
2. Install the drive shaft complete with inner rotor, then the outer (driven) rotor
making sure that the face which holds the tapered edge enters the pump
body first (Fig. 7–63). Now make the three following dimensional checks:
(a) Check the clearance between the inner and outer rotor (Fig. 7–64). Outer
Rotor
(b) Check the clearance between the outer rotor and the pump body (Fig.
7–65).
(c) Check the clearance between the rotors and the end cover assembly
using a straight edge and feeler gauge (Fig. 7–66).
3. Install the end cover assembly and install the four bolts. Be sure of correct
positioning so that the suction and delivery pipes will fit correctly. A–02311
Fig. 7–63 Rotor And Oil Pump
4. Press the oil pump drive gear onto the shaft.
5. Rotate the pump by hand to make sure that it turns quite freely.
3. Tighten the delivery pipe at both ends, install the screw holding the suction
pipe assembly.
4. Tighten the suction pipe at the pump end, then install the strainer on the end
of the suction pipe.
NOTE: The strainer which fits on the end of the suction pipe must be
thoroughly cleaned in cleaning fluid before being installed. It is best
to remove the strainer and clean it thoroughly whenever the oil pan
is removed.
A–02312
5. Carefully install the sump as described earlier and fasten with the bolts. Fig. 7–64 Checking Rotor Clearance
6. Fill the oil pan to the correct level with clean oil of an approved grade.
NOTE: Be careful starting the engine, since it will take a moment for the oil
pump and pipes to charge. The engine speed should be kept to a
minimum until the gauge shows enough pressure. (Oil pressure
warning light is off.)
The best way to prime the lubricating oil
pump is to crank the engine for about 10
to 20 seconds before starting the
engine.
7–9.9 Oil Pressure Relief Valve
The oil pressure relief valve is part of
the oil pump end cover, which is
fastened to the rotor housing by four
capscrews. This relief valve controls
the maximum oil pressure by moving a
spring loaded plunger and sending
extra oil back to the oil pan when the oil
pressure goes above the spring
pressure setting. A–02346 B–01879
Fig. 7–65 CheckingOuter Rotor Clearance Fig. 7–66 Oil Pump Rotor Clearance
825 Loader
131 of 176 –7–27– Service Manual
7–9.10 To Dismantle The Oil Pressure
Relief Valve
Housing
1. Empty the engine oil from the oil
pan.
Plunger
2. Remove the oil pan fastening bolts
and carefully remove the oil pan. Spring Cap
6. Remove the split pin from the end of the housing and pull out the spring cap,
spring and plunger. A view of the assembly is shown in Figure 7–67.
7. Thoroughly clean the parts, inspect for wear or damage and install new when
necessary.
1. Install the plunger, spring and spring cap, then fasten with the split pin.
If a tester is available, check the pressure setting of the relief valve. If a tester is
not available, then be careful when starting the engine until it is sure that the
pressure relief valve is working correctly.
825 Loader
132 of 176 –7–28– Service Manual
NOTE: When a new belt has been
installed, check the 1
adjustment again after a 12
short running period. 1. Pump Body
2 3 3 2. Seal
11 3. Shaft Bearings
7–10.3 Water Pump 4. Retaining Circlip
4
5. PUmp Shaft
The water pump shaft rotates within two 6. Distance Piece
bearings. The impeller aids the 5
7. Flange–Oil–Seal
circulation of the water through the Retaining
system. Water is held within the impeller 8. Retainer–Oil Seal
chamber by a carbon–faced seal which 9. Flange–Water Pump
is spring pressed against the face of a Thrower
phosphor bronze bearing in the pump 10. Impeller
body. Figure 7–68 shows the positions of 10 11. Seal
the assembled parts. 12. Insert
8 6
7–10.4 Remove The Water Pump 9 7
2. Remove the water pump pulley with a puller, the holes in the pulley face may
be used for this purpose (Fig. 7–69).
3. Press the shaft out of the pump body from the pulley end complete with water
pump thrower, insert, seal and impeller.
4. Remove the impeller from the pump drive shaft with a puller or press.
5. Remove the bearing snap ring. Use a press to push out the two shaft
bearings, complete with spacer, out through the front of the pump body.
6. Remove the felt seal and holding flanges. A–02309
Fig. 7–69 Water Pump Pulley Removal
7–10.6 Inspection
2. Inspect the pump body for cracks, corrosion or any other damage. Install
new when necessary.
3. Inspect the shaft and bearing assembly for wear or corrosion. Install new
when necessary.
4. Inspect the water thrower flange for damage or corrosion. Install new when
necessary.
5. Inspect the water pump seal and inspect for wear, scoring or cracks on the
sealing faces. Install new when necessary.
6. Remove rust and scale from the impeller and inspect for corrosion or other
damage. Install new when necessary.
7. Inspect the pump pulley for signs of cracks, corrosion or any other damage.
Install new when necessary.
825 Loader
133 of 176 –7–29– Service Manual
7–10.7 To Assemble The Water Pump
1. Install the oil seal holder and oil seal, followed by the oil seal holding flange.
2. Fit the two bearings and spacer onto the shaft and pack the space between
the two bearings about 3/4 full of high temperature grease.
3. Press the bearing and shaft assembly into the pump body, impeller end first
and locate with the snap ring.
4. Press the water thrower flange into position on the drive shaft.
5. Thoroughly clean the insert recess and drain hole in the pump body.
A–02313
6. Lightly coat the inner diameter of the insert area and outside diameter of the Fig. 7–70 Pump Impeller Clearance
insert with sealing material.
7. After removing any traces of oil or grease from the insert, press it fully in.
Remove all extra sealing material.
NOTE: Special care must be taken during this operation not to mark the
face upon which the seal contacts.
8. Place the carbon–faced seal on the drive shaft so that this face contacts with
the insert face.
9. Press the impeller onto the shaft over this seal until the clearance of 0.005
10. Press the pulley fully onto the shaft and install the nut.
1. Make sure that the faces of the water pump, water pump backplate and
cylinder block are clean and free from pieces of old gasket.
2. Fit the backplate followed by the water pump to the cylinder block, using new
gaskets. Put a light application of gasket compound on the two surfaces.
3. Fasten the water pump assembly to the cylinder block with the four bolts.
7–10.9 Thermostat
A thermostat is located in a housing at the front of the cylinder head, inside the
water outlet connector to the radiator.
The thermostat works by restriction of the water circulation until the water in the
thermostat housing is at a specific temperature. A valve in the thermostat then
opens and the normal coolant circulation through the system takes place.
7–10.10 To Remove The Thermostat
1. Empty the coolant from the radiator.
2. Remove the water hose from the engine water outlet connection at the front
of the cylinder head.
3. Remove the two nuts and washers which hold the outlet connection to the
thermostat housing.
825 Loader
134 of 176 –7–30– Service Manual
4. Remove the outlet connection and gasket.
3. If the unit does not function properly, then a replacement thermostat will be Fig. 7–71 Removing Thermostat
necessary. No adjustment of these units is possible.
3. If no fuel flows, check for fuel in the tank and that the pipe from the fuel tank
is clear and has no air leaks. If there still is no delivery of fuel, replace the
pump.
4. After you have fuel flow, connect a 0–10 PSI pressure gauge to the outlet
of the pump. Make sure connections are tight so there are no leaks. Turn the
engine for ten seconds and record the maximum pressure on the gauge.
Make reference to the chart and when pressure is not to acceptable
minimum, replace the pump.
5. Check the time necessary for the pressure to drop to half the pressure
reached while the engine was turning. If the time was less than thirty
seconds, replace pump.
ACCEPTABLE
PUMP STANDARD MINIMUM
ENGINE TYPE PRESSURE PRESSURE
4.108 2 or 4 bolt 6 PSI (41,37 kPa) 4.5 PSI (31,02 kPa)
2. Remove the two nuts and washers holding the pump to the tappet inspection
cover.
825 Loader
135 of August
Revised 176 79 –7–31– Service Manual
7–11.3 Fuel Injection Pump
7–11.4 To Remove The Fuel Injection Pump
1. Remove the four high pressure pipes between the pump and the injectors
and cover all openings to keep out dirt.
2. Remove the low pressure fuel pipes from the inlet and outlet connections and
cover the openings.
3. Disconnect the stop and throttle controls and return springs. Fuel Pump
4. Remove the two nuts and the socket headed bolt which hold the fuel pump
to the fastening flange together with the spring and flat washers. B–01995
Fig. 7–74 Removing Fuel Pump
5. Carefully remove the fuel pump (Fig. 7–74).
7. Connect the throttle and stop controls together with their return springs.
8. Charge the fuel system with fuel oil as explained on page 7–35.
1. Turn the engine until No. 1 piston is at T.D.C. on the compression stroke.
(Both valves of No. 4 cylinder moving.)
2. Loosen the valve adjusting screw on No. 1 exhaust valve enough so that the
rocker lever can be moved to one side and the push rod removed. Rotate
the rocker lever on the shaft so that there is access to the valve springs for
using a valve spring compressor.
825 Loader
136 of 176 –7–32– Service Manual
3. Remove the valve springs from No. 1 exhaust valve and let the valve head
rest on the piston crown.
825ServiceManual#6549899–EngineServiceSectionPart2of4
4. Mount a dial indicator on top of the valve stem as shown in Figure 7–76 and
zero the gauge at the point of maximum cylinder height (determined by
turning the engine just over T.D.C.).
5. When the gauge has been set at zero, turn the engine AGAINST normal
direction of rotation until the piston (and valve) have moved a distance of
0.120 inch (3,05 mm) down the cylinder bore.
NOTE: This is equal to 19° angle movement of the flywheel B.T.D.C. and is
the static timing point.
A–02347
6. When this static timing point has been accurately determined, the C line on Fig. 7–76 Fuel Pump Timing
the fuel pump rotor must be in alignment with the straight edge of the timing
snap ring (Fig. 7–77).
NOTE: Do not move the snap ring in the pump. It is set by the manufacturer.
9. When the fuel pump timing adjustment has been made, slowly turn the
engine to T.D.C. in the normal direction of rotation, remove the dial indicator
and install the valve springs.
10. Install the push rod and make valve clearance adjustment.
7–11.6a Timing The fuel Injection Pump (Using Timing Tool MS67123)
2. Turn the engine until No. 1 cylinder is a T.D.C. on the compression stroke
(Both valves of the No. 4 are moving).
B–01883
Fig. 7–78 Fuel Pump Gear
825 Loader
137 of October
Revised 176 79 –7–33– Service Manual
3. Loosen the adjusting bolt of the rocker arm on the No. 1 cylinder exhaust
valve, so that the rocker arm can be moved to the one side and the pushrod
removed. Move the rocker arm so that a valve spring compressor can be
used to remove the valve springs (Fig. 7–78a).
4. Remove the valve springs from the No. 1 cylinder exhaust valve and put the
valve head on the top of the piston crown.
5. Install a dial indicator on the top of the valve stem (Fig. 7–76). Turn the
engine backward and forward to find T.D.C. (maximum piston height) and
zero the dial indicator.
NOTE: Do not turn the engine crankshaft too far because the valve can fall
into the combustion chamber. B–03303
Fig. 7–78a Removing Valve Springs
6. Remove the fuel injection pump (See Paragraph 7–11.4).
7. Loosen the screw (Fig. 7–78b, Item 1) on the timing tool and set the gauge
as shown in the chart below. 3
1
8. Install the shaft of the timing tool into the drive hub for the injection pump (Fig.
7–78c). The tool will fit in only one position because of the special spline. Be
sure that the tool is tight against the flange on the engine.
9. Tighten the screw (Fig. 7–78b, Item 2) to hold the body and the shaft
together. B–03352
Fig.7–78c Installing Tool On Engine
10. Loosen the screw (Fig. 7–78d, Item 1) and move the plate with the mark Flange
close to the flange on the engine (Fig. 7–78d). Tighten the screw.
11. Turn the timing tool in the opposite direction of the normal rotation of the
injection pump so that there is no play in the gears.
12. After completing steps 1– thru 11 above, the mark on the plate must be in
alignment with the mark on the flange on the engine.
NOTE: If the marks are 180° apart, the No. 1 cylinder is not at T.D.C.
825 Loader
138 of Feb.
Revised 176 82 –7–33a– Service Manual
13. If the marks are not in alignment, make adjustments to the gear for the
injection pump (Fig. 7–78). (See Paragraph 7–8.1, To Remove Cover On
825ServiceManual#6549899–EngineServiceSectionPages33a–33b
1. Loosen the screw (Fig. 7–78b, Item 2) and remove the shaft from the body
of the timing tool.
2. Loosen the screw (Fig. 7–78b, Item 3) and remove the plate with the mark. 1
Install the plate again the opposite way. Tighten the screw.
B–03353
3. Loosen the screw (Fig. 7–78b, Item 1) and set the gauge as shown in the
chart. Fig. 7–78e Timing Tool On Injection Pump
4. Install the timing tool on the shaft of the injection pump. The tool will fit in only
one position because of special spline (Fig. 7–78c).
5. Connect a test pump (for testing injection pumps and fuel injectors) to the
No. 1 outlet of the injection pump.
6. Operate the test pump until the pressure is 440 PSI (3033 kPa) maximum.
7. Turn the tool in normal direction of rotation (normal rotation is shown on the
plate of the pump) until you cannot turn it further.
9. The mark on the plate must be in alignment with the mark on the pump
flange.
NOTE: The mark on the flange of the pump is made at the factory. The mark
will almost all the time be correct, but if it is not, you must grind the
old mark off and make a new mark.
825 Loader
13982
Revised Feb. of 176 –7–33b– Service Manual
7–11.9 Injector Problems
The following are an indication of possible faulty injectors:
1. Misfiring (running rough).
2. Knocking in one (or more) cylinders.
3. Engine overheating.
4. Loss of power.
5. Smoky exhaust (black).
6. Increased fuel required.
Injector
B–01860
7–11.10 Testing For Faulty Injector Fig. 7–79 Injector Position
If an injector is not working correctly and it is not known which one is at fault, loosen
the pipe nut at the injector end of the high pressure fuel pipe. Do this with each
injector (with the engine running at approximately 1,000 rev/min). Tighten each
pipe nut before going to the next. The faulty injector, when checked in this manner,
will have little or no effect on the running of the engine.
7–11.11 Injector Removal
After stopping the engine, remove the nuts from the flange of the faulty injector
and pull the complete unit from the cylinder head.
7–11.12 Injector Installation (Fig. 7–79)
NOTE: These copper sealing washers are specially made for the job. They
must seal against very high pressures and be of correct thickness
to give the best engine performance. Do not use washers of
different type.
3. Put the injector in position in the cylinder head, locate the flange correctly on
the fastening studs and press the injector fully into the bore, against the
sealing washer.
4. Hold the injector squarely into its location with one hand, and install the
fastening nuts on each stud, just finger tight, with the other hand.
NOTE: Do not tighten the nuts fully down on the fastening studs yet.
6. Fit the high pressure fuel pipes between the fuel pump and the injectors,
again at this time, just finger tight.
7. Tighten the injector flange fastening nuts evenly to the torque specification
given on page 8–7. (Tighten each nut a little at a time, going from one to the
other until torque is correct.)
8. Tighten the high pressure fuel pipes at both ends, and install the fuel return
lines.
825 Loader
140 of 176 –7–34– Service Manual
The pipes must be clean (wash in clean fuel oil and blow through the fine bore with
compressed air), the fittings at each end should not be split or compressed, or
leakage will result and a new pipe will be needed.
Be sure when installing, that the pipe fits squarely at both ends and that the nuts
are tight but not over tight.
When changing an injector, always loosen both the nuts or remove the pipe
completely, do not leave one end tight and the pipe under tension. The correct size
wrench for the job is a 5/8 inch open end.
7–11.13a Using C.A.V. Thermostart Units
If the engine is difficult to start in cold weather or, black smoke is coming from the
exhaust, the thermostart unit has a defect and must be replaced.
If the engine has not been started for five days or more, operate the starter until
it turns the engine several times or operate the priming lever several times to get
fuel pressure.
3. Try to start the engine. If the engine does not start in 20 seconds, push the
preheat button again and hold it ON for 10 seconds.
825 Loader
141 of August
Revised 176 79 –7–35– Service Manual
825ServiceManual#6549899–EngineServiceSectionPart4of4
5. When the engine starts, release the starter switch and set the throttle for the
smoothest slow running speed.
1. Loosen the air vent valve (Item 1) near the top of the control gear housing
(Refer to 7–80).
2. Loosen the vent valve (Item 2) fitted on one of the two hydraulic head locking
3. Loosen the vent screw on the top of the secondary fuel filter (Refer to Fig.
7–81).
4. Operate the priming lever on the fuel feed pump (Refer to Fig. 7–82) and
when fuel, free from air bubbles, flows from each venting point, tighten the
screws in the following order:
(a) Filter cover vent screw (Fig. 7–81).
(b) Hydraulic head screw (Fig. 7–80, Item 2).
(c) Gear housing vent valve (Fig. 7–80, Item 1).
5. Loosen the tubeline fitting at the injector end of all the injector high pressure
lines (Fig. 7–83).
7. Turn the engine with the starter until air–free oil comes out from the loose
fittings. B–03873
Fig. 7–82 Fuel Lift Pump
8. Tighten all the injector line fittings and start the engine.
Loosen Fittings
B–03948
Fig. 7–83 Injectors Fittings
825 Loader
14282
Revised Feb. of 176 –7–36– Service Manual
SPECIFICATIONS
Paragraph Page
Number Number
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4 8–5
DE–RATING FOR ALTITUDE . . . . . . . . . . . . . . . . . . . . . . . . . . 8–7 8–7
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5 8–5
LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 8–10 8–11
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 8–5
SERVICE WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6 8–6
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9 8–10
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 8–1
TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2 8–5
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 8–8 8–7
825 Loader
143 of 176 –8––1– Service Manual
Dealer Copy -- Not for Resale
825 Loader
144 of 176 –8–0– Service Manual
8–1 SPECIFICATIONS
a
8–1.1 Cylinder Block
Camshaft Bore Dia. No. 1 . . . . . . . . . . . . 1.794/1.7955 in. (45,568/45,606 mm)
Camshaft Bore Dia. No. 2 . . . . . . . . . . . . . . 1.784/1,787 in. (45,314/45,390 mm)
Camshaft Bore Dia. No. 3 . . . . . . . . . . . . . . 1.776/1.778 in. (45,110/45,161 mm)
8–1.2 Cylinder Liner (Cast Iron)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry – Interference Fit
Interference Fit of Liner . . . . . . . . . . . . . . . . . . 0.003/0.005 in. (0,076/0,127 mm)
Inside Dia. of Liner after
Finish Boring and Honing . . . . . . . . . . . . . 3.125/3.126 in. (79,375/79,400 mm)
Height of Liner in Relation to Cylinder Block
Top Face . . . . . . . . . . . . . . . . . . . . . 0.023/0.027 in. (0,584/0,686 mm) ABOVE
8–1.3 Pistons
Piston Height in Relation to
Cylinder Block Top Face . . . . . . . . 0.002/0.006 in. (0,051/0,152 mm) ABOVE
Bore Dia. for Piston Pin . . . . . . . . . . . 1.96255/1.96275 in. (26,989/26,994 mm)
Compression Ring Groove
Width – Top . . . . . . . . . . . . . . . . . . . . . . . . . 0.0805/0.0815 in. (2,045/2,070 mm)
Compression Ring Groove
Width – Second . . . . . . . . . . . . . . . . . . . . . . 0.0645/0.0655 in. (1,638/1,664 mm)
Compression Ring Groove
Width – Third . . . . . . . . . . . . . . . . . . . . . . . . 0.0645/0.0655 in. (1,638/1,664 mm)
NOTE: There is a 0.030 in. (0,762 mm) x 0.148/0.152 in. (3,759/3,861 mm)
steel insert fitted into the top groove and located immediately above
the top compression ring. Do not remove this insert.
8–1.4 Piston Rings
Top Compression Ring Width . . . . . . . . . . 0.0771–0.0781 in. (1,958/1,984 mm)
Ring Clearance in Groove . . . . . . . . . . . . . . 0.0024/0.0044 in. (0,051/0,102 mm)
Second and Third Compression Ring Width
0.0615/0 .0625 in. (1,562/1,587 mm)
Ring Clearance in Groove . . . . . . . . . . . . . . . . 0.002/0.004 in. (0,051/0,102 mm)
Fifth Scraper Ring Width . . . . . . . . . . . . . . . 0.1865/0.1875 in. (4,737/4,762 mm)
Ring Clearance in Groove . . . . . . . . . . . . . . 0.0025/0.0045 in. (0,063/0,114 mm)
Ring Gap – (Cast Iron) . . . . . . . . . . . . . . . . . . . . . 0.009/0.020 in. (0,23/0,51 mm)
(Chrome) . . . . . . . . . . . . . . . . . . . . . . 0.012/0.023 in. (0,31/0,59 mm)
The above ring gap is for a bore diameter of 3.125 in. (79,38 mm). Where the bore
diameter is greater than this, the ring gap will be greater and for every 0.001 in.
(0,03 mm) increase to the above bore diameter, 0.003 in. (0,08 mm) should be
added to the quoted ring gap.
8–1.4 Piston Pin Bushing
Length of Bushing . . . . . . . . . . . . . . . . . . . . . 0.935/0.955 in. (23,749/24,257 mm)
Outside Diameter of Bushing . . . . . . . . . . . . 1.221/1.222 in. (31,013/31,039 mm)
Inside Diameter Before Reaming . . . . . 1.0495/1.0545 in. (26,657/26,784 mm)
Inside Diameter After Reaming . . . . . . 1.06315/1.0632 in. (27,004/27,005 mm)
Clearance Between Bushing
Piston Pin . . . . . . . . . . . . . . . . . . . . . . . 0.00045/0,0007 in. (0,0114/0,0178 mm)
8–1.5 Connecting Rod
Big End Bore Diameter . . . . . . . . . . . . . . . 2.146/2.1465 in. (54,508/54,521 mm)
Small End Bore Diameter . . . . . . . . . . 1.21875/1.21975 in. (30,956/30,981 mm)
Connecting Rod Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.375 in. (3/8 in.) U.N.F.
Connecting Rod End Float . . . . . . . . . . . . . . 0.0065/0.0105 in. (0,165/0,267 mm)
825 Loader
145 of Feb.
Revised 176 82 –8–1– Service Manual
8–1.6 Connecting Rod Alignment
Large and small end bores must be square and parallel with each other within the
limits of ± 0.010 in. (0,25 mm) measured 5 in. (127 mm) each side of the axis of
the rod on test mandrel as shown in Fig. 1. With the small end bushing installed
the limit of ± 0.010 in. (0,25 mm) is reduced to ± 0.0025 in. (0,06 mm).
Crankshaft
Main Journal Diameter Nos. 1 and 2 . . . . 2.248/2.2485 in (57,099/57,112 mm)
Main Journal Diameter No. 3 . . . . . . . . . . 2.2475/2,248 in. (57,086/57,099 mm)
Main Journal Length No. 1 . . . . . . . . . . . . . . . . . . . . . . . 1.40625 in. (35,719 mm)
Main Journal Length No. 2 . . . . . . . . . . . . . . 1.496/1.504 in. (38,075/38,151 mm)
Main Journal Length No. 3 . . . . . . . . . . . . . . 1.499/1.502 in. (38,075/38,151 mm)
Main Journal Fillet Radii . . . . . . . . . . . . . . . . . . 0.125/0.141 in. (3,175/3,581 mm)
Crankpin Diameter . . . . . . . . . . . . . . . . . . 1.9995/2.000 in. (50,787/50,800 mm)
Crankpin Length . . . . . . . . . . . . . . . . . . . . 1.1875/1,1895 in. (30,969/4,366 mm)
Crankpin Fillet Radii . . . . . . . . . . . . . . . . 0.15625/0.17187 in. (3,969/4,366 mm)
Surface Finish – All Journals . . . . . . . . . . . . . 8––16 micro–in. (0,2––0,4 micron)
Main Journal and Crankpin
Regrind Undersizes . . . . . . . . . . . 0.010,0.020,0.030 in. (0,25,0,51, 0,76 mm)
Oil Seal Helix Diameter . . . . . . . . . . . 2.21075/2.21175 in. (56,153/56,178 mm)
Oil Seal Helix Width . . . . . . . . . . . . . . . . . . . . . 0.050/0.080 in. (1,270/2,032 mm)
Oil Seal Helix Depth . . . . . . . . . . . . . . . . . . . . . 0.004/0.008 in. (0,102/0,203 mm)
Flange Diameter . . . . . . . . . . . . . . . . . . 3.9985/3.995 in. (101,562/101,587 mm)
Flange Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.500 in. (12,700 mm)
Spigot Bearing Recess Depth . . . . . . . . . . . . . . . . . . . . . . . 0.875 in. (22,225 mm)
Spigot Bearing Recess Bore . . . . . . . . . . . . . . . . . . . . . . . . 1.250 in. (31,750 mm)
825 Loader
146 of 176 –8–2– Service Manual
8–1.11 Camshaft
No. 1 Journal Diameter . . . . . . . . . . . . . . . . . 1.791/1.792 in. (45,491/45,517 mm)
No. 1 Cylinder Block Camshaft
Bore Diameter . . . . . . . . . . . . . . . . . . . . . 1.794/1,7955 in, (45,568/45,606 mm)
No. 1 Journal Running Clearance . . . . . . . . . 0.002/0.0045 in. (0,051/0,114 mm)
No. 2 Journal Diameter . . . . . . . . . . . . . . . . . 1.781/1.782 in. (45,237/45,263 mm)
No. 2 Cylinder Block Camshaft . . . . . . . . . . 1.784/1.787 in, (45,314/45,390 mm)
No. 2 Journal Running Clearance . . . . . . . . . . 0.002/0.006 in. (0,051/0,152 mm)
No. 3 Journal Diameter . . . . . . . . . . . . . . . . . 1.773/1.774 in. (45,034/45,060 mm)
No. 3 Cylinder Block Camshaft
Bore Diameter . . . . . . . . . . . . . . . . . . . . . . . 1.776/1.778 in. (45,110/45,161 mm)
No. 3 Journal Running Clearance . . . . . . . . . . 0.002/0.005 in. (0,051/0,127 mm)
Cam Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.266 in. (6,766 mm)
8–1.12 Camshaft Thrust Plates
Thrust Plate Outside Diameter . . . . . . . . . . 2.555/2.557 in. (64,897/64,948 mm)
Thrust Plate Inside Diameter . . . . . . . . . . . . . . . . . . . . . . . . 1.500 in. (38,100 mm)
Thrust Plate Thickness . . . . . . . . . . . . . . . . . . . 0.160/0.162 in. (4,060/4,115 mm)
Thrust Plate Height in Relation to
Cylinder Block Face . . . . . . . . . . . . . . . . 0.004 in. (0,102 mm) Above or Below
Camshaft End Float . . . . . . . . . . . . . . . . . . . . . 0.003/0.013 in. (0,076/0,330 mm)
8–1.13 Cylinder Head
Milling Allowance on
Cylinder Head Face . . . . . . . . . . . . Cylinder Head Face Must Never be Milled
Pressure for Water Leakage Test . . . . . . . . . . . . . . . . . . . . . 20 PSI (1,4 kgf/cm2)
825 Loader
147 of Feb.
Revised 176 81 –8–3– Service Manual
8–1.17 Valves (Inlet)
Valve Stem Diameter . . . . . . . . . . . . . . . . . . . . 0.312/0.313 in. (7,925/7,950 mm)
Clearance Fit of Valve Stem in Guide . . . . 0.0015/0.0035 in. (0,038/0,089 mm)
Valve Head Diameter . . . . . . . . . . . . . . . . . . 1.410/1.414 in. (35,814/35,916 mm)
Valve Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Valve Head Depth Below Cylinder Head Face . 0.028 in. (0,711 mm) Minimum
0.048 in. (1,220 mm) Maximum
Overall Length of Valve . . . . . . . . . . . . . . 4.592/4.608 in. (116,637/117,043 mm)
Sealing Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rubber Oil Seal
8–1.18 Valves (Exhaust)
Valve Stem Diameter . . . . . . . . . . . . . . . . . . 0.3115/0.3125 in. (7,912/7,937 mm)
Clearance Fit of Valve Stem in Guide . . . . . . 0.002/0.004 in. (0,051/0,102 mm)
Valve Head Diameter . . . . . . . . . . . . . . . . . . 1.191/1.195 in. (30,251/30,353 mm)
Valve Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Valve Head Depth Below Cylinder Head Face . . 0.021 in. (0,53 mm) Minimum
0.048 in. (1,22 mm) Maximum
Overall Length of Valve . . . . . . . . . . . . . . 4.600/4.616 in. (116,840/117,246 mm)
Sealing Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . None fitted to exhaust valve
8–1.19 Inner Valve Springs
Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.530 in. (38,862 mm)
Load at Fitted Length . . . . . . . . . . . . . . . . . . 28.6 lbf ± 2 lbf (13,0 kgf ± 9,91 kgf)
Fitted Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Damper Coil to Cylinder Head
825 Loader
148 of 176 –8–4– Service Manual
8–2 TIMING GEARS
8–2.1 Injector Pump Gear
Running Clearance of Drive Hub in Bearing
0.0031/0.0051 in. (0,079/0,129 mm)
Drive Hub End Float . . . . . . . . . . . . . . . . . . . . . 0.002/0.010 in. (0,051/0,254 mm)
8–2.2 Crankshaft Gear
Inside Diameter of Gear . . . . . . . . . . . . . . 1.250/1,2512 in. (31,750/31,780 mm)
Crankshaft Diameter for Gear . . . . . . . . . 1.250/1.2506 in. (31,750/31,765 mm)
8–2.3 Timing Gear Backlash
Clearance Between Crankshaft/Idler and
Camshaft/Idler Gears . . . . . . . . . . . . . . . . . . 0.0015/0.003 in. (0,038/0,076 mm)
8–3 LUBRICATION SYSTEM
Lubricating Oil Pressure . . . . . . . . . . . . . . . . . . . . . . 30/60 PSI (2,1/4,2 kgf/cm2)
At maximum engine speed and normal working temperature
8–3.1 Lubricating Oil Pump
Minimum Delivery Rate at 800 Pump RPM
40 PSI (2,81 kgf/cm2) . . . . . . . . . . . . . . . . . . . . . . . . 2.4 U.S. GPM (9,1 liter/min)
825 Loader
149 of Feb.
Revised 176 82 –8–5– Service Manual
8–5.1 Fuel Lift Pump
Method of Drive . . . . . . . . . . . . . . . . . . From Eccentric on Camshaft via Pushrod
Total Stroke of Operating Lever . . . . . . . . . . . . . . . . . . . . . . 0.192 in. (4,877 mm)
Static Pressure – No Delivery . . . . . . . . . . . . . . . . . 4–7 PSI (0,28–0,49 kgf/cm2)
Pump to Spacer Gasket Thickness . . . . . . . . 0.018/0.022 in. (0,457/0,559 mm)
8–5.2 Final Fuel Filter
Element Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper
Overflow Valve Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gravity Ball Check Valve
Valve in Fuel Pump Drain Connection . . Spring Loaded Non–Return Valve set
at 0.75 ––1.25 PSI (0,0525––0,0875 kgf/cm2)
8–5.3 Fuel Injection Pump
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.A.V.
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.P.A.
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
Plunger Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm
Timing Letter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
No. 1 Cylinder Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W
Static Timing Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18° B.T.D.C.
Piston Displacement From T.D.C. at 19° . . . . . . . . . . . . . . . . 0.109 in. (2,75 mm)
8–5.4 Injectors
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roto–Diesel or C.A.V.
825 Loader
150 of 176
Revised January 77 –8–6– Service Manual
8–7 DE–RATING FOR ALTITUDE
When engines are operated in high altitude areas, such engine should be
de–rated. The following table is given as a general guide, which may be applied
on a percentage basis, where specific figures for a particular engine rating are not
available.
Any necessary adjustments in this respect to the fuel pump should be carrier out
by the C.A.V. dealer for the territory concerned.
8–8 TORQUE SPECIFICATIONS
The following torque figures are with the components lightly oiled before
assembly.
Ft.–Lbs. (Nm)
The tab and shim washers can be left out where used on earlier engines, but the
capscrews must be tightened to the torque loading shown.
Ft.–Lbs. (Nm)
8–8.1 Hydrostatic Pump and Motor:
3/8 inch Fastening Bolts 30 (40,6)
8–8.2 High Pressure Relief Valves:
Hex Plugs 60 (81,4)
8–8.3 Loader Torque Specs
Bolts at Pivot Points 40 (54,2)
Wheel Lub Nuts 90–100 (122–136)
Final Drive Idler: 3/4 Bolt 125–145 (170–197)
1/2 Bolt 45–55 (61–75)
Gearbox–to–Frame Bolts 220–230 (298–312)
Axle Housing to Upright Bolts 240–280 (325–380)
Axle Housing to Frame Bolts 125–140 (170–190)
Bushings Through Frame Walls for
Steering Shaft 100–120 (136–163)
5/8 Nut on the End of Steering Shaft 50–70 (68–95)
Piston Nut for the Lift Cylinder
(1–1/2 inch Rod) 200 (271,2)
(1–1/4 inch Rod) 160 (216,9)
Piston Nut for the Tilt Cylinder 160 (216,9)
Nuts on the end of axles: tighten until there is resistance when turning axle by
hand.
Nuts on steering centering spring: tighten until length of spring if 2.260 inches –
2.340 inches (57,5–59,4 mm)
825 Loader
151 of 176 –8–7– Service Manual
STANDARD TORQUE SPECIFICATIONS FOR BOLTS
The above illustration shows the most common hex screw marking for each grade. A Grade 2 screw has no markings,
a Grade 5 screw has three radial dashes 120 degrees apart, a Grade 8 screw has six radial dashes 60 degrees apart.
825 Loader
152 of 176 –8–8– Service Manual
DECIMAL AND MILLIMETER EQUIVALENTS
825 Loader
154 of 176 –8–10– Service Manual
825 LOADER SPECIFICATIONS
60
(1524)
155
(3937)
131.5
21.25 38.5° (3340) 76
(540) (1930)
37 94.25 120
(940) (2394) (3048)
46.5
85 (1181)
45° 113
(2159) (2870) 57
65 (1448)
(1651)
44
8.5 (216) (1118)
32° 26°
9.75 (248)
34 51.5
38 (864)
96 (965) (1308)
60.75
PI–01829
SPECIFICATIONS
Weights:
Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5780 lbs. (2624 kg)
Rated Operating Capacity (SAE Rating) . . . . . . . . . . . . . . . 1500 lbs. (681 kg)
Tipping Load (SAE Rating) . . . . . . . . . . . . . . . . . . . . . . . . . 3100 lbs. (1407 kg)
Travel Speed:
Work Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 4.4 MPH (7,1 km/hr.)
Transport Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 7.3 MPH (11,7 km/hr.)
Controls:
Vehicle . . . . . . . . . . . . . . . . . . . . Direction & speed controlled by two steering
levers & hand grip range selector
Loader Function . . . . . . . . . . . . . . . . . . . . . . . . . . Lift, Tilt & Auxiliary functions
controlled by separate foot pedals
Engine . . . . . . . . . . . . . . . . . . . . . hand lever throttle & key type starter switch
Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . mechanical disc, hand operated lever
ENGINE
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Perkins
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.108
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel
Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 HP (28 kW)
Maximum Governed RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2500 RPM
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 ft.–lbs. (108 Nm) @1900 RPM
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.125 (79,4)/3.5 (88,9)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107.4 cu. in. (1759,9 cm3)
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure System W/filter
Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Open
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry replaceable paper element
825 Loader
155 of 176 –8–11– Service Manual
SPECIFICATIONS (Cont’d)
a
825ServiceManual#6549899–SpecificationsSection
LOADER HYDRAULICS
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine driven, gear type
Pump Capacity . . . . . . . . . . . . . . . . . . . . . . 12.5 GPM (47,3 L/min.) @2500 RPM
System Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2100 PSI (14478 kPa)
Hydraulic/Hydrostatic Fluid (Type) . Use Only Clark Hydraulic/Hydrostatic Fluid
(P/N 6563328) or Rando HDAZ Oil (Texaco Product 1629)
Hydraulic Fluid Filter . . Two 10 Micron replaceable elements on the hydrostatic
inlet, 25 Micron suction replaceable element
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doubleacting
Bore Diameter
Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 (57,1)
Tilt Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 (57,1)
Rod Diameter
Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 (38,1)
Tilt Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25 (31,8)
Stroke
Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.00 (787,4)
Tilt Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.13 (435,1)
Control Valve . . . . 3–spool, open center type lift, tilt & auxiliary with float on lift
Fluid Lines . . . . . . . . . . . . . . . . . . . . SAE standard full flow tube, hoses & fittings
Hydraulic Function Time
Raise Lift Arms to Maximum Height . . . . . . . . . . . . . . . . . . . . . . . 4.8 seconds
Lower Lift Arms from Maximum Height . . . . . . . . . . . . . . . . . . . . . 3.8 seconds
ELECTRICAL
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt driven, 22 amp. enclosed
Battery . . . . . . . . . . . . . . . . . . . 12 volt, 435 cold cranking amps. @0°F (–17.8°C)
125 minute reserve capacity
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt, gear drive
DRIVE SYSTEM
Transmission . . . . . . . . Two infinitely variable fully reversing hydrostatic pumps
Primary Reduction . . . . . . . . . . . . . . Spur gear operating in sealed oil lubrication
Final Reduction . . . . . . . . . . #100 roller chain, operating in sealed oil lubrication
Total Engine to Wheel Reduction:
Work Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.8:1
Transport Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.1:1
Fluid Type . Clark Bobcat Fluid (P/N 6563328 [5 gal. package]) if fluid is not
available use 10W–30 or 10W–40 Class SE Motor Oil
CAPACITIES
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 qts. (9,5 L)
Fuel (Plastic Tank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 gals. (60,5 L)
(Steel Tank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 gals. (125 L)
Engine Lubrication W/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 qts. (5,7 L)
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 gal. (102 L)
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 gal. (102 L)
TIRES
Standard . . . . . . . . . . . . . . . . . . . . . . . . 8.25 x 15, 6 ply Rating, Nylon W/Bar Lug
Pressure:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45–50 PSI (310 kPa)
Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 PSI (241 kPa)
825 Loader
15682
Revised Aug. of 176 –8–12– Service Manual
ALPHABETICAL INDEX
Paragraph Page
Number Number
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 9–1
825 Loader
157 of 176 –9––1– Service Manual
Dealer Copy -- Not for Resale
825 Loader
158 of 176 –9–0– Service Manual
9–1 ALPHABETICAL INDEX
Subject Page Subject Page
ADJUSTMENT OF SPEED RANGE LINKAGE . . . . 3–1 LIFT ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
ALTERNATOR OUTPUT . . . . . . . . . . . . . . . . . . . . . . . 6–1 LIFT VALVE SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
ALTERNATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . 6–1 LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 8–1
AXLE BEARING & SEAL REPLACEMENT . . . . . . . 4–1 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
AXLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . 7–1, 8–1
BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
BOB–TACH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 5–1
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1, 2–1
CHECKING HYDROSTATIC SYSTEM . . . . . . . . . . . 3–1
CHECKING RELIEF VALVES . . . . . . . . . . . . . . . . . . . 3–1 PIVOT PIN & BUSHING REPLACEMENT . . . . . . . . . 5–1
CONNECTING RODS AND PISTONS . . . . . . . . . . . 7–1 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . 1–1
CONTROL LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 PROBLEM ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
CONTROL PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 7–1, 8–1 REDUCTION HOUSING ASSEMBLY . . . . . . . . . . . . . 4–1
CRANKSHAFT AND MAIN BEARINGS . . . . . . . . . . 7–1 REDUCTION HOUSING DISASSEMBLY . . . . . . . . . . 4–1
REDUCTION HOUSING REMOVAL . . . . . . . . . . . . . . 4–1
DE–RATING FOR ALTITUDE . . . . . . . . . . . . . . . . . . . 8–1
REGULATOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
DRAINING THE FLUID RESERVOIR . . . . . . . . . . . . 1–1
DRIVE CHAIN INSTALLATION . . . . . . . . . . . . . . . . . . 4–1 REMOVING AIR FROM THE FUEL SYSTEM . . . . . . 1–1
DRIVE CHAIN REMOVAL . . . . . . . . . . . . . . . . . . . . . . 4–1 ROPS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
825 Loader
159 of 176 –9–1– Service Manual
Dealer Copy -- Not for Resale
825 Loader
160 of 176 –9–2– Service Manual
161 of 176
Dealer Copy -- Not for Resale
162 of 176
Dealer Copy -- Not for Resale
163 of 176
Dealer Copy -- Not for Resale
164 of 176
Dealer Copy -- Not for Resale
165 of 176
Dealer Copy -- Not for Resale
166 of 176
Dealer Copy -- Not for Resale
167 of 176
Dealer Copy -- Not for Resale
168 of 176
Dealer Copy -- Not for Resale
169 of 176
Dealer Copy -- Not for Resale
170 of 176
Dealer Copy -- Not for Resale
171 of 176
Dealer Copy -- Not for Resale
172 of 176
Dealer Copy -- Not for Resale
173 of 176
Dealer Copy -- Not for Resale
174 of 176
Dealer Copy -- Not for Resale
175 of 176
Dealer Copy -- Not for Resale
176 of 176
Dealer Copy -- Not for Resale