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c.
II ' ,

~'
. -.. '

C,LqRK Division
Melroe
,
This 825 Service Manual contains. the following Service Bulletins: 825-001, .
825-002, 825 - 003, 825-004, 825-005, 825-006. Also Service
Manual Revisions: 825-1,825-2.

654989912 -82) - 1M 3rd Ed ition Printed in U .S.A .

..
 CORRECT

AWARNING
DO NOT service the Bobcat
loader without instructions or
taking the necessary safety
precautions.

Always use lift arm stops or other

supports .
A Read the Op erator ' s M anual. A Stop and cool engine before adding
fue l. NO SMOKIN G.
CORRECT
A Do not service loader without usi ng a
WRONG
lift arm stop w hen lift arms are rai se d .

Do not 11ft or lower operator guard

without instructions f rom Operator's
Manual or Service Manual .

Do not lift or lower operator guard

w ithout jackstands or blocks under the
lo ad er.

A Do not stand on loader when lifting or

lowering operator guard.
A C heck o il daity . U se A Do not wear loose clothi ng around
recommended fluids . Keep . rear door closed except for the loader .
CORRECT service.
WRONG
Stop, cool, and clean engine of
flam mable material.

Keep body, loose objects , and clothing

away from electrical c ont&<:ts , moving
parts , hot par ts, and ex haust .

When co nnecting extra battery for

A ;.Ise lift arm stops before worki n g
under raised lift arms .
CORRECT
" jump" start always m ake the last
connection (neg ative ca b le) to the
engine never at the battery. When
removing the "jump " start cables .
always rem ove the negative ( - ) cable
fro m the engine first.
Machine must be stopped and
cool before checking fluids.
Lead acid batteries produce flamma b le WRONG
and explosive g ase s. Kee p arcs, sparks,
fla m es , and lighted tobacco away from
the battery .

Battery acid ' ca uses severe bu rns. If

acid con ta cts eyes, skin or clothing
flu sh well w ith w ater . For contact with
eyes get imm ed iate medical attention .

Do not mod ify equ ipment or add

at t achmen t s n ot approved .by
ma nu facturer .

Cleaning and maintenance are WARNING: Failure to obey wa rnings

required daily . may cause injury or death . A Do not arc battery .

Safety Alert Symbol

"
 FOREWOR'D
U PREVENTIVE
MAINTENANCE
This manual provides instruction for proper routine servIcing and adjustment of the
Bobcat, and detailed overhaul instructions of the power train, loader hydraulic/hydrostatic
system and general mainframe components.

Refer to the Owner's Manual for general operating instructions (Starting Procedure, Daily
HYDRAULIC
Checks, Bucket Operation, Minor Maintenance, etc.).
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.

2. Inspect for any sign of fuel, oil or hydraulic fluid leaks. HYDROSTATIC
3. Lubricate the machine.
SYSTEM

4. Check battery condition, electrolyte level and cables.

5. Inspect air cleaner system for damage or leaks. Check element and make
replacement, if necessary.
MECHANICAL
6. Check alternator drive belt for condition and tension. TRANSMISSION

7. Check for loose drive chains by lifting the rear of the machine and turning the rear
wheels by hand.

8. Check tires for wear and pressure.

9. Check the Bob-Tach attachment for condition. Inspect the wedges for damage or MAIN FRAME
wear.

10. Inspect safety items for condition (ROPS Guard, Seat Belt, Safety Treads, Lights,
etc.).

11. Make a visual inspection for loose or broken parts or connections. ELECTRICAL
12. Operate the loader, checking all functions.
SYSTEM

Advise the owner if any of the above items are in need of repair.

CONTENTS ENGINE SERVICE

ALPHABETICAL II\lDEX 9-1

ELECTRICAL SYSTEM 6-1
ENGINE SERVICE 7-1 SPECI FICATIONS
HYDRAULIC SYSTEM 2-1
HYDROSTATIC SYSTEM 3-1
MAIN FRAME 5-1
MECHANICAL TRANSMISSION 4-1
1-1 ALPHABETICAL
PREVENTIVE MAINTENANCE
INDEX
SPECIFICATIONS 8-1

Model 825
Service Manual
"\. 'r
 PREVENTIVE MAINTENANCE
PREVENTIVE
Paragraph Page MAINTENANCE
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
PREVENTIVE MAINTENANCE ....... . 1 2 1-3
REAR GRILL . . . . . . . . . . . . . . . . . . . . 1-3 1-4
I REMOVING AIR FROM THE FUEL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1-14 1-9
TILTING THE ROPS . . . . . . . . . . . . . . . 1-4 1-4
TIRE MAINTENANCE . . . . . . . . . . . . . . 1-25 1-15
TIRE REPLACEMENT . . . . . . . . . . . . . . . 1 27 1 15
TIRE ROTATION . . . . . . . . . . . . . . . . . . 1-26 1-15
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 1-14
I WHEEL MOUNTING NUTS ......... . 1-29 1-15

Model 825 !
*Revised Feb. 82 Service Manual I

_J
INTRODUCTION
.(, Serial Number
1-1.1 Symbols
II Plate

AWARNING ~
The warning symbol is an
identification of warning for
important safety items in this
manual. When this symbol is
shown, look for the possibility of
danger to personnel when doing a
specific job. Carefully read and
follow the instructions that
follows this symbol. Q
B·2969R

Fig. 1-1 Loader Serial Number Plate

IMPORTANT
The important symbol is an
identification for warning of the
possibility of damage to
equipment when doing work on a
specific part of the machine.
Carefully read and follow the
instructions that follows this
symbol.

1-1.2 Serial Number Identification

It is important to make correct reference

~1r""
to the serial number of the loader when
',( \
making repairs or ordering parts. Early or I ,;i
later made models (identification made ' "
'h:~
either by "Lot" or serial number group)
sometimes use different parts, or it may
be necessary to use a different procedure Fig. 1-2 Engine Serial Number Plate

in doing a specific job.

1-1.3 Loader Serial Number

The loader serial number plate location is on the left upright in the engine compartment
(Fig. 1-11. Two types of serial numbers are used. Early loaders use a serial number with
a lot code and a 4 number production sequence. Later machines use a 5 number
production sequence.

The serial number is made up as follows for early loaders.

A 1001 M
I
TI
PI ant Locatioo.
Production Sequence
Lot Code
Model, Engine Version

The serial number is made up as follows for later loaders.

M
Production Sequence
Plant Location
Model, Engine Version

Model 825
Revised August 79 -1-1· Service Manual
1-1.4 Engine Serial Number

The location of the engine serial number is on the fuel injector pump adaptor (Fig. 1-2). -
_h.___"__'"
10K"" lOAOER
J1Mt~tl£lIVEIiY
WSfaECTlON
.-
'­

1-1.5 Pre-Delivery Inspection

The purpose of the pre-delivery inspection is to make sure that the loader is in correct
operating condition when it comes to the dealer and before it is delivered to the
customer.

The pre·delivery inspection also lets the factory know when something is wrong with the
loader so that action can be taken to prevent the problem form happening in the future.

* Fig. 1 - 3 Pre· Delivery Inspection Form

All items on the inspection form (Fig. 1-3) must be completed according to
specifications in this manual.
CUIRI
so
"bobo:lt
"0\1. OI'uu,l'IOfIIIAl c==~7~
• • uvtea IliIIt.HC:tU)iIII

One copy of the completed form is to be mailed to the attention of Quality Control,
Melroe Division.
-,-- .... ,.... _.,.._""
....._-_.......
"
,._
(1::::....-:._ ...,_-'"
-
-"""'":'':'''1.:--<"..,
!,.....- ....... ,.. """"._,..-
~-t":~S-_I,

1-1.6 30 Hour Inspection A ~£:~-~-:;e

The 30 hour inspection must be completed soon after the first 30 hours of loader
.........
"'--"'--"
...,._ .. _--,_. -
operation.

....
-~~
_~....,.;o;;

~:~;:!,.:;;::==-":':::::::.!,~.;,.-..::...~:.:;':..:":..:::::,:=::
The purpose of the 30 hour inspection is as follows:

(1) For adjustment and inspection after first work period. Fig. 1 -4 30 Hour Inspection Form

(2) To correct wrong maintenance and operating methods.

(3) For demonstration of correct service procedures to customer.

All items on the 30 hour inspection form (Fig. 1-4) must be completed by the mechanic
according to specifications in this manual.

When the 30 hour inspection has been completed, the form must be signed by the
mechanic completing 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 copy is for
the Deiller.

Model 825
Revised Feb. 82 ·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, dusty or corrosive conditions.

DO NOT work on the loader with the lift

AWARNING arms in a raised position without

support. Use lift arm stops or other
methods.

SERVICE SCHEDULE HOURS

ITEM SERVICE REQUIRED 100 1200

Engine Air Cleaner Check the condition indicator. Make inspection of the
air cleaner system. Replace the element when the red
ring shows in the indicator window.
Engine Cooling System Make inspection and clean the radiator as necessary.
Check the coolant level and add coolant if level is low.

Seat Belt, Operator Guard &

Seat Bar

Safety Signs (Decals)

I
Wheel Nuts Tighten wheel nuts to 120 ft.-Ibs. (163 Nm) torque
(Check every 8 hours for the first 20 hours).

Control Pedals and Steering Check both for correct operation. Make repairs and
Linkage adjustments as needed.
Bob-Tach Check the locking levers and wedges for their condition
and correct operation.
Brake Check the brake for correct operation. Make
adjustment as needed.
Drive Belt (Alternator & Water Check condition and tension of the belt.
Pump)

I NOTE: Check the torque of the cylinder head bolts during the 30 hour inspection. Adjust valve tappets after making torque adjustment.

825 Loader
Revised Feb. 82 -1-3- Service Manual
 1 -3 REAR GRILL

The rear grill is opened by pulling

forward and up on the rubber fastener
(Fig. 1-51. Lift up the engine cover,
pull up on the handle to release the grill.
Pull the grill open (Fig. 1-6).

I 1 - 4 TILTING THE OPERATOR GUARD

The ROP (RollOver Protective

Structure) can be tilted, when desired
to make more space when servicing the
Bobcat.

I To tilt the Operator Guard (SIN 19126

& Below)

(1) Remove the retaining nuts at

the left and right rear corners of the
Fig. 1 5 Releasing Engine Cover Fastener Fig. 1-6 Opening Rear Grill
ROPS (Fig. 1 - 7).

(2) Move the "Cab Tilt" switch (Fig. 1 -8) up to tilt the ROPS forward (Fig.
1 -9).

NOTE: Always install the retaining nuts after ROPS is lowered and before operating
Bobcat.

To tilt the Operator Guard (SIN 19127 & Above):

(11 Stop the loader on a level surface.

(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.

(3) Stop the engine, engage the parking brake.

(4) Remove the nuts on each side of the operator guard at the rear corners (Fig.
1-71.

(5) The hex bolt for the mechanical tilt is located on the right side of the loader
between the wheels (Fig. 1-8al. Use a rachet and socket (Fig. 1-8a) and tilt Fig. 1 - 7 ROPS Retaining Nuts
the operator guard into the full forward position (Fig. 1-91.

NOTE: DO NOT exceed 50 ft.-Ibs. 168 Nml torque on the hex bolt used to raise or
lower the operator guard.

AWARNING o

DO NOT raise or lower the

operator's guard with the
engine running.

LOWER
B·3626
To low@r the operator guard, use the
a bov@ prol;edure in the reverse order, Fig. 1 - 8 Cab Tilt Switch .. Fig. 1 -88 lifting thQ OpQr:nor Guard

Model82B
Revised Feb. 82 -1-4­ Service Manual
1 -4.1 ROPS Tilt Motor

To seal out water from the RaPS tilt

motor clean the area (Fig. 1 - 9a, Item
1 ). Seal electric wire opening the
R.T.V. (Room Temperature Vulcanizing)
type compound.

1 - 5 ENGINE MAINTENANCE
B-1809

Fig. 1 - 9 Tiltin9 the ROPS

1 - 5.1 Engine Oil

(1) Check oil level every eight hours of operation.

B-2419

Fig. 1-9a ROPS Tilt Motor

(2) On new machine check the oil level every four hours during the first 50
hours of operation.

(3) Oil level must always be kept between the "Min" and "Max" marks on the
dipstick (Fig. 1 -10 & 1 -11).

1 - 5.2 Specifications

Use good quality detergent motor oil that meets the API service classifications (See
Chart).

A-1528

Fig. 1 -10 Dipstick

Fig. 1 - 11 Engine Oil Dipstick/Fill Locations

Model 825
Revised Feb. 82 -1-4a­ Service Manual
NOTE: Do not use svthetic 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.

RECOMMENDED SAE VISCOSITY NUMBER

(LUBRICATION OILS FOR ENGINE CRANKCASE)

Co -34 -29 -23 -'B -'3 -7 -, +4 +'0 + 15 +21 +27 +32 +3B

FO -30 -20 -'0 0 + 10 + 20 + 30 + 40 + 50 + 60 + 70 + 80 + 90 +'00

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE
(GASOLINE: USE API CLASSIFICATION SE or SF)
(DIESEL: USE API CLASSIFICATION CC or CD)

1 -6 ENGINE OIL AND FILTER REPLACEMENT

Engine oil and filter require replacement after every 50 hours of operation. To
remove the engine oil, remvove the plug at the outside of the upright on the right side
of the loader (Fig. 1 -12). Remove oil when the engine is hot and allow it to flow for
at least five minutes. Install the plug and fill with 4-1/2 quarts of oil of correct
specifications (See Chart).

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.

(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. Fig. 1-12 Engine Oil Drain Plug

Model 825
Revised Feb. 82 -1-5­ Service Manual
1 - 7 ENGINE AIR INLET SYSTEM (AIR
CLEANERI

Correct maintenance of air inlet system

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:

(1) Empty dust cap daily or as

necessary to keep it from
becoming full (Fig. 1 13). Install
dust cap with arrows up.

(2) Make replacement of the filter

cartridge (element) only when the
red ring shows in the sight window
of the condition indicator (Fig.
Fig. 1 13 Removing Dust Cap
1 14).

(3) Before installing the new cartridge, wipe all foreign material from the filter
housing. Reset Button

(4) Install clean cartridge carfully to be sure of good seal. Be sure that the
cartridge gasket is in good condition and the new plastic washer is correctly
installed under the wing nut. Tighten the wing nut by hand (Fig. 1 15).

(5) Press the reset button on the condition indicator to reset the red ring.

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. A-2291

Fig. 1 -14 Condition 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 body
if necessary.

(3) In the case of leakage, if

adjustment does not correct the
trouble, make replacement of the
necessary parts, hoses, or
gaskets.

r TE

(4)
The seal surface of the filter
element must seal correctly or
dust will enter the engine
causing engine failure.

Inspect the intake manifold

gasket for damage or looseness
whiCh can cause dirty air to enter
the engine.
Fig. 1 15 Removing Air Cleane, Element

Model 825
Revised August 79 -1-6­ Service Manual
1-8 ENGINE COOLING SYSTEM

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" below the filter 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).
Fig. 1-16 Checking Radiator Level

A When using air pressure. wear goggles to protect eyes

from flying objects. Do not use water on a hot
engine or in any fertilizer application.

1-9 FAN BELT ADJUSTMENT

Loose fan belt will result in unnecessary wear of the belt. If adjustment is over·tight, the
bearings in the water pump and generator will be overloaded. If the tension is under-tight,
the engine can overheat due to loss of belt drive at the water pump pulley. A loose belt
can also cause low charging rate of the generator.

Adjustment of the fan belt:

(1) Loosen the generator adjustment lever bolt (Fig. 1-18. Item 1). 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 3/8 of an inch of play at
the middle point between the pulleys (Item 3).

(4) When belt tension is correct, tighten the adjustment bolt and fastening bolt.

1-10 FLUSHING THE COOLING SYSTEM

Regularly, at least once each year, the complete cooling system must be flushed and filled
with clean coolant and conditioner. When flushing the system, backflushing has the most
effect. Remove the top and bottom radiator hoses and flush through the bottom hose
connection and out through the top of the radiator. To flush the engine, first remove the
thermostat. Flush the engine in through the top hose connection and out through the
bottom connection. I nstall a new gasket when installing the thermostat housing. Fig. 1-18 Adjusting Fan Belt
Model 825
* Revised January 77 -1-7­ Service Manual
 1 11 FUEL SYSTEM

AWARNING
N ever add fuel to the Bobcat
loader when the engine is
running or is hot. NO
SMOKING!

The fuel fill pipe is located at the rear of B-3756

the Bobcat to the left of the engine (Fig.
1 20, Item 1).
* Fig. 1 - '9 Fuel Fill Warning

(1) Use a clean, approved safety

container to add fuel.

(2) The key switch must be off

and the engine must be cool.

(3) Add fuel only in an area that

has a free movement of air and no
open flames or sparks. NO
SMOKING (Fig. 1 19),

(4) Use only clean fuel of the

correct specifications.

(5) Tighten the cap on the fuel

tank (Fig. 1 - 20, Item 1).
Fig. 1 20 Fuel Fill Pipe Location

1 -12 FUEL SPECIFICATIONS

I
The diesel engine uses clean No.2 diesel fuel (At extreme low temperatures, No.1
diesel fuel!. The steel fuel tank capacity is about 30 gallons and the plastic fuel tank
capacity is 16 gallons.

1 -12.1 Water In The Fuel Tank

To prevent water from getting into fuel tank:

( 11 Keep the filler cap in place.

(2) Always fuel after machine has been stopped. (Water can increase
overnight in an empty fuel tank).
B-1811
B-1812

(3) Regularly remove the fuel tank plug (Fig. 1 21), and remove water. Fig. 1 - 21 Fuel Tank. Drain

Model 825
-Roviaod Nth. 82 -1-8- Service Manual
1 - 1 3 TO SERVICE THE FUEL
SYSTEM

The engine is equipped with two (2)

fuel filters; a filter which holds water
and a secondary filter (Fig. 1 22). The
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).

T a replace the filter element:

(1) Clean the area around the Fig. 1 - 22 Fuel Filters IPrimary & Secondary)
filter housing.

(2) Remove the bolt at the top of

the final filter (Fig. 1 22, Item 3).

(3) Remove the element and the

o-ring,

(4) Lubricate and install a new

o-ring.

(5) Install the new filter element

in position and install the bolt. Do
not over-tighten the bolt.

Fig. 1 - 23 Venting Injection Pump

(6) After the new filter is
installed, the air must be removed
from the fuel system.

1 14 REM()VE THE AIR FROM THE FUEL SYSTEM

To remove the air from the fuel system, use the following procedure:

(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).

(3) Loosen the bolt (Fig. 1 - 24, Item 1) on the top of the final fuel filter. Fig. 1 24 Fuel Filter Bolt

Model 825
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 11.

(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 no air bubbles show at the
* Fig. 1 - 25 Fuel Lift Pump
fittings of the injectors. Tighten all
the high pressure fittings.

M
(8) Tighten the two injector line
fittings and start the engine. \
\
(9) If the engine does not run
smoothly, try loosening e~ch
injector fuel line fitting a little with
engine idling, to release any air still
in the injector lines.

1 -15 ELECTRICAL SYSTEM

MAINTENANCE

1 - 15.1 Electrical System

The Bobcat is equipped with a 1 2 volt

generator charging system. Maximum
output is 22 Amp. Service Electrical
System as follows:
* Fig. 1-26 Loosening Injector Fitting

( 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 3/8" play at the middle point
between pulleys (Fig. 1 -18).

(4) Check the condition of the wiring to the warning indicators (Alt., Trans­
Hot, 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
s witch 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. Fig. 1 27 Grounding Sender Wire

Model 825
Revised Feb. 82 -1-10­ Servica 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. 1 OW-30 or 1OW-40 SAE Motor Oil API Class SE
or SF can also be used.

DO NOT use automatic transmission fluids in this loader or permanent damage to the
transmission will result.

Where temperatures below zero are common, loaders must be kept in a warm
tuilding. Extra warm-up time must be used each time the loader is started during
cold temperature conditions. Cold fluid will not flow easily and it makes action of the
hydraulic function slower. Loss of fluid flow to the hydrostatic transmission pump
(indicated by "TRANS" light "ON") will cause transmission damage in less than 60
seconds time.

1 17 CHECKING AND ADDING HYDRAULIC FLUID

The hydraulic reservoir dipstick is located at the left side of the engine (Fig. 1 - 28).
It is important that correct fluid level be maintained at all times. Add fluid at the Fig. 1 - 28 Hydraulic Reservoir Dipstick
reservoir fill pipe or fill plug (Fig. 1 - 29)
(See "Hydraulic/Hydrostatic Trans­
mission Fluid").

To check and/or add fluid:

( 1) Place a machine on a level
surface.

12) Lower the lift arms and tilt the

Bob-Tach fully back.

(3) Remove the dipstick and read

the fluid level.

(4) If the level is below the

"Add" mark, add oil and fill to the
"Full" mark on the dipstick.

1 18 HYDRAULIC FLUID FILTERS

Three filters are used in the hydrostatic
system. The first filter (25 Micron)
serves as a suction filter and all oil used
in the system must pass through it. The
second filter (10 Micron) is installed in
the return line to the pump. This filters
Fig. 1 -29 Hydraulic Reservoir Fill
all oil to the final filter for the
hydrostatic transmission and return oil
to the hydraulic pump. Both filters are
located at the right side of the
transmission (Fig. 1 - 30). They use
spin-on replacement elements.

Make replacement of the filters after

each 250 hours of operation, or
sooner, when the (Trans-Filt) warning
light is lit during operation. If the
"Trans-Filt" light comes on during
loader operation, stop the engine at
once and make replacement of the
return line filter (10 Micron element)
first. If this fails to extinguish the
warning light, then make replacement
of the suction filter (25 Micron
element).

A third final filter (10 Micron) is

installed inside the hydraulic reservoir
(transmission housing). Replace this
filter every 1000 hours. You must
remove the transmission cover (floor
panel) to replace this filter (See "Final
Filter" page 3-10). Fig. 1 - 30 Hydraulic & Hydrostatic Filters

Model 825
Revised Feb. 82 -1 11­ I Service Manual
1 - 18.1 Replacement of the Suction
(25 Micron) Filter (Fig. 1-31):

(1) Tilt the ROPS forward.

(2) Clean around the outside of

filter base.

(3) Use a strap wrench or large

size filter wrench to unscrew the
25 micron filter element. (Place a
reservoir under the loader to catch
fluid spill.) Throwaway oil
element.

(4) Clean the filter housing and

check the seal ring for condition.
make replacement of the seal ring
if it has defect. Add lubricant to the
seal ring before installing filter.
Fig. 1 - 31 Removing Hydraulic Filter

(5) Install the new element and

turn it on until it contacts the
gasket, then tighten it another 1/2
turn.

(6) Lower the ROPS and start the

engine and run at 1/2 throttle.

(7) Run the engine until all air has

been removed from the system.

1 -1 8.2 Replacement of the Return line

Filter (10 Micron):

(1) Tilt the ROPS forward.

(2) Thoroughly clean the exterior

of the filter.

(3) Use a filter wrench to remove

the 10 micron filter element. Fig. 1 -32 Hydraulic Reservoir Drain Plug
Throwaway the old element.

(5) Lower the ROPS cab, set the throttle at about 1/2 throttle, set steering
controls in neutral and start the engine.

(6) With the engine running, check the filter housing area for any indication of
leaks.

(7) 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.

1 -19 DRAINING THE FLUID RESERVOIR

A drain plug is located at the left front of the transmission case (Fig. 1 -32). Make
replacement of transmission fluid after every 1000 hours of loader operation.
(Sooner, if it has become dirty.

To remove fluid from the reservoir, raise the rear of the machine and remove the
plug. Install the plug after letting out fluid and fill with 27 gallons of fluid. (See
"Hydraulic/Hydrostatic Transmission Fluid".J

Model 825
-, 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, jf 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 ti me. Most leaks are easily repaired.
Sometimes, tightening a fitting or hose
clamp is all that is necessary. Do not
overtighten tube fittings, as this can cause Fig. 1-33 Cleaning the Oil Cooler
a greater leak. A tube fitting that still
leaks after it has been properly tightened
must 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.

1-21 OIL COOLER

The oil cooler, mounted at the rear of the loader, cools the transmission fluid. The grill
area of the cooler must be kept clean, free of foreign material, or it will not cool
correctly.

To clean the cooler:

(1) Remove the cooler fastening screws and move the cooler away from the engine
radiator. Do not disconnect the hose lines to the cooler.

(2) Use an air nozzle or water spray and blow from the outside of the cooler (Fig.
1-33).

A Always wear goggles when using air pressure, to

protect eyes from flying material.

(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 that 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 1-111.
Model 825
* Revised January 77 -1-13­ Service Manual
1-22.1 Loader Start-Up

Follow these procedures when starting the

loader, after servicing:

(1' Be sure that the system is

filled with good grade transmission
fluid.

(2, Follow correct engine starting

procedure (See Owner's Manual).

(3' Start the engine and run at 1/2

throttle.

(4) Operate controls a few times

for several minutes until they
operate smoothly.
C-1759

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.

1-23 FINAL DRIVE CHAIN

A roller chain makes the final reduction between the reduction gear housing and the
loader wheels. One chain is used to drive each side of the loader.

To check chain tension:

(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. 1-341. If
there is more than 1/4" 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 tile 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, guarry, mine.
12:00 x 16:5 - 6 ply, flotation, . . . . . Flotation and traction, mud, swamp, coal mine,
bar lug tread sand.
Mod.1825
.. Revi5li!d J8I1UBrV 77 -1-14­ Service Manual
 NOTE: 00 not use ballast in tires.

1-25 TIRE MAINTENANCE

Correct 8:25 x 15 tire inflation is 45 PSI, maximum. If pressure is allowed to go

below 45 PSI, the machine will be hard to turn and tire wear will be much greater.
12:00 x 16.5 flotation tires must also be inflated to 45 PSI.

1-27 TIRE ROTATION

If both rear or both front tires wear more than normal, move them to the opposite end
of the machine as shown in (Fig. 1-35). This must be done as soon as the wear is noted.
,
A large amount of wear may be caused by wrong inflation, wrong bucket size for the
loader application (overloading) or by not operating loader correctly (loading bucket with
front or rear wheels off the ground).

A·1250

Fig. 1-35 Tire Rotation

1-27 TIRE REPLACEMENT

CODE FOR SYMBOLS
The tires on the Bobcat Loader are
specially designed for it. Exchanging them
with any other tire tread, or size, can
result in poor loader performance. When
8 GREASE
®
-if AIR FILTER
@ ENGINE
OIL FILTER

exchanging a damaged or worn tire, it is

important that the replacement tire be of
the same size as the tire still on' the
Bobcat. Two different size tires on the
same side of the machine will cause drive
chain and tire wear, and loss of power. If
S
G)
COOLANT

ENGINE OIL
8
®
..
~~
FUEL FILL

FUEL FILTER
­..:J
F-~~
) i
HYDRAULIC
OIL FILTER

HYDRAULIC
OIL RESERVOIR

two new tires are used for replacement of

two worn ones, put both new tires on the
same side.

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 (Current)
engine throttle pivot. Use medium engine
oil for this purpose. Also remove the seat
and put grease on the seat rails to keep
them working smoothly.

11 29 WHEEL MOUNTING NUTS

Wheel mounting nuts must be regularly

checked to see that they are tight. This
is most important after the first few
hours of operation. Loose wheel nuts 2-1813
will result in wear of the stud holes and

I
C-1756
can cause loss of wheel. Correct wheel
nut torque is 120 ft.-Ibs. (163 Nm). Pig. 1-36 Lubrication Chart
Model 825
.. Revised Feb. 82 -1-15- Service Manu.t
1-30 BOB-TACH

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 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.

lf new style Bob-Tach is to be installed

~W.d"S -

I
on a Bobcat with old style cylinder,
B-150B
(Serial Number 1 2000 & Below) it will
be necessary to cut off 5/8" from each Fig.1-37 Bob·Tach (Old Style)
end of the rod end trunnion (Fig.
1 -38a).

1-31 PARK BRAKE

Adjustment of the park brake is done

with the end of the lever. Make
adjustment by turning the grip until the I
I
lever will go over center into the lock
position (Fig. 1 39). I
/~
/,.~ r ~
. ::.
I
I • I I jW ':'""
':.....
I ,/ I I / I

'
)~6i' ~

/V/ ) .
//'~/
/ 0I / ( , ~
I
.... I.
.. f·~'Jfi'
//

/
~.,

".
.'

,;/~(:.
NOTE: If the brake lever hits the left
t"
""I­

steering lever install a new left

hand steering lever. (See .." ,J ~) I .~.:
f1".::.'.:.

Bobcat Technical Information

Bulletin Number 1351. (See
!
B·1246
3- 5 Steering Control
Fig,1-3S Bob-Tach (New Style)
linkage) for removal.

Tighten

5/S' 5/S"

A-2427 A-2464
Fig. 1- 3 Sa Cutting Old Style Cylinder Rod Fig. 1 - 39 Park Brake

Model 825
Reviled August 79 -1 1 e- Service Manual
 HYDRAULIC SYSTEM

Paragraph Page
Number Number

CONTROL PEDALS 2-9 2-9

HYDRAULIC
CONTROL VALVE 2-7 2-6
SYSTEM
GEAR PUMP 2-4 2-4
GEAR PUMP DISASSEMBLY 2-5 2-4
HYDRAULIC CYLINDERS 2-10 2-10
HYDRAULIC CYLINDER REPAIR 2-11 2-10
HYDRAU LlC 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

Model 825
Service Manual
HYDRAULIC FLOW CHART
825

•
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.

2-2 TUBELINES, HOSES, FITTINGS

Since tubelines, hoses and several types of fittings are used in the 825
hydraulic/hydrostatic system, certain procedures in maintenance must be used.
Wrong tightening procedures and O-ring installation will result in fluid leaks.

The correct method of installation is as follows:

2 2.1 37° Flare Connection

These are the most used in the system. They are installed on all tubelines and hose
lines. Most leaks on this type of connection are due to wrong tightening. There is a
correct torque to which all fittings must be tightened, but since the special type of
torque wrench needed is usually not availble in most shops, the following procedure
can be used when tightening flare fittings.

Model 825
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" 2

5/S" 1·112 - 2

3/4" 1

7/8" 3/4 1
Misalignment of Marks Shows
1" 3/4 - 1 Amount to Tighten (See Chard
- - ­

(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.
A-1B97
If the fitting leaks after tightening, disconnect it and inspect the seat area for damage. Fig. 2-2 Tightening Flared Fittings
Make replacement of the part if it is damaged.

2-2.2 Straight Thread O-Ring Fitting (Elbows, Adapters, Etc.)

When installing this fitting, the O·ring must be first lubricated with oil. Loosen the jam
nut, screw the fitting into place and connect the tubeline first, before tightening the jam
nut.

Tighten the jam nut until it and the washer is tight against the face of the opening (Fig.
2-3). The "O"-ring must be pushed into the space shown.

2-2.3 Pipe Thread Fittings

Pipe threads tend to leak more at high pressure and will leak if under·torqued or
over-torqued.

Always use a good pipe sealant on the thread. When applying pipe sealant, do not put
any on the first two threads from the end. Put the sealant on the male thread only .
never on the female thread.

Be sure the threads are clean and free from any scratches. Make replacement of damaged
fittings.

2-2.4 Tubelines and Hoses

Make replacement of tube lines which are bent or have become flat. They will make
restriction of fluid flow, resulting in slower hydraulic action and cause heat. Make
replacement of hose lines which show signs of wear, damage or weather cracked rubber.
When installing tubelines or hoses, be sure to support them with clamps.

2-3 HYDRAULIC SYSTEM TROUBLESHOOTING

PROBLEM ANALYSIS
PROBLEM PROBLEM

No Hydraulic Action . . . . . . . . • . . . . . . . . . . . . . • . . . . . . • . . . . . . . . . . . .A
Slow Hydraulic Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..A
Rough Hydraulic Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B
No Lift Hydraulic Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C
A-1852
No Tilt Hydraulic Action • . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . C
No Auxiliary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C Fig. 2-3 Straight Thread Seal

Model 825
-2-2- Service Manaul
 CHART A
NO OR SLOW HYDRAU LlCS

Check Fluid
Level
And Type
Check Suction
Side Fittings
(Of Pump)
If ~
Good
Check Pump
Output
Page 2-4
If
Good
Check Pedal
Linkage
Page 2-9
Defect
If

Is
1 Make epalr
R
Or Replacement
Of Linkage
Found

If Not If Fittings If Output If No Defect

Correct Are Loose Is Low Is Found

~Q
t
Add Fluid
Or Make
Repair
Make Replace-
ment of 25
Micron Filter
Check Seals
In Cylinder •
If
oefect
Is
-1 -. R.p.;,
Or Replacement
Replacement Page 2-11 F Of Seals
Page 1-12 ound

If Output
•
If No Defect
Is Still Low Is Found
t
If
Check
Pump Output
Check Release
Pressure :re,w"1
Is Not
Make Repair
Or Adjust
Page 2-4 Page 2-6 As Needed
Correct

If Output If Pressure
Is Still Low Is Correct

Make Repair
Or Replacement
Check Valve
Assembly
If
Defect
Is
1 M... R'P';'
Or Replacement
Of Pump Page 2-6 Of Valve
Found

CHART B CHART C

ROUGH ACTION OR NO ACTION NO LIFT, NO TILT OR NO AUXILIARY

OF HYDRAULIC CYLINDERS

If No If No
Check Check Suction Check Check Check
If Defect Defect
Fluid Level t- .... Side Of Pump Cylinder Seals Linkage Rods Valve Section
Correct Is Is
And Type For Air Leaks Page 2-11 Page 2-9 Page 2-6
Found Found

If Not If Defect If Defect If Defect

Correct Is Found Is Found Is Found
t
Add Or Make Add Or Make Make Make
Replacement Replacement Repair Of Replacement
Of Fluid Of Seals Linkage Rods Of Valve Section

Model 825
-2-3­ Service Manual
2-4 GEAR PUMP

2-4.1 Testing

(1) Disconnect the gear box (See

Fig. 3-25, Page 3 15).

(2) Tilt ROPS forward.

(3) Remove transmission housing

cover.

(4) Connect Y-90 to the outlet of

the pump (See Fig. 2-41.

(5) Lower ROPS until steering

levers are centered.

(6) Turn the pressure control

valve on the tester fully out
(counterclockwise!. Fig. 2-4 Testing Gear Pump

(7) Start engine and run at low

RPM.

loader must not be run with ROPS in

AWARNING raised position.

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.

(8) Increase engine RPM to maximum.

(9) Turn the pressure control valve slowly until the pressure is 2100 PSI.
Correct flow is 1 2.5 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.

2-4.2 Removal
B·2166

(1) Tilt the ROPS forward. Fig. 2-5 Removing Gear Pump

(2) Remove transmission case

cover.

L
(3) Remove hydraulic lines and
protect them with poly bags.
/ /11--0- .10 • 3
(4) Remove two fastening bolts
and remove pump assembly (See
Fig. 2-5). Do not force anything
~f=-
~
Q %:1
. ".,
~--v-
II i-.-,I .1 14

I
between the two surfaces. Use a

I f
_ ._ _ _ L
____ J
soft hammer to loosen the pump, if
necessary.
1 /~
Reverse the above procedure to install. 16 C-1090
Tighten the fastening bolts to 33
ft.-Ibs. torque. Fig. 2-6 Gear Pump Breakdow"

Model 825
Revised Feb. 81 -2-4­ Service Menue'
 2-5 DISASSEMBLY OF GEAR PUMP (Fig. 2-61
(1) Clean outside of pump thoroughly.

(2) Clamp pump in vise, shaft down.

(3) Remove 4 tie bolts litem 1).

(4) Remove 2 tie bolts litem 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 litem 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 litem 9), 2 each, and steel balls (Item 10), 2 each,
from the front plate.

I NOTE: Some pumps only have one spring litem 9) and ball (Item 10). Make sure
they are installed in the correct location (pressure side of the gears).

(11) Lift the back-up gasket (Item 11) and protector gasket (Item 1 2 J from the
front plate.

(12) Lift the diaphragm seal (Item 13) from the front plate.

(13) Remove the shaft seal litem 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.

2-6.1 Gear Assembly

(1 ) Inspect the drive gear shaft.

(2) Inspect both the drive gear and idler gear shafts at bearing points and seal
areas for rough surfaces and wear.

(3) If shafts measure less than .6850 in bearing area, the gear assembly needs
replacement (One gear and shaft assembly can have individual replacement).

(4) Inspect the gear face for wear.

(5) If the gear width is below the following figures, gear assembly needs
replacement.
Pump Disp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.250
Gear Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .924

(6) Make sure that snap rings are in grooves on each side of the drive and the
idler gears.

(7) If edges of the gear teeth are sharp, break the edge with an emery cloth.

2 6.2 Front and Back Plates

( 1 ) Oil grooves in the bearings in both the front plate and back plate must be in
line with the dowel pin holes and 1 80 degrees apart. This puts the oil grooves
closest to the respective dowel pin holes.

(2) If 1.0. of bearings in front plate or back plate are more than .691 ", the front
or back plate needs replacement (Bearings are not available as separate items).

Model 825
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 .0015", 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".

2-6.4 Assembly of Gear Pump (Fig. 2-6)

(1) The diaphragm, back-up gasket, diaphragm seal, protector gasket, a-ring and
shaft seal must have replacement made as new parts.

(2) Putdiaphragm seal (Item 13), (shown cutaway) in drawing, into grooves in front
plate with open part of "V" section down. (Use a not sharp tool.)

(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.

(5) Put diaphragm (Item 8) on top of back-up gasket bronze face up.

(6) All of diaphragm must fit inside the high part of rim of the diaphragm seal.

(7) Put gear assemblies into oil and install in front plate bearings.

(8) Install dowel pins (Item 16) in body (Item 5).

(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.

(10) Install a·ring (Item 71 in groove in back plate (Item 4).

(111 Slide back plate over gear shafts unti I dowel pins are engaged.

(121 I nstall bolts (Items 1 & 2) and tighten evenly to 23 ft.-Ibs. torque.

(13) Install shaft seal overdrive gear shaft taking care not to cut rubber sealing lip.
(Put oil on seal before assembly.)

(14) Install shaft seal by hitting with plastic hammer.

(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.

2-7 CONTROL VALVE

2-7.1 Relief Valve Check

(1) Pull out levers to take transmission out of gear.

121 Connect hydraulic tester to auxiliary circuit (Fig. 2-7).

(3) Start engine and run at idle.

(4) Activate auxiliary pedal and check flow meter to see if tester hoses are
correctly connected.

(5) Increase engine to full RPM. Fig. 2-7 Testing Relief Prcmlre
Model 825
-2-6­ Service Manual
 (6) Activate auxiliary pedal so
pressure goes over relief setting.
3
cf
tt- 4
~
(7) Correct pressure is 2100-2150 ( ~~
PSI.
~I : rcr/~
j 0°"'"
(8) If pressure is not correct, make
1 :

,0'I 1~/
replacement of valve.

2-7.2 Internal Leaks ~Ij

/°1 /
1/1 ~.
To find an internal leak in valve assembly, cf J..& 0
first check condition of cylinders. If lift
0° //
arms or bucket still drift after cylinders
are found to be good, then check the
4~,C0/ <-_ //
".... ~- -­
control valve for the following: CT --_/ 0'
(1) Spool not centering in the 6 /@f,:l
valve body when pedal is released.
/0
Check for broken centering spring
by removing the bonnet at the back I o)@
of the valve section. Be sure to
tighten spring screw. Center the
spool to neutral and make pedal
/,,/ 0°
adjustment to fit the spool position.
2 0'/~
.
(2) Poppet in the valve section
(Fig. 2-8, Item 1) leaking. Remove
the check plug on the top of the
I
,/~/\
-1 -d/

valve section, also remove and clean

the po ppet parts.
O/~ 5
8·1539
(3) Leak in the valve because of
Fig. 2-8 Lift Control Valve
wear, a cracked valve, or leakage
between sections. Replace the valve
if defect is found.

2-7.3 Control Valve Repair

Removal

(1) Lift the lift arms and install cylinder stops.

(2) Tilt ROPS forward.

(3) Disconnect control rods from

valve bank.

(4) Disconnect tubelines at valve

bank and protect with poly bags.

(5) Remove bolts which hold valve

bank assembly (Fig. 2-9).

(6) Remove valve from rear of

machine.

Disassembly

(1) Clean the control valve

assembly with solvent. Blow it dry
with low pressure air and put valve
on a clean surface for disassembly.

8-2240
(2) Mark each valve section (1, 2,
3, 4, etc.) for identification. Fig. 2-9 Removing Valve Bank

Model 825
-2-7- Service Manual
 (3) Remove the nuts (1) from the
three thru bolts which hold the
Cover Aux. Aux. lift Tilt Inlet
valve sections together (Fig. 2-10).

(4) Remove each section by sliding

it off the thru bolts. Hit lightly
wIth a soft hammer if necessary, to
i
i't--~·
I
........../_.,,-~o
I
[~ ~o_-c-:'-:'
loosen the seal between sections.
Throwaway the used O-rings. Clean
the O-ring counterbores and the
..
:~

-~--=---(lj

machined surface of each section.

(5) If a valve section is to be

disassembled, place it in a vise. Be B-1511R
careful not to clamp the machined
Fig. 2-10 Hydraulic Control Valve Breakdown
surface in the vise jaws.

NOTE: It is recommended that repair be made on one valve section at a time to

prevent mixing of parts.

(6) Remove the die cast bonnet from the back of the section (F Ig. 28, Item 21.

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, Item 3).

(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).

(101 Wash all the parts in solvent and place them on a clean surface.

2-8 LIFT VALVE SPOOL (Float Detent)

2-8.1 Repair of the Float Detent of the lift Spool

(1) Remove the detent rod (Fig. 2-8, Item 5) and hit the end of the spool on a
hard surface. The four steel balls will fall out (Fig. 2-8. Item 6).

(2) The float detent sleeve is threaded on and turned into a hole in the valve
spool end_ Use a tool which can be forced into detent rod hole and turn the sleeve
out from the spool (Fig. 2-11). Wash all parts with solvent.

2-8.2 To Assemble the Detent Assembly

(1) Use thick grease to hold the steel balls in their holes.

(2) Install the spring retainers. spring and sleeve and turn the sleeve into the spool
end. Check to see that the steel balls are still in place and install the detent rod.

2-8.3 Inspection, Repair and Assembly of Control Valve

(1) Inspect the spool and spool bore for wear. The spool or valve body cannot
have separate replacement. If either is worn or damaged, the control valve section
will need replacement.
8-2094

(2) Make lubrication of parts with oi I and install in the valve body section. Fig. 2-11 RemOVing Deten t

Model 825
.2-8. Servic@ Manual
NOTE; Install the rear O.ring sealt and
seal retainer on the spool before
installing spool in the valve
section. Push the spool into the
rear of the valve section (Fig.
2-121.

(3) Make lubrication of new Retaining Washer

O·rings with oil and press them into
the seal grooves at each end of the
valve section.
\
(4) Install the bonnet at the rear
of the valve. section. (On lift section,
install the snap ring on the detent
rod.)

(5) Install the seal plate at the

front end of the valve section. A-1799
Fig. 2-12 Installing Valve Spool with Seals
(6) Install the load check valve
poppets. springs and hex plugs. Use
new O·rings, lubrication made with
oil, on the plugs.

(7) Install new a-rings into the counterbores on the sides of the valve sections.

(8) To aid in assembly of all the valve sections, put the control valve inlet section
on its side in a vise, so that the other sections can be put in their order of
assembly (Fig. 2-131.

(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.

A-1924
If any spool restriction is noted and spool Fig. 2-13 Reassembly of Valve
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 STEP 3
now normal, use care in tightening the
YOke~~
Adjust
thru bolt nuts. To install the valve back
into the machine, reverse the removal ,,--~-
procedure. , -tfJ "~ ~
ti_ (J}--
,~ , <'"" 1

2-9 CONTROL PEDALS /~~71 STEP 4

2-9.1 Adjustment STEP 1

/' //",;
L__ V--rt-" Remove Pin , ,
Adjustment of pedals so that the spool ",.I'r_-..,// 'Lri,/ 1/4"

8
has full movement and centers correctly. ,, , ,
To make adjustment, tu/n the yoke at the .~ /
STEP 2
pedal end (Fig. 2-14). Loosen Nut
D-1170 f A-2385

NOTE: Make adjustment to fit operator. Fig. 2-14 Adjustment of Control Pedals
Model 825
-2-9­ Service Manual
9-9.2 Removal of Pedal Assembly
(1) Lift the lift arms and install cylinder stops.

(2) Tilt or remove ROPS.

(3) Remove cotter pins at valve end and remove linkage rods.

(4) Remove side plate fastening bolts (Fig. 2-15).

(5) Remove brake lever, if equipped (Fig. 2-15.1).

(6) Remove pedal assembly.

Side Plate
B·1817
To install pedal assembly. reverse the procedure for removal.
Fig. 2-15 Slide Plate Removal
NOTE: All Model 825 Bobcat loaders between serial number B·1000 and C·1000 have a
spacer between the pedals (Fig. 2-15.2, Item 1). This spacer must be in place
or the pedals will not operate oorrectly.
2-10 HYDRAULIC CYLINDERS
2-10.1 Checking for Internal Leak (lift Cylinder)

(1) Lower lift arms fully down.

(2) Remove hose line from base end of cylinder. Install a plug in the hose.

(3) Start engine and press toe of lift arm pedal.

(4) No more then four drops per minute must come out of opening.
2-10.2 Removal of lift Cylinder (Fig. 2-16)

(1) Lift the lift arms and hold with a support or hoist.
Fig. 2-15.1 Brake Lever Removal
(2) Disconnect hydraulic hoses and protect ends with plastic bags.

(3) Remove pivot pins.

(4) Remove cylinder.

To install, reverse removal procedure.

2-10.3 Removal of Tilt Cylinder (Fig. 2-17)

(1) Tilt Bob-Tach forward to the floor.

(2) Shut off engine and activate

lift and tilt pedal to release
hydraulic pressure. lift Cylinder
, - - - , r- - - ~,~-r- - B-2270 B-2241

(3) Disconnect hydraulic hoses and Fig. 2-15.2 Foot Pedal Spacer Fig. 2-16 Lift Cylinder Removal
protect ends with plastic bags.

(4) Remove pivot pins.

(5) Remove cylinder.

To install. reverse removal procedure.

2-11 HYDRAULIC CYLINDER REPAIR

There are several conditions which can
cause hydraulic cylinder failure. They are:
(1) A scratch on cyl inder shaft can
cause head seal damage and external leakage. Inspect the cylinder shaft by feeling with
hand up and down the length of the shaft with the cylinder fully extended. Look for
scratches which can cause damage to cylinder head seals. Carefully remove scratches on a
cylinder shaft with a fine carborundum stone (Fig. 2-18). Fig. 2-17 Tilt Cylinder Removal
Model 825
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 the Stone
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. I
(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
and result in internal leakage. Use caution when opening hydraulic lines or PI·1221b
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
Head
2-11.1 To Disassemble a Hydraulic Lift or Tilt Cylinder

(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 linesl.

(2) Use a special spanner wrench to remove the head from the cylinder (Fig.
2-19).

(3) Pull the shaft and piston assembly from the cylinder case.
Spanner Wrench ~
NOTE: If the piston comes loose from the cylinder rod, it can have the wrong piston A·1896
or nut. The piston should be made of aluminum, not zinc. The nut should be
Fig. 2-19 Cylinder Spanner Wrench
5/8" 116 mml thick (Fig. 2-19.11.

2-11.2 To Replace the Cylinder Seals 5/8" (16 mm)

~
(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 1Bl. 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. f
A·2425

2-11.3 To Assemble the Hydraulic Cylinder Fig. 2-19.1 Locking Nuts

(1) Install the cylinder head seals

and put the cylinder head carefully
onto the cylinder shaft (Fig. Rod Seal
2 21).

(2) Install the spacer on the shaft

(lift cylinder only).

(3) Install the piston seals and

put the piston onto the end of the
cylinder shaft.

Install the piston locking nut

I
(4)
and tighten to 150 - 160 ft.-Ibs. Wiper Seal
PI·1221ij A·l8li8
(203 217 Nm) torque.
Fig. 2-20 Beveling the Shoulder Fig. 2-21 Installing Cylinder Head
Model 825
Revised Feb. 81 -2-11­ Service Manual
2-12 OIL COOLER

2-12.1 Cleaning of Grill

(1 ) Use air pressure or water to

remove debris from cooling fins.

2 -12.2 Removal of Oil Cooler

(1) Remove lines which go to

cooler and protect open ends with
plastic bags.

(2) Remove wire to temperature

sending unit.

Fig. 2-22 By-Pass Valve Location

(3) Remove fastening bolts and

lift oil cooler out

To install, reverse procedure for r - - ______ _

removal. /

~ Q-~ -~- c@rt-

2-12.3 By-Pass Valve

The by-pass valve is set to open at 65

PSI (Fig. 2-22), Current Bobcats have a
reducing bushing and the by-pass valve
is set to open at 20 PSI.

To remove the by-pass valve:

(1 ) Remove tubelines from valve. 0-1168

(2) Remove valve (Fig. 2-23. Fig. 2-23 Removal of By-Pass Valve

Item 1).

To install as shown in figure 2-22 & 23.

2-12.4 COOLER BY-PASS HOSE

Check to see that the by-pass hose has a pressure rating of SAE 100 RI. If not
correct pressure rating the by-pass hose must be replaced. (Refer to current parts
catalog.

Model 825
Revised Feb. 81 -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 HYDROST ATIC
HYDROSTATIC MOTOR REMOVAL 3-12 3-12 SYSTEM
HYDROSTATIC PUMP INSTALLATION 3-11 3-11
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

Model 825
Service Manual
.-~
HYDROSTATIC FLOW CHART
Neutral Position
825

•
HYDROSTATIC FLOW CHART
Forward Position
825

•
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-2 512, PI-2513
and System Operation description for the full operation the Hydrostatic System.

3 2 HYDROSTATIC TRANSMISSION TROUBLESHOOTING

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

Model 825
-3-1- Service Manual
 CHART A· NO DRIVE
SYSTEM PRE-CHECK

Check
Oil
Level
~ If

Correct
1 T"," 0. ".,,,".
& Check "Trans
Filt" Light
. . If
~ LIght
~:
Start Engine
& Run At
1/2 Throttle
Check "Trans
Filt" Light
(Max. 5 Sec.
For Light To
Light
Will
Not
Operate
Lift Arm
Control
o Out
Go Out}

If Level If Light If Light

Is Low Is Off Goes Out If Lift Arms
Operate Correctly

Add Oil
Make Repair On
Light System
I
If Lift Operate Lift Arms Charge Hydraulic
If Machine Now
Go To Arms To Full Height System & Repair If Lift Arms Will
Operates Return i-
Chart C Operat & Over Release Air Leaks Not Operate
To Service
Correct Valve Page 3-15

If Lift Arms Will

Not Operate

Go To
Chart B

CHART B· NO DRIVE
GEAR PUMP CHECK

t- ......j
..
Check Output Of If GallMin Go To
Implement Pump Is Correct Chart C
Page 2-4

If Gal/Min
Is Low

i
Make Replacement Of ~ If Gal / Min .....j
~
Check Pump If Pressure
25 Micron Filter
. Is Correct Pressure Is Low
& Recheck Gal/Min
I
If Gal/Min If Pressure
Is Low Is Correct

Make Replacement
Implement
Pump
If System
Operates Normally
Return To Service
If System
Does Not
Operate
1 Go To
Chart
C
Correctly

Model 825
Revised Marc:h 1976 -3-2- Service Manual
 CHART C
NO DRIVE

Check Charge
Pressure
Page 3-8
~I"
Is
1ft1
Pressure

Correct
Check Stroked
Charge Pressure
Page 3-8
~ Pressure
If
Is
low
1"-' Com",•••"
& Case Drain
Page 3-14
If
D.f.ct
Is
Found
-I Install
New
Component

I
If Pressure If Pressure If No Defect
Is low Is Correct Is Found

t
Install External
10 Micron
Filter
If System
Operates Correctly
Return To Service
Inspect Charge
Relief Spring
Page 3-14
If
D.f.ct
Is
Found
-I Make
Repair
Of Spring

If No Defect
Is Found

Check Install Internal

Charge ~ 10 Micron
Pressure Filter

CHART D
DRIVE WITH WARNING LIGHT ON

If If If
Check Charge Pump Check Check Change
Inlet Pressure
I
I-­
Pressure
--.... 50·60 PSI ~
Pressure
20 PSI Pressure ~ Internal 10 Micron
Is Is Still Is Still
Page 3-8 Valve Valve Filter
low low low

If Pressure
Is Correct

t
If If
Pressure ---..J If System Now Pressure
Is ~ I Operates Correctly I .. Is ----'
Correct Return To Service
Correct

Model 825
·3-3· Service Manual
 CHART E
NO DRIVE ON ONE SIDE

If No If
Inspect Check Stroked Inspect
Defect Pressure
Control f-- Is Charge Pressu re Drive
Is
Linkage Page 3-8 Chain
Found Correct

Jf Defect If Pressure If Defect

Is Found Is Low Is Found

t t
If
Make Check Case Make Repair
Flow
Repair Of Drain Of Both ~ Or Install
Is
Linkage Pump And Motor New Drive Chain
Correct

I
If Flow Is Large
In Motor Or Pump

t
Install New
Component

CHART F
LOADER PULLS TO ONE SIDE

1
(T
nspect Lmkage

wo.~
S •d

Control Lever)
d ~ Adjustment
If
I.
Correct
1 Check Wheel
RPM In High
And Low Range
~ If
RPM
Is
Correct
-1 Check Tire
Pressure
And Diameter

If Adjustment If Defect If Defect

Is Not Correct Is Found Is Found

Make Repair Make Make Repair

Or Adjustment Adjustment Of Or Install
.As Necessary Lever Stops New Tire

Model 825
·3~4- Service Manual
 CHART G
LOADER OPERATES ONLY ONE DIRECTION - ONE SIDE

If No
Inspect Inspect High Pressure Inspect Charge
Control
Defect
I-- Is
. Relief Valves Relief Valves
Linkage Page 3-9 Page 3-9
Found

I
If Defect
. .
If Defect
If Defect
Is Found Is Found Is Found

t t t
Make
Adjustment
And/Or Repair
'"~~
New
Valve
~" New
Valve

CHART H
SYSTEM OVERHEATING

Check
Oil level
And Type
If
Correct
Inspect
Oil
Cooler
If No
Defect
Is
Found
Inspect
Fan
Belt
If No
Defect
Is
Found
1 Check For
Suction
Air leak
~ Ifleak
No
Is
Found

If low Or If Defect If Defect If Leak

Wrong Type Is Found Is Found Is Found

~Q
t
Add Or Make Make
Make Replacement Repair Or Repair Of
Repair
Of Oil Clean Belt

Install New
Transmission f- : Low
Chock '0'
L"",,,
Being Operated
~ Defect
If No
Is
1 Inspect Cooler
By-Pass Valve
Assembly In High Range Page 2-12
Range Found

If In If Defect
High Range Is Found

t L
Operate Make Repair
In Low Or Install
Range New Valve

Model 825
-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).

(2) Tilt ROPS and remove

transmission cover.

(31 Disconnect linkage from

levers on pump assembly (Fig.
3 2).

(4) Lower ROPS.

(5) Start engine and run at full

RPM. Levers will automatically go
to neutral. Make sure that levers
are not loose on pintle shafts in
pumps.

(6) Put steering levers in neutral

position.

(7) Loosen lock nut and turn

swivel linkage rod until eye of
swivel is in alignment with bolt in
pump arm.
Fig. 3 - 2 Removing Drive Linkage
(8) When alignment is correct,
fasten swivel with bolt and tighten
lock nut on swivel. Tighten nut for
swivel bolt to 10 ft.-Ibs. (14 Nm)
torque.

II
'II
~
! I
,
I!J
I
I!J

I (9) Install a new gasket before

putting transmission cover on.
L -;1 L -i I

, ,
3-4 ADJUSTMENT OF SPEED RANGE
•, .:
LINKAGE
• _jJ--~~7

Adjustment of length of linkage rod

(Fig. 3- 3, Item 1) must be correct to
give equal travel of control lever (Fig.
3 3, Item 21 between high and low
..
"
.~,/

range.

There is no other adjustment of the

T .'
;I
;' 2
speed range linkage. ~-;,'" '/
If wheel RPM is different between left
and right side of loader, first check for .,,
,
I
1
correct adjustment of the steering
,,
I
control linkage. (Control lever travel,
.)
equal from vertical (center) position to
6 5 , /

,,
/
low and high ranges.) If wheel RPM
I 1// . --.
\-,~~>.-
between sides is within 20%, no 4
adjustment is necessary.

Also check for loose bolts on linkage .-0"",-

bar and motor control arms. Check for
hose or tubelines in wrong position and C-1754
stopping movement of linkage. Fig. 3-3 AdjuIltm9nt of linlcagQ Rod

Model 826
ReviBBd April 80 -3-6­ Service Manual
To remove speed-range linkage:

(1 ) Remove the bolt holding the

linkage to the arm on the rear
motor (Fig. 3-4).

(2) Remove the bolts holding the

linkage to the arm of the front
motor and bell crank (Fig. 3- 5).

(3) Remove the bolts holding the

bellcrank and linkage rod (Fig.
3- 3, Item 3).
Fig. 3 - 4 Removing Rear Motor Linkage

14) Remove nuts (Fig. 3 3, Items 4 & 5). control arm (Item 6) and control
lever (Item 2).

Fig. 3 - 5 Removing Front Motor Linkage

3- 5 STEERING CONTROL LINKAGE

3-5.1 Removal

(1 ) Tilt or remove ROPS (See

Section 5 2).

(2) Lift the lift arms and install

the cylinder support.

(3) Clean the area thoroughly.

(4) Remove the brake if ~

equipped.

(5) Remove the steering levers

(Fig.3 6).

Fig. 3 6 Removing Steering Lever Fig. 3 7 Steering Lever Support Nuts

(6) Disconnect linkage.

(7) Loosen the support nuts (Fig.

3-7'.

(8) Slide lefthand shaft over to

welded bracket.

(9) Remove lefthand support nut.

(1OJ Remove lefthand rod.

(11) Remove righthand support.

nut.

(12) Raise lefthand end of shaft

and remove assembly from B-1906
transmission (Fig. 3-8). Removing Control Lever Assembly

Model 825
Revised Feb. 81 -3-7­ Service Manual
 ". .; ~--11'~-"
100-
120 ft.-Ibs.
2Nml

J J
~' ~ 11/36
- 16
if
,i; 25 - 28 ft.-Ibs. 50 - 70 ft.-Ibs.
:;z
134 - 38 Nml (68 - 94 NmJ
~·-~~~Yi
I I (j·o-@--o
l'
·-8- -(j" I
"l]-O'CfII'Qj)_
;,-

'1
Ii @ ni~@ I -~-IB
-r-. '''''.ii'lll_c",ml",•.
~~~ I
~f1I<D '=lJ ( /
.(1
/~
j
, ),lib
,'"
"'-- I • -li- flS.
""--",,\"'I1l'l",,
Lr- , .. -.",.,
I,.,ii.:,·',.',•. _'(1
­ 180 - 200 in.-Ibs.
(21 23 Nml

25 28 ftAbs.
(34 - 38 Nml
il it:ci_J.II..f.'lI. __ •
/- /I
e,_.,./~,...
-.' .~ I!if

I~'.'
__ . ~/_<li~
':',A ~..'=lJ 1fI.::"'~i----~-
10 _ 1~' ft.-Ibs. rP/ /
1j.3' ..AI (14 20 Nml
, "11'. ':.J"{j--F===ID
H """-25 - 28 ft.-Ibs.
(34 38 Nml
D·1357

* Fig. 3 - 8.1 Steering Assembly Bolt & Nut Torque

I 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-1 000 and C-l 000 have a
spacer inside the steering levers (Fig. 3-S.2.ltem 11. The spacers must be
in place or the levers will not operate correctly.

3 - 6 CHECKING HYDROSTATIC SYSTEM

3-6.1 Test Kit

(1) 0-300 PSI gauge.

(2) 200 PSI pressure gauge.

Model 826
Revised Feb. 82 -3-7a- Service Manual
 3-6.2 Charge Pressure Check

Steering Levers in Neutral Position:

(1) Remove the sending unit from

the right rear of the tank and install
0-300 PSI presure gauge (Fig.
3 9),

AWARNING
The transmission must not be
disengaged with the loader
parked on a slope. 8-2267
t1J
Fig.3-8.2 Steering Lever Spacer Fig.3-9 Checking Charge Pressure

I (2) Correct charge pressure (at idle RPM) is 90 PSI (620 kPa).

Steering Levers in Stroked Position (Forward and Reverse):

(1) Remove the oil sender unit from the right rear of the tank (Fig. 3-11, Item
1 ).

(2) Install a guage with approximately 4 feet hose (101,6 mm) in location
shown in figure 3 - 11 , Item 1).

~
(3) Push transmission levers in (Fig. 3--10).

(4) Lower the RaPS. Position the hose so it will not be damaged (pinched)
when lowering the RaPS.

(5) Fasten the gauge to the side of the RaPS so it can be seen when operating
the Bobcat.

(6) Install the RaPS bolts and tighten.

82949R
(71 Operate the machine under
* Fig. 3 ~ 1 0

I
load at full RPM and check Trans. Disengagement Lever

pressure on the gauge. 100 PSI

(689 kPa) is the minimum
acceptable reading.

3-6.3 Charge Pump Inlet Pressure

Steering Levers in Neutral Position:

(1) Install 200 PSI gauge at the

left rear of the frame (Fig. 3 11,
Item 2).

(2) Pull out the transmission gear

box levers (Fig. 3 10).

(3) Start the engine and run at full

RPM.

(4) Normal charge inlet pressure

is 15-20 PSI (103-138 kPa). \
Minimum charge inlet pressure is 4 \
8-2167
PSI (28 kPa).
Fig. 3-11 Checking Inlet Pressure to Charge Pump

* Revised Feb. 82 Model 825

-3-8- Service Manual
3 -7 CHECKING RELIEF VALVES

3 - 7.1 Charge Relief Valve

I
NOTE: See Bobcat Technical Information Bulletin #162 for more information on
the Charge Relief Valve.

To check condition of charge relief valve it must be removed from unit and visual
inspection made as follows:

(1) Remove inlet line to charge pump.

(2) Use a screwdriver and compress spring.

(3) Use snap ring pliers to remove snap ring.

Fig. 3-12 Rernovrng Check Valve

(4) Remove spacer, spring and poppet (Fig. 3-12).

Reverse the above to install.

NOTE: Put clean grease on poppet to

help hold to spring during
installation.

3 - 7.2 Filter Relief Valve (Fig. 3 -13)

(1) Disconnect tubelines and

remove valve from unit.

(2) Connect compressed air line

to each end of valve to see if air
goes through.

(3) Air must go only one way.

3 - 7.3 Charge Inlet Relief Valve (Fig.

3-13)

( 1) Disconnect tubelines and

remove valve from unit.

(2) Connect air hose to each end

to see if air goes through.
Fig. 3-13 Hydraulic and Hydrostatic Filters
(3) Air must go only one way.

3 - 7.4 High Pressure Relief Valve

(1) lift the lift arms and install

cylinder stop on lift cylinder (Fig.
3-14).

(2) Tilt ROPS forward.

(3) Clean transmission housing

area.

(4) Remove transmission cover.

(5) Remove valves and exchange

valves from one side to the other
(Fig. 3-15).

(6) If the drive system problem is

now on other side, make
replacement of valve with defect.
* Fig. 3 - 14 Lift Arm Cylinder Stop Fig. 3-15 Removing Relief Valve

Model 825
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).

(2) Remove steering levers by

removing bolts and hitting with
hammer to force lever off.

(3) Activate tilt switch and tilt cab

all the way forward.

(4) Attach overhead hoist to ROPS

and take up all loose play.

(5) Remove bolt which fastens tilt

assembly to ROPS.

(6) Tilt ROPS fully forward and

hold in position with a support.

(7) Disconnect linkage rods and C-1878

remove pedal assembly.
Fig. 3-16 10 Micron Final Filter Location

NOTE: CLEAN LOADER FLOOR AREA

THOROUGHL V (Transmission
Housing).

(8) Remove floor plate.

(9) Remove the final filter element.

(10) Install new 10 micron element.

Tighten it hand tight.

3-9 TEMPERATURE AND PRESSURE

SWITCHES

The hydrostatic warning system is made up

of 2 pressure sending switches (charge
pressure and charge pump inlet pressure)
and one temperature sending switch (See
Fig. 3-1).

C-1828
The charge pressure switch (1) is set to
activate when pressure goes below 65 psi. Fig. 3-17 Removing Pump SU(;tion Hose
Model 825
-3-10­ Service Manual
The charge pump inlet switch (2) is set to
activate when pressure goes below 4 psi.

The temperature inlet switch (3) is set to

activate when temperature goes above
2100 F (990 C).

REMOVAL OF HYDROSTATIC PUMP

ASSEMBLY

(1) Tilt or remove ROPS (See

Section 5-2),

(2) Lift the lift arms and install

cylinder stops (Fig. 3-14).

(3) Steam clean the loader

thoroughly,

(4) Remove fluid from transmission

and remove the transmission housing
cover.

0-1827
(5) Remove all hoses from fittings Fig. 3-18 Removing Pressure Hose
on pump assembly (Figs. 3-17 &
3-181. Protect ends of hoses with
plastic bags. Put caps on open
fittings (Fig. 3-20),

(6) Disconnect steering linkage

from pump assembly (Fig. 3-19).

(7) Remove front support bolt

(Fig. 3-20),

(8) Remove fastening bolts and

remove the pump assembly (Fig.
3-21). Weight of pump assembly is
80 pounds.

3-11 INSTALLING HYDROSTATIC

PUMP

(1) Make alignment of pump drive

(spline) shaft and fasten pump
assembly to transmission housing
with two bolts.

(2) Install front support bolt (Fig.

3-20), Fig. 3-19 Disconnecting Steering Linkage
Model 825
.. Revised January 77 -3-11­ Service Manual
 (3) Connect steering linkage to
pump control arms.

(4) Connect hoses.

I (5) Install new cover and gasket.

3-12 REMOVAL OF HYDROSTATIC

MOTOR

(1) Tilt or remove ROPS (See

Section 5-2).
Fig. 3 - 20 Removing Front Pump Support

(2) Lift the lift arms and install

cylinder stops (Fig. 3-14).

(3) Steam clean the loader thoroughly.

(4) Remove fluid from transmission and remove the transmission housing cover.

(5) Remove the pump assembly.

(6) Disconnect 2 speed linkage (Fig. 3-22).

(7) Remove hoses and elbows when removing right hand motor.

(8) Remove 2 bolts which hold the motor to reduction gear housing (Fig. 3-23),

Fig. 3 - 21 Removing Pump Fastening Bolts

(9) Remove the motor. Weight is 22 pounds.

Fig. 3 - 22 Removing Speed-Range Linkage Fig. 3-23 Hydrostatic Motor

Model 825
Revised August 79 -3-12- Service Manual
3 - 13 INSTALLING HYDROSTATIC
MOTOR

( 1) Install elbows and hoses

~.)
(right hand motor) (Fig. 3-23a).
r,
.,'

Hose
(2) Install motor in reduction o•
housing and fasten with bolts.
Hose

~
0
l)
/ r", "5:"

(3) Connect 2 speed linkage to I; ,

control arm on motor. o~,
ro
o
~, "' 0
.~ 0

3 -13.1 New Hydrostatic Pump &

Motor C·1752
Fig, 3 - 23a Hydrostatic Hose
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. To check to see which unit you by checking the letters
on the pump (Fig, 3 23b).

Old Style Letters New Style - Letters

Front Pump RAB Front Pump - RCB

Rear Pump RAA Rear Pump - RCA

Motor DAG or DAZ Motor - DBA

When hydrostatic units have been changed they must be marked to show the
change,

ID.No.

ID.No.

ID.No.

8·2670
Fig. 3 - 23b Checking Hydrostatic Units

Model 825
Revised Feb. 82 -3-12a­ Service Manual
3 14 HYDROSTATIC PUMP OR
MOTOR OISASSEMBlY (Fig. 3-241

The inner parts of hydrostatic pumps

and motors are similar. The following 22: 23
procedure for pump disassembly can /
be sued for disassembly and assembly
of motor (Do not do the steps which
belong to pump disassembly). 18
1
f 2122
II
\

To disassemble the pump, begin by:

( 1 ) Remove pump assembly from

the transmission housing. Put
plugs in all fluid openings to keep
out dirt.
3 6 49
(2) Separate pump from the 2/ _t ';·::1-­
lJ~\
assembly. //
.,;?/

To disassemble motor, begin by:

. 50
4
(1) Remove the motor from the
transmission housing.

(2) Remove the back plate from

the motor. I
30
Continue to disassemble the pump or * In Motor Only
motor by: * See the Parts Microfiche for the correct kit PIN
* * Some Pumps Do Not Use This Bearing (See BTIB #162) (,1958
(3) Clamp the end of the drive
shaft in a protected jaw vise with * Fig. 3 - 24 Hydrostatic Pump 6reakdown
the body of the pump up and
remove the four bolts (Fig. 3-24, Items 48 and 50) from the gerotor plate of
the pump.

(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.

(11) Remove the pump from the vise.

(12) Remove the snap ring (Item 1), shaft seal (Item 2) and the washer (Item 3)
from the housing.

(13) Remove the shaft (Item 7) 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 151, the two o-rings (Item 12), the one inner race (Item 111 and the two
bearings (Item 101. The camplate can now be pushed to one side and removed.
The two camplate pivot bearings are a loose fit into the housing.

Model 825
* Revised Feb. 82 -3-13­ Service Manual
3 -15 INSPECT PARTS FOR WEAR
( 1 ) Inspect the charge pump (gerotor) relief valve seat inside the charge pump
adaptor. It must be smooth and free of defects.

(2) Inspect the charge pump relief valve spring (Item 45).

(3) Inspect the gerotor chamber inside the charge pump housing (Item 43) for
damage.

I
(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 cndition. They must
not show wear or deep scratches. The shoes must fit well on the ball end of the
pistons with no more than .003 in. (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 .148 in.
(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.
(10) Inspect the pivot (Item 22). It must be smooth and show no signs of wear.
(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.

3 - 1 6 TO ASSEMBLE PUMP OR MOTOR

( 1) Clean all parts in solvent, use oil to lubricate all moving parts before
assembly. If necessary, install new needle bearings in the housing. The
camplate pivot bearings are a slide fit. The shaft bearing (Item 8) is a press fit.
Install with numbered end of the bearing toward the outer side.
(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) cn 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.-Ibs. (37-42 Nm) torque.
(e) Tighten the two bolts to 90-100 ft.-Ibs. (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 1 1) 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 7l. Install the thrust washer (Item
5). thrust bearing (Item 6) and second thrust washer (Item 5). Fasten with
second snap ring (Item 4).

Model 825
Revised Feb. 82 -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·2648
(1 1) 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).

(12) Install new gasket (30).

Pull Out
(13) Install back plate (32).

(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.

(16) Install the outer geroter gear (41) over the inner geroter gear (40). Use oil Nut
to lubricate the outer gear.
B-2949R
NOTE: On the new adaptor plate (Item 43) the bearing has been removed. When *Fig.3-25 Gearbox Lever
installing this type of adaptor plate (Item 43) use the following procedure
for correct alignment.

(al Clamp the drive shaft of the front pump in a protected vise with the
back plate up.

(b) Install the adaptor plate and four bolts. Tighten the bolts evenly with
your fingers.

(c) Install the coupler and rear pump assembly. Install the two bolts and
tighten to 110 115 ft.-Ibs. (149 1 56 Nm) torque.

(d) The four bolts in the adaptor plate can now be tightened to 27 - 31
ft.-Ibs. (37 42 Nm) torque. This procedure will insure the correct
alignment between the two pump assemblies.

(16) Install a new o-ring (34) on the relief valve assemblies (35) and install
seats(33) and relief valves in the back plate(32l.

3 - 1 7 STARTING PROCEDURE, AFTER REPAIR

The transmission pumps and motors must be primed and charged with clean oil after
disassembly and repair.

To prime the system, use the following procedure:

( 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.

Model 825
* Revised Feb. 82 -3-15­ Service Manual
 (3) Connect the pressure line to
the implement pump.

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).

AWARNING
The transmission must not be
disengaged with the loader
parked on a slope.
Fig. 3 26 Oil Cooler Temperature Sender

(2) Tilt the RaPS fully forward.

(3) Remove the temperature sender from the oil cooler (Fig. 3 - 26) and install
a l l 0 0 PSI (0- 700 kPa) gauge.

(4) Remove the outside 10 micron filter (Fig. 3 - 27, Item 1) and install a 3
micron filter (PIN 6511278) in its place.

(5) Loosen an 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 loader. Install a 0-200 PSI
(0 400 kPa) gauge at this
location (Item 5).

(7) Lower the RaPS. Start the

engine and run at idle until charge
pressure increases, then run at 2/3
throttle for 112 hour.

(8) Read the gauge in the oil

cooler. If the pressure shows an
increase of 10 PSI (69 kPa), make
a replacement of the 3 micron filter
and run the machine again for 1/2
hour.

(9) Read the gauge at the right

side of the loader. If the pressure
goes below 110 PSI (760 kPa)
make a replacement of the 10
micron filter in the reservoir and
run the machine again for 1/2
hour.

(10) After running the machine,

remove the outside filter and install
new 10 and 25 micron filters in
their correct locations. Install a
new 10 micron filter in the
reservoir if the hydrostatic motors
or pumps are removed from
service.
Fig.3-27 Cleaning and Charging System

Model 825
R.vhred Feb. 82 -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

Model 825
Service Manual
4-1 FINAL DRIVE SYSTEM Front of Loader
Reduction
4 -1.1 Description (Fig. 4 - 11

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). Clean
the transmission area thoroughly.

(2) Lift the lift arms and install

the cylinder stops (Fig. 4-2).

(3) Remove the fluid from the

reservoir.

(4) Remove the transmission C-1842

covers, hydrostatic pump Fig. 4-1 FInal Drive Chain System
assembly and motor (See Section
3) and the final drive chain.
Remove the lever for engaging the
d rive gears (Fig. 4 - 3).

The transmission must not be

disengaged with the loader
parked on a slope.

( 5) Connect the hoist to the

reduction housing. Remove three
bolts holding the reductions
housing to the transmission
housing (Fig. 4-4).

NOTE: The bolts on the reduction

housing must be tightened to *Fig.4-2 Lift Arm Cylinder Stop
220-230 ft.-Ibs. (298-312
Nml torql:le when installing the
housing (Fig. 4-41.
(6) Use the hoist to remove the
reduction housing from the B-2949R
transmission housing (Fig. 4 5).
Weight of reduction housing is * Fig. 4- 3 Drove Gear Lever
120 Ibs.

4-3 DISASSEMBLY OF REDUCTION

HOUSING (Fig. 4-6) Reduction
4 - 3.1 Removal of the Intermediate
Gear (6)

( 1 ) Remove the bolts which hold

the detent part (1 ) to the reduction
housing.
(2) Remove the snap ring on the
intermediate shaft (Fig. 4- 7).

(3) Slide the shaft a short way

out of the housing. Do not remove
the shaft at this time.
(4) Remove the thrust washer
and small steel ball (2). *Fig. 4-4 Removing Gearcase Bolts Removing Reduction Housing

Model 825
Revised Feb. 82 -4-1­ Service Manual
 (5) Remove the shaft from the
housing,

(6) Remove the gear (6).

15 20 19
4- 3.2 Removal of Input Drive Gear (7)

( 1 ) Remove the snap ring from

\/\
~{)-I {)
/\
-J·O·· O-~\;,W
the end of the shaft (8) and snap 11"''' \18
ring holding ball bearing (13).
\ '\
~
,,,0/ \ ' -',-
2
(2) Remove the gear and shaft (7)
~- .~. , 3 , /
~ -~-(].
with bearing (13).
~ -"L r~. t.fL

II Y! T~ '~--4
>" /
(3) Remove the snap ring (10)
holding needle bearing (11) and -3 (]-J
remove the needle bearing.

4-3.3 Removal of Output Gear (14)

/I
11 10
C1640
(1 ) Remove the snap ring (1 5).

(2) Slide the shaft (16) out of the

housing.

(3) Remove the gear (14), shaft (16), snap rings (19, 20) and bearings (17.
18).

4-4 ASSEMBLY OF REDUCTION HOUSING (Fig. 4-61

4-4.1 Installing the Output Shaft and Gear

(1) Install needle bearing (18) and snap rings (19).

(2) Install ball bearing (17) and snap rings (20).

(3) Install output shaft (16). thrustwasher (6), gear (7) and snap ring (8).

4-4.2 Installing Input Shaft and Gear

(1) Install the needle bearing (1 ) and snap rings (10).

(2) Install the ball bearing (13) and the snap ring (12).
Fig. 4- 7 Removing Snap Ring
(3) Install shaft and gear (7).

(4) Install final snap ring (8) on the shaft.

4-4.3 Installing Intermediate Gear

(1) Install the shaft (3) and gear (6) in housing. Put the shaft only part way into
the housing.

(2) Install the thrustwasher (2) and small steel ball on the shaft. Push the shaft
fully into the housing.

(3) Install the snap ring (4) on the shaft.

(4) Install the detent parts on the housing (Fig. 4- 8).

To install reduction gear housing, reverse the removal procedure.

4-4.4 Drive Chain Adjustment (Internal Adjustment Type)

(1 ) Put the machine on safe blocks.

(2) Lift the lift arms and install cylinder stops (Fig. 4-2).
Fig. 4- 8 Detent. Ball and Spring

Model 825
Revised January 77 -4-2- Service Manual
 (3) Tilt or remove ROPS

~
enclosure (See Section 5-2).

(4) Clean area thoroughly.

(5) Remove foot pedal assembly

(See Section 2).

(6) Remove the floor plate.

jj
(7) Loosen idler fastening bolts
a nd 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 tightening (Fig.
4 - 10). Tighten the drive chain
when freeplay at the wheel
reaches 1/2" maximum.

(9) tighten the idler fastening

bolts.
I
(10) Install a new gasket under the
floor plate. //,

( 1 1) Reverse steps 1 - 7.
~ B·1773
4-4.5 Drive Chain Adjustment
(External Adjustment Type) Fig. 4-9 Drive Chain Adjustment (Internal Adjustment)

( 1) Place the machine on safe

blocks.

(2) Loosen the idler fastening

bolts (Fig. 4-10) and the lock-nut
for the adjustment bolt.

(3) Turn the large bolt (Fig.

4-10a) to 35-55 ft.-Ibs. (55-75
N m) torque. Check at several
locations on the circumference of
the sprocket to prevent
overtightening (Fig. 4-1 Ob).

NOTE: Tighten the drive chain when

freeplay at the wheel reaches B·2653
1/2" maximum. * Fig. 4-10 Loosening Bolts * Fig. 4-1 Oa Adjusting Chain Tension
(External)
(4) Tighten idler fastening bolts
to 230 ft.-Ibs. (312 Nm) torque.

4 -4.6 Drive Chain Idler Removal

(Internal Adjustment Type)

(1) Lift the lift arms and install

cylinder stops (Fig. 4-2).

(2) Remove the ROPS enclosure.

®
(3) Clean area thoroughly.

(4) Remove the transmission

cover.
C·la17
(5) Remove the pedal assembly
and floor cover. * Fig. 4-1 Ob Checking Chain Tension

Model 825
-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. cP
( r--- ..
)
(8) Loosen the reduction gear
, co
housing fastening bolts and more (@.@~
the gear housing away from the
side wall of the transmission
housing. tV' Fastening
Nuts
(9) Remove the 2 fastening nuts
on the idler assembly (Fig. 4-11). B·1577
Fig. 4-11 Idler Assembly (Internal)
(10) Remove the idler assembly.

(11) Install a new gasket under the

I floor plate.

(12) Reverse
install.
above steps

4-4.7 To Disassemble the Idler Gear

(Internal)
to

(1) Remove the two bolts (Fig.

4 12),

(2) Separate components (Fig.

4-13).
Fig. 4-13.1 Remove Adjustor (External)
NOTE: Spacers and bearings are a
matched set. Replace as a unit.

4-4.8 Drive Chain Idler Removal Spacer

(External Adjustment Typel

(1) Lift the lift arms and install

the cylinder stops (Fig. 4-2).

(2) Tilt the ROPS enclosure.

(3) Clean area thoroughly.

(4) Remove the transmission

cover.

(5) Remove the pedal assembly

and floor cover. Fig. 4-13 Separating Components

(6) Loosen the idler bolt (Fig. 4-10.1, Ref. 1).

(7) Loosen the three idler fastening bolts.

(8) Remove the adjustment bolt.

(9) Remove the idler fastening bolts.

(10) Remove the idler bolt, sprocket and bearings.

(11) Remove the adjuster (Fig. 4-13.1).

(12) Remove the sprocket from the chain. Do not turn the sprocket or bearing
cups and races will not match.

Reverse the above steps to install the drive chain idler.

Fig. 4-13.1 Remove Adjustor IExternal!

Model 825
Revised Feb. 81 -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 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
location for removal with chain
breaking tool. (If no white link is
found, break at any link).
(11) Remove connector link and
separate the chain.
(12) Remove from sprocket, from
the axle (Fig. 4-15).
(13) Connect a long wire to the
chain to aid when installing chain
(Fig. 4-16). (If chain replacement
only.)
(14) Gather up chain while pulling
it out of transmission. Disconnect
wire from chain and leave wire in
loader.
4-6 INSTALLING DRIVE CHAIN

(1) Fasten wire to chain. Pull wire

around sprockets in same position
chain is to be installed (Fig.
4-17).
(2) Rotate rear wheel while
pulling chain over sprockets.
(3) Install front sprocket, nut and
lock bolt (Fig. 4-1 5).
(4) Pull chain around sprocket
and install new connector link with
press-on plate.
(5) Use wrench to tighten chain
idler bracket (Fig. 4 - 9). Tighten
until there is 1/4" maximum wheel
movement. Rotate wheel several
revolutions to prevent over
tightening as a result of high spots
on sprockets..
Fig. 4 -16 Removing Drive Chain Fig.4-17 Installing Drive Chain

Model 825
* 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).

4-7 REMOVAL OF AXLE

4 - 7 .1 Removal of Rear Axle

(1) Steam clean the loader

thoroughly.

(2) Remove the ROPS enclosure

(See Section 5-2).
Fig.4-19 RemovingAxle Nut
(3) Lift the lift arms and install
cylinder stops (Fig. 4-2).

(4) Remove drain plug and let out

the hydraulic fluid. (If fluid is to be
used again, store it in a clean, covered Fig.4-18 Installing Chain Guide
\
reservoir.)

(5) Remove the pedal linkage and pedal assembly.

(6) Remove the front floor plate.

(7) Remove the transmission housing cover.

(8) Remove transmission pump assembly and rear hydrostatic motor (See
Section 3).

NOTE: Put plugs in all openings.

Fig. 4- 20 Removing Axle Housing

(9) Remove lock bolt on .axle and remove axle nut (Fig. 4-19).

(10) Remove wheel from housing.

(11) Put reduction housing gear in neutral (Fig. 4- 14). (Remove nut and pull
out on lever.)

(1 2) Rotate drive chain until master connector link is in position for removal.

(13) Loosen idler sprocket until

chain is loose (Fig. 4-9).

(14) Use chain breaker tool to

remove master link.
1 " to 2" Welds

i~a_~-~
(1 5) Tie a wire to one end of chain
then pull on other end of chain
while turning axle.

l /@,-)/@
I / '

U
V ~
I
(16) When chain is out, '- <£)
disconnect wire and leave wire in
'~
loader to aid in installation.

(1 7) Remove the sprocket from

axle (Fig. 4-15).
3/4"8
OltsIASR.~~ "­ 0 !­ I

I@('j

(18) Remove bolts which

axle housing to frame.

(19) Remove axle assembly (Fig.

hold
~~
4-20).

4- 7.2 Removal of Front Axle

~------------~ ~
Use the same steps as rear axle except 1 " to 2" Welds
C-2186
omit step 7,8, 12, 14. 15 & 16.
Fig_ 4- 208 Axle Housing Mounting Repair

Model 825
Revised August 79 -4-6­ Service Manual
4- 7.3 Installation of th@ Axl@

Reverse the above steps to Install

axles. Replace the. gasket between the
axle and the transmission case if Bearing
damaged. When installing the axle Puller
housing, tighten the upright bolts (item
3) to 240 - 280 ft.-Ibs. (326 - 380 Nm)
torque (Fig. 4 21). Tighten fastening
bolts (Item 8) to the frame to 1 25 1 40
ft.-Ibs. (170· 190 Nm) torque.

NOTE: If repairs are being done on

loaders (SIN 15640 & Below)
used in heavy work conditions
or when solid tires are used Fig. 4- 21 Installing Axle Housing.:
also weld the axle housing to
the loader main frame (Fig.
4 20a). The welds shown in figure4-20a are all that are needed. Any more
than this will cause axle housing distortion and removal will not be possible. B·1909

4-8 AXLE BEARING AND SEAL REPLACEMENT Fig. 4- 22 Removing Outer Axle Bearing

(1) Remove the axle assembly

(axle with housing) from the
loader.

(2) Remove the inner bearing and

axle from the housing.

(3) Remove the outer bearing

from the axle (Fig. 4 22J.

(4) Remove the seals and races

from the axle housing. Check the
wear ring (Fig. 4 27, Item 5) for
damage and replace as needed.
NOTE: The early model 825s use a
wear ring with an inside dia­
meter of 2.7553-2.7559"
69.984-69,999 mm). The
later model 825s use a wear
ring with an inside diameter of
3.117-3.121" 179.17-79.27
mml.
Fig. 4-23 Installing the Axle Bearings Fig.4-24 Installing Axle Seal
Put heat on the wear ring until it can be
removed from the axle. To install a new
ring, put loctite on it, heat it and put it
on a cold axle.

(5) Install new races, outer

bearing and seal in housing (Fig.
4-23,4-24 & 4-25).
(6) Install axle in housing. Use a
press to prevent damage to the
bearing and seal (Fig. 4-26).

(7) Use a press to install the inner

bearing.

(8) Assemble the sprocket on the

axle.
(9) Tighten the axle but (Fig.
4 -19) until there is no free play.

(10) Tighten the nut one slot

further to align it with the bolt hole
and install the lock bolt and nut.
Fig.4-26 Installing Axle In HOUSing

Model 825
Revised Feb. 81 . -4-7­ Service Manua'
4-9 I NSTALLATION OF AXLE
SPROCKET

~ ~
Install the axle sprockets after the axle is 125 - 140 ft.-Ibs.
installed in the loader. (170 190 Nml Torque

\
~,
To install the axle sprockets:
i-(@--@-@
(1) Install the axle sprocket (Fig.
I
4-27, Item 1).

(2) Install the axle nut and tighten

the nut until there is no end play
to the axle (Fig. 4-27, Item 2).
-e­ -..,
I
I
(3) Hit the end of t~le axle and I
check for end play. I
--- I
I

(4) Tighten the axle nut to the

--------------- I
I
nearest hole on the axle nut that : (5) -----J

l-O .-o-~-
will align with the hole in the axle
and remove end play from the axle.
. ~

(5) Install the lock bolt and nut

(Fig. 4-27, Item 3 & 4). Tighten
the nut to 55 ·.70 in. Ibs. (6,2 ­
7,9 Nm).

4-10 PARK BRAKE REMOVAL

(1) Lift the lift arms and install C-1638

cylinder stops (Fig. 4-2). * Fig. 4- 27 Installation of Axle Sprocket

(2) Tilt the ROPS enclosure.

(3) Clean area throughly.

(4) Remove transmission cover.

(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.

(6) Remove shoulder screws from the case and lift out brake assembly. Use
caution to not drop the actuator lever from the bottom of the brake assembly (Fig.
4-28).
Fig. 4-28 Removing Brake Assembly
Reverse the above steps to install the brake.

Model 825
Revised Feb. 81 -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

I •

MAIN FRAME

Model 825
Service Manual
5 MAIN FRAME
5 -1.1 Description (Fig. 5- 1)

The loader main frame is separate from

the upright frame assembly. The main
frame is the housing for the drive
system and is part of the support for
the engine.

5-2 REMOVAL OF ROPS

(1) Remove rear fastening bolts

(one on each side).

(2) Lift the lift arms about 12

inches (30 cm) off the stops and
hold with blocks.

(3) Tilt the ROPS forward,

disconnect the electrical wiring
connectors (2) and remove the
ground strap.

(4) Attach a chain to the ROPS,

connect to an overhead hoist and
take up all loose play.

(5) Remove the two front pivot

bolts.

(6) Remove the bolt which

fastens the tilt assembly to the cab

1 (Fig. 5 2 for electric tilt and Fig.

5- 6 for mechanical tilt).
(7) Lift ROPS vertically until it
clears the steering handles. TO
INSTALL THE ROPS, REVERSE
THE ABOVE PROCEDURE.

5 - 3 PIVOT PIN AND BUSHING

REPLACEMENT (Fig. 5-3)

(1) Remove the pivot pin thru

bolts.
1:·1086
(2) Connect the hoist and lift the
Fig. 5-1 Main Frame
rear of the lift arms until it is clear
of the uprights.

(3) Remove the bushings with a driver tool.

(4) Use a bushing driver and install new bushings.

INOTE: Make sure that when the new bushings are installed that the grease hole in
the bushing and the hole in the lift arm is in correct alignment.

(5) Lower the lift arms into'place and install new pivot pins. Fasten with thru
bolts.

5-4 BOB-TACH REMOVAL (Fig. 5-3)

(1) Tilt the Bob-Tach forward until it is flat on the ground.

(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.

Model 825
Revised Feb. 81 -5-1- Service Manual
5-5 LIFT ARMS REMOVAL (Fig. 5-3)

(1) Remove the Bob-Tach.

~
!_~ ____ ~ __ \.~.,..
~~'_\11\
(2) Remove the lift cylinder pivot I I

pins at rod end. -l-r

@~-=iD
Jtt - ,;_\
Remove the auxiliary and rear
&4.
~___
l:-f \ \\\\
~
(3) I. \ I () "r \ -.
® __ •• \ \ (I
I~\o
tilt hose lines. j

(4) Attach overhead hoist and -"'"

take up all play.

(5) Remove the rear thru bolts

and pivot pins.

(6) Remove the lift arm ---I--'''

assembly.

0·1172
5-6 FUEL TANK REMOVAL
.. Fig. 5 - 2 ROPS (Cab) Tilting Mechanism (Electric)

5-6.1 Removing Fuel Tank on Loader

SIN 16999 & Below (Fig_ 5 -1 )

(1) Remove the engine. ......- Thru Bolt

.J
(2) Remove or loosen the hoses
and electrical wires.

(3) loosen the upright frame to

axle housing bolts and move the
frame about 1" toward the rear.
. ' .~J.}
r:.. . / " Bushings
c..,h .

\"/
(4) Remove the fuel tank fasting .•''::.1 .·.. 1
~i,

bolts.

(5) Move the fuel tank toward the Pivot :----"""

:
rear and remove from under the Pins
loader.

5-6.2 Removing Fuel Tank on Loader 0.1169

SIN 17001 & Above (Fig. 5-4)
Fig. 5-3 Lift Arm and Bob-Tach Assemblies
(1) Remove the filler hose.

(2) Disconnect the sender wire.

(3) Remove the fuel outlet hose.

(4) Install a floor jack under the

belly pan.

(5) Remove the bolts on the belly

pan.
r~-"

,k~/1
(6) lower the floor jack with the
belly pan to remove the gas tank.

5-7 ELECTRIC MOTOR FOR ROPS

(Cab Tilt SIN 19126 & Below)

~_.~.
i /,
The cab tilt mechanism (Fig. 5-2) is an
electric screw jack. Do not service this
~>-=oo~!
1

~ A/
unit. If there is a defect, make a
replacement of the complete unit.
~- E·1086R

"Fig. 5-4 Fuel Tank Removal (SIN 17001 & Above)

Model 825
"Revised Feb. 82 -5-2­ Service Manual
5 - 7.1 Removal of Tilt Mechanism

(11 Tilt the ROPS forward and hold with overhead hoist.

(2) Remove the electrical wires to the motor.

(3) Remove the fastening bolts.

(4) Remove the motor.

Fig. 5 - 5 Cab Tilt Motor

(5) Reverse to install.

NOTE: If water enters the motor

through the electrical wire
opening it will cause failure of
the tilt motor. To prevent this
problem. thoroughly clean this
area with rubbing alcohol. Use
a R.T.V. (Room Temperature
Vulcanizingl type compound
to close the opening (Fig.
5 5, Item 11.

5 - 8 MECHANICAL TILT FOR THE if

RaPS (SIN 19127 & Abovel '"
The ROPS tilt mechanism (Fig. 5-6) is
a mechanical operated screw jack. The 0-1534
mechanical jack is operated by turning
*Fig.5-6 ROPS Tilt iMechanical)
the adjustment bolt on the jack (Fig.
5-7).

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.-Ibs. (163 -203 NmJ
~\
torque.
s:
B~3626

Fig. 5 7 Raising & Lowering the ROPS

Model 825
Revised Feb. 82 -5-3­ Service Manual
 ELECTRICAL SYSTEM

Paragraph Page
Number Number

IALTERNATOR OUTPUT . . . . . . . . . . .
ALTERNATOR SERVICE . . . . . . . . . . .
ELECTRICAL CIRCUITRY . . . . . . . . . . .
.
.
.
6-4
6-6
6-1
6-3
6
6
4
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

ELECTRICAL
SYSTEM

Model 825
Revised Feb. 82 Service Manual
 OVERHEAD GUARD WIRING DIAGRAM
WIRE LEGEND PARTS LEGEND
#'s COLOR GAUGE
0 Overhead Guard Harness Connector

••
1 Purple 14
2 Yellow 14 Transmission Light (Hot)
3 White 14
4 Light Blue 14 Transmission Light (Pressure)
5 14

••
Red
6 Purple/White 14
7 Light Blue 14 Engine Light (Oil)
8 Brown 14
9 Pink 14 Engine Light (Hot)
10 Tan 14
11 Grey 14 0 Alternator Light
12
13
14
15
Red
Red
Red
Purple
14
10
10
14 •• Resistor
Hour Meter

•
16 Purple 14
17 Purple 14 Cold Start Switch
18 Black 14
19 Black 14 Ci) Circuit Breaker

••
20 Black 10
21 Brown 14 Ignition Switch
22 Red 14
23 Red 14
24 Purple 14 Fuel Gauge
25 Red 14
26 Red 14 G Terminal Connector
27
28
29
30
Red
Red
Yellow
Red
14
14
14
14
•
G)
Overhead Guard· Lift Switch
(SIN 19126 & Below)
Overhead Guard Motor
(SIN 19126 & Below)

•
 ENGINE WIRING DIAGRAM
WIRE LEGEND PARTS LEGEND

I's COLOR GAUGE

0 Transmission Oil Temperature

••
1 Purple 14
2 Yellow 10 Engine Temperature
3 White 14
4 Light Blue 14 Thermal Start (Glow Plug)
5 Red 10
6
7
8
9
10
Purple/White
Light Green
Brown
Pink
Tan
14
14
14
14
14
•• Alternator
Fuel Level Sender

11 Grey 14 0 Engine Oil Pressure

12
13
14
15
Red
Red
Grey
Red
10
10
14
4 •• Starter
Harness Connector

•
16 Black 4
17 Black 4 Transmission Filter Pressure
18 Black 14
G Transmission Charge Pressure
G) Battery

- - - - - - _•..._ - -----­

..
6 ELECTRICAL SYSTEM
6 -1 ELECTRICAL CIRCUITRY

There are two basic circuits in the

electrical system:

( 1) Charging circuit

(2) Starting circuit.

The ignition switch must be turned on

to activate these circuits.

The charging circuit includes the

I
alternator, (with intergral regulator),
warning indicator light (ClT) and
battery.

The starting circuit includes the starter,

solenoid and other parts needed to turn
the engine.

NOTE: When using an extra battery

(jump start) to start the engine
the ground wire (Fig 6 - 1,
Item 1) can burn through the
insulation. Replace the ground
wire (Fig 6 -1, Item 1) with a
4 gauge wire. Do not put the
ground wire through the
harness clip.

See figure 6 1 for wiring diagram.

The two most common problems with

the electrical system are:

(1) Battery loses charge.

(2) Starter will not turn engine.

Refer to problem analysis charts to find

problem with starting or charging
circuits.
I

~
'.'''.
IMPORTANT .. Fig. 6 -1 Electrical System
E-l108

~A

When working on the electrical

circuity, first remove the
ground (negative) cable from
the battery.

6- 2 PROBLEM ANALYSIS

See the charts for diagnosis of electrical problems:

Chart 1: Battery loses charge.

Chart 2: Starter won't turn engine over.

The charts give the correct sequence for finding problems and making repairs.

Model 825
.. Revised Feb. 82 -6-1­ Service Manual
 CHART A

BATTERY LOSES CHARGE

~ If -1 f f Outpu

1
Check Check Check Check Charging
If .... If
Generator Condition of Good .... Wiring G d Output Is System Works
Good (Page 6-3) (Page 6-3) Correct Correctly
Drive Belt Battery & Cable 00

If Loose If Output
If Defect If Defect
Or Defect Is Not
Is Found Is Found
Is Found Correct

~ l ~
Make Repair
As Needed
(Page 6-3)
Make
Repair As
Needed
Make
Repair As
Needed
Check
Regulator
(Page 6-4)
t" INo Remove And
Defect..... Inspect Generator
Is Found (Page 6-4)

If Defect
Is Found

~
Remove Generator
Make Replacement
Of Regulator
(Page 6-4)

CHART B

STARTER WILL NOT TURN ENGINE OVER

~heck
Check
rG!~d--.....1
Check If Engine .... Check Wiring,
For Engine Condition Of If
Good Starter Ignition Switch
Is Good
Seizure Battery & Cables (Page 6-6) & Circuit Breaker

If Engine If Defect
Has Defect Is Found

~
Correct Remove and Make
Engine Repair As Needed
Problem (Page 6-6)

Model 825
* Revised January 77 -6-2­ Service Manual
6-3 FAN BELT

Check the drive belt for correct tension. A loose belt can cause charging problems.
Correct tension is 3/8" (10mm) play at the midway point (Fig. 6-21.

A new belt must be installed when:

(1) It is worn narrow.

(2) It has cracks or is separating.

(3) It has oil on it.

(4) There is no more adjustment.

To check wiring:
Fig. 6-2 Fan Belt Adiustment
(1) Turn the ignition switch on. Connect a voltmeter from chassis to: (Fig. 6-3)

No.1 alternator connection

No.2 alternator connection

"Bat" connection

(2) If any of these connections show zero voltage, the wiring has defect. Find
defect and make repair. Then check voltage again.

6 -4 TO CHECK ALTERNATOR
1
OUTPUT

( 1) Put the machine on safe

blocks.

(2) Disconnect negative battery

cable. Connect an ammeter in line
with the "Bat." terminal of the
lIBat"
generator. Connect the battery cable.
Terminal
(3) Lower the electric charge in
battery. (Turn engine with starter,
connect lights, etc.)

(4) Start engine and run at full

throttle. The minimum indication on
the ammeter must be 22 amperes.

I
(5) If the indication is correct,
the alternator is good. If the indi­
cation is high or low, check the
regulator.

Test Hole
6-5 TO CHECK THE REGULATOR

11·2113
(1) Leave the ammeter connected
as in Paragraph 6-4. * Fig. 6 - 3 Alternator
Model 826
* Revised Feb. 82 .6-~ Service Manual
 (2) Lower the electric charge in battery. (Turn engine with starter, connect lights,
etc.) I Test Hole

I (3) With the engine running at full throttle, connect the alternator field to
chassis with a small screwdriver or wire (Fig. 6-4).

(4) Check the ammeter. The indication must be 8 - 28 amperes. If the indication
is correct, the regulator probably has a defect. If indication is not correct, the
problem is in the diode trio, the rectifier, the stator or the rotor.

16-6 ALTERNATOR SERVICE B·2113

A·22 11

6-6.1 Removal (ROPS Must be Tilted) Fig. 6-4 To Check the Regulator

(1) Disconnect negative battery cable.

I
(2) Disconnect wires from alternator.

(3) Remove the two bolts that hold alternator in place and lift alternator from
the Bobcat.

(4) Installation is the reverse of removal.

6-6.2 Disassembly

(1) Put a mark across each housing half to help in correct assembly.
C·1959

(2) Remove the pulley from the shaft. * Fig. 6 - 5 Separating Alternator Housing

(3) Remove the four bolts which hold the housing together.
(Check for Ohmmeter Shorts and OpensJ
(4) Use a screwdriver to separate each half of housing (Fig. 6-5). Slide the rotor
out of the housing.

(5) Remove the nuts which hold the three stator wires to the frame. Remove
the stator.

(6) Disconnect the diode trio.

6-6.3 To Check Rotor (Fig. 6-6)

A·1857
(1) Connect an ohmmeter from one slip ring to the shaft. There must be
maximum resistance. Fig. 6-6 Checking Rotor Coil Wires

I (2) Connect an ohmmeter to both slip rings. There must be 21.8 to 24.0 ohms
of resistance on the alternator. If not, there is a defect in the rotor. Check For
Opens

6-6.4 To Check Stator (Fig. 6-7)

(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
Check For Ohmmeter
connection. If the light doesn't come on, there is a defect in the stator.
Opens (Check for Grounds)
13-2108
(3) Connect the test light from one of the connections to the frame of the stator.
If the light comes on, there is 11 df'!ff'!ct in th@ stator. Fig. 6-7 Chocking Stator Coil Wires
Model 825
-Revised Feb. 82 .8-4­ Service Manual
6-6.5 To Check Diode Trio (Fig. 6-·8)

(1) Connect a D.C. test light from

one of the three connections to the
single can nection. Then, reverse the
connections. The light must come
on when connected one way, but
not when connected the other way.

WARNING A·2382

Fig, 6-8 Checking Diode Trio

Do not use high voltage to check
diode tri or rectifier,

Half B·2101
B·2102

Fig. 6-9 Checking Rectifier

(2) Do Step 1 for the other two diodes.

(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.

6-6.6 To Check Rectifier (Fig. 6-9)

(1) Remove the rectifier from the generator.

Insulated Washers

(2) Tighten the three nuts on the connections.

(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.

Fig. 6-10 Insullation Washers and Spacers

(5) Repeat Steps 3 and 4 on both the other connections. If any of the tests are
bad, complete rectifier replacement is necessary.

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).

B·2097
To instali the rotor, put a piece of straight wire through the case to hold the brushes in
place (Fig. 6-11). Fig. 6-11 Holding Brushes

Model 825
·6-5· Service Manual
6-7 STARTER SERVICE
Jumper Wire
6-7.1 To Check the Starter

(1) Lift the Bobcat on safe blocks. Keep the ignition switch off. Be sure the
battery has full charge and the connections are clean and tight.

(2) Connect a jumper wire from the "5" connection on solenoid to the "Batt"
connection on solenoid (Fig. 6-12). The engine will turn rapidly. If the starter
turns, but not the engine, the defect is in starter drive. If the starter doesn't turn,
do this:

A·1991
(3) Connect the jumper from the "Batt" connection on solenoid to the "M"
term ina I on starter (F ig. 6-131. If the starter will turn rapid Iy, the defect is in the Fig, 6-12 Checking Solenoid
solenoid. If starter does not turn, the defect is in the starter.

Jumper Wire

6-7.2 To Remove Starter

(1) Disconnect negative battery cable.

(2) Disconnect the wires from starter connections.

(3) Remove the bracket which holds the rear of the starter. Remove the three nuts
which hold the starter in place, and lift it out.
A·1992

Fig. 6-13 Checking Operation

6-7.3 Disassembly and Inspection

(1, Remove the three screws which hold the solenoid in place. Twist the solenoid
1/4 turn and slide it off.

(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.

Fig. 6-14 Armature Testing IGrounds)

(4) Check the armature on an
armature tester (Fig. 6-15).

(5) Check the condition of the

commutator, and make repairs as
needed.

(6) Connect a test I ight from the

outside connection to each of the
inside connections (Fig. 6-16). If
the light doesn't come on, the field
coils have a defect.

6-7.4 Assembly
Assembly is the reverse of disassembly. Fig. 6-15 Armature Testing (Shorts) Fig. 6-16 Checking Field Coil Wires
Model 825
-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
FL YWHEEL AND FLYWHEEL HOUSING 7-7 7-17
FUEL SYSTEM 7-11 7 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

ENGINE SERVICE

Model 825
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.

7 -2 STARTING A NEW OR RECONDITIONED ENGINE

(1) Remove the plug on the thermostat housing so that all the air will be
removed from the system when the radiator is filled.

(2) Fill the cooling system with a 50 - 50 mixture of antifreeze and water.

(3) Start the engine and check to make sure the oil pressure is satisfactory.

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 is
warm up.

(5) After the engine has been warmed up thoroughly it must be stopped and
head bolts tightened to the correct torque (See Specifications Section). The
valve clearances must be adjusted after the head bolts are tightened.

(6) Check for oil and coolant leaks. Check to make sure the coolant and oil
levels are correct.

7 - 3 ENGINE OVERHAUL

For overhaul of cylinder head. it is not necessary to remove the engine from the
loader. Remove only those items such as engine cover, fuel lines, hoses, tee., to
make clearance to cylinder head possible.

The engine must be removed when it is necessary to overhaul the block assembly.

I
The engine must be at operating temperature and turning at about 175 RPM. The
compression must be between 300 and 500 PSI (2069 3448 kPa) with no more
than 50 PSI (345 kPa) difference between the cylinders.

7 3.1 Engine Removal

The engine is most easily removed with the engine coolant radiator and transmission
oil cooler attached. Remove the engine as follows:

(1) Tilt the operator guard forward.

(2) Remove the rear grill.

(3) Disconnect the battery cables, electrical wiring, fuel lines and throttle
linkage.

(4) Let out engine oil and disconnect drain hose from the frame connection.

(5) Remove the engine cover and muffler.

(6) Remove the hydraulic hoses from the oil cooler. Plug the openings.

0) Remove the three engine fastening bolts from the engine supports at the
sides and rear of engine.

(8) Fasten chain hoist to engine as shown in figure 7 1.

(9) Lift the engine up and to the rear slowly to release the drive coupling.

Model 825
Revised Feb. 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

system by opening the radiator and
cylinder block plug and valve.

(2) Disconnect the battery

terminals.

(3) Remove the fastening nuts

and remove the muffler from the
exhaust manifold.

(4) Disconnect the water outlet

connection on the front of the
cylinder head.

(5) Remove the air cleaner.

(6) Disconnect the fuel pipe and

electrical connection to the
starting aid located in the intake
manifold. Fig. 7 - 1 Removing Engine

(7) Remove the cylinder head

cover together with the breather
pipe.
rk­
(8) Remove the oil feed pipe to
the rocker shaft at the cylinder
head end.

(9) Remove the eight rocker shaft

fastening nuts evenly and remove
the rocker shaft complete with the
oil feed pipe (Fig. 7-2).

(10) Remove the eight push rods

and place somewhere safe
(possibly in the cylinder head
cover) to prevent them from being
bent.

(111 Unscrew the small bolts on

the tops of the injectors and
remove the leak-off pipe by turning
the fitting on top of the fuel filter.
Rocker Shaft Removal

Model 825
Aevis&d .Jan. 77 -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

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.

7-3.3 To Remove The Valves

All valves are numbered so that they may be fitted to their original locations during
assembly (Fig. 7 -4). The cylinder head is marked with corresponding numbers next
to the valve seat.

( 1 ) Put the cylinder on the bench

with the machined face down.

(2) Use a valve spring

compressor to remove the two
collets by compressing the valve ··1,
springs as shown in figure 7 5.
Repeat for each valve to be
removed.

(3) Remove the spring caps,

springs, seals and spring seat. The
valves are now free to be removed
from their guides when the
cylinder head is turned over.

NOTE: "0" sealing rings are fitted

to the inlet valve stems. The
inlet valve spring caps have a Fig. 7 - 4 Valve Numbering Fig. 7 - 5 Valve Spring Compression
deeper center portion to fit
this seal. During re-assembly,
be sure that the correct spring
caps are fitted to the inlet
valves and the seals are fitted
in the sequence detailed on
page 7-7.

7-3.4 Combustion Chamber Inserts

When it is necessary to remove
combustion chamber inserts from their
seats in the cylinder head, they can be
pushed out of their locations by a short
curved bar through the injector bore.
When installing inserts they must be
held by expansion washers in the seats
to prevent them from turning. The
expansion washers are fitted as shown
in figures 7 6 and 7-7. Fig. 7 -6 Fitting Expansion Washers Fig. 7 - 7 Seating Expansion Washers

Model 825
-7-3­ Service Manual
7 3.4a Reconditioning Cylinder Heads
When reconditioning cylinder heads, it is not always necessary to replace cracked
pre-combustion chamber inserts. As a general rule, inserts having a single straight
crack less than 1/4" (16 mm) in length going out and away from each end of the
throat (Fig. 7 - 7a) are acceptable. If an insert has a crack that turns toward the
center of the insert (Fig. 7 - 7b, Item A) or one starting from the straight edge of the
throat (Fig. 7 - 7b, Item B) it must be replaced.
Also when replacing a cylinder head (supplied without inserts), the inserts may be
used from the old head if the inserts are acceptable to the list above.
NOTE: Cracks are easier to see by checking the inside face of the insert.
7 3.5 Cleaning
A2681
Plug all openings, oilways, etc., where the entry of foreign mattery could cause
damage to the working parts. Remove any carbon carefully from the tops of pistons Fig.7 7a Pre-CombustionlnsertslGoodl
(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 water
leakage after this cleaning.
Clean all the studs on top of the cylinder head and those in the top face of the
cylinder block. Examine for thread damage or stretching and replace with new ones
where necessary.
Any loose studs must be tightened and any cylinder head nuts found with damaged
threads replaced.
NOTE: Studs and nuts are phosphate coated. Be sure that only genuine parts are
used as replacements. A 2681
7 3.6 Inspection
Fig. 7 - 7b Pre-Combustion Inserts IBad)
After the cylinder head has been disassembled and cleaned, the following
components should be inspected as follows:
(11 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
insJ,Jected, paying special attention to squareness of ends and pressures at
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 .800" to .815 ".

NOTE: Be careful during this

operation since guides are
brlnla. Fig. 7 - 8 valve Guide RQmOval

Model 825
Revited Augult 19 -1-4­ 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.

7-3.7 Reconditioning of Valves and Valve

Seats

The valve and valve seat faces using

specialized equipment or with grinding
compound, according to their condition. A
valve seat (hand operated) cutting tool is
shown in figure 7-10. Valves should
always be fitted to their original seats and
B-1863
any new valve fitted should be marked to
identify its position if removed later. (See Fig. 7-9 Valve Guide Installation
Fig. 7-4 for illustration of valve
numbering.)

Before installing the valves, be sure to check the valve head depth in relation to the cylinder
head face, within the limits given on page 8-3. This depth' can be checked, as shown in
figure 7-11, by placing a straight edge across the face of the cylinder head, then use a feeler
guage to measure the distance between the straight edge and the head of the valve.

Where this depth is more than the maximum limit and when the fitting of a new valve does
not reduce this depth below the maximum limit, then install a new valve seat insert.

When refacing valves or valve seats see that only the minimum amount of metal necessary to
obtain a satisfactory seat is removed, and that as narrow a valve seat as possible is
maintained.

7-3.8 Valve Seat Inserts

Valve seat inserts are not installed in production engines. Inserts can be installed in these
engines where it is considered necessary.

When installing inserts be sure that only genuine replacement parts are used.

7-3.9 To Install Inserts, Proceed As

Follows:

(1) Install new valve guides as

described on page 7-4.

(2) Using a new valve guide bore as

a pilot, machine cut the insert area in
the cylinder head face to the
dimensions shown in figure 7-12.

(3) Remove all loose material and

thoroughly clean the cut out area
(removing any burrs which may be
present. Fig. 7-10 Relacing Valve Seats Fig. 7-11 Checking Valve Head Depth
Model 825
-7-5­ Service Manual
 (4) Using the valve guide bore as a Valve Valve
pilot once again press the insert in
Inlet Exhaust
with the insert driver, this tool is
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.
NOTE: The insert must not be driven by
hammer and lubrication must not
t
(5)
be used.

Visually inspect to be sure that

t A
..
Inlet Exhaust
tbe insert has been pressed fully in A - 1.530" to 1.531" A - 1.296" to 1.297"
(flush with the bottom of the recess). B - 0.3125" to 0.3175" B - 0.3125" to 0.3175"
C - 0.015" Chamfer at 45 0 (Max.) • C - 0.015" Chamfer at 45 0 (Max.)
(6) Cut the valve seat at an
included angle of 90 0 (which will A·235 0
give the normal 45 0 seat) until the
Fig. 7-12 Valve Insert Detail
val ve head depth reaches the
minimum limit which is given on
page 8-3. lightly lap the valve to its new seat.

INSERT DRIVER (Fig. 7-13)

Inlet Dimensions Exhaust Dimensions
A 2.75 in. A - 2.75 in.

B. - 2 in. B. ·2 in.

C. 0.75 in. C. - 0.75 in.

D. 0.309 in. to 0.310 in. D. - 0.309 in. to 0.310 in.

E. - 1/16 in. at 450 E. - 1/16 in. at 45 0

F. - 1/16 in. at 450 F. - 1/16 in. at 45 0

G. 1/32 in. Radius G. - 1/32 in. Radius

H. 1.238 in. to 1.239 in. H. - 1.018 in. to 1.019 in.

J. 0.222 in. to 0.225 in. J. - 0.222 in. to 0.225 in.

K. - 1.523 in. to 1.533 in. K. - 1.287 in. to 1.297 in.

E
7-3.10 To Disassemble the Rocker Shaft Assembly

.(17 Remove the snaprings from each end of the rocker shaft.

(2) Withdraw the rocker levers, springs and support brackets from the rocker shaft.

(3) Unscrew the oil feed pipe from the connector and remove the connector. (When
refitting this feed pipe, it should be noted that the end ot the pipe locates the A
connector position on the shaft.) Bi
I
After disassembly, thoroughly wash all parts in clean solvent. Inspect the rocker bushings
and shaft for wear. The rocker levers should be an easy fit on the rocker 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.
B·2016

New rocker levers are supplied complete with bushing fitted and reamed to size. Fig. 7-13 Insert Driver
Model 825
·7-6- Service Manual
NOTE: When fitting new bushings, ,@@ that the oil feed hole~ are in alignment before
Align Oil Feed Hol@s
pre"ing in, and when pressed fully in Gee that the hal.., ilre in alignment (Fig.
7-14),

7-3.11 To Assemble the Rocker Shaft Assembly

(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.

7-3.12 Push Rods A-2352

Fig. 7-14 Rocker Arm Bearing

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 sideways along the shaft.

(3) Remove the old push rod and

install new rod.

(4) Make adjustment of valve B·1892

clearance.
Fig. 7-15 Rocker Sha, t Assembly
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 snapring and push rod replacement.

7-3.13 To Install the Valves

(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
coil,
valve springs have a damper
when correctly installed this
0 __ ;-<D
coil is nearest the cylinder head e

~11
top face. See note on spring II Inner
caps on page 8-4. 2 a......-val~e
Spring

(5) Use a valve spring compressor,

Outer
ass how n in figure 7 --16, to
~
compress the valve springs and locate
the retaining semi-conical collets.
o .. ""-Valve
Spring

NOTE: Inlet valve stems are fitted with

rubber O·ring seals. They fit
inside the valve spring cap bore
and must align with groove on
CD---..
the valve stem. Assembly of the
inlet valve assemblies should be A-2340
carried out as follows: (Fig.
7-17) Fig. 7-16 Valve Spring Compression Fig. 7-17 Valve Assembly
Model 825
-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 3l.

(9) Compress with the valve

spring compressor until the valve
stem is through the cap enough to
install the a-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).

Top Front 9-1990
7 -4 INSTALLING CYLINDER HEAD
Fig. 7-18 Installing Cylinder Head Gasket
7 - 4. 1 Cylinder Head Gasket
Whenever the cylinder head is
removed, it should NOT be installed
using the old gasket again. Be sure that
only the correct type is used. It is made
of a black composite material and is
known as a Klinger type. It MUST be
fitted DRY, and gasket cement must
not be used.

The copper asbestos type of cylinder

head gasket is not suitable and must
not be used.

Since the cylinder liners on this engine,

when correctly installed, are above the
cylinder block face, it is very important
that the gasket is placed correctly,
otherwise the steel beading may be
pinched between the cylinder head
face and the top of the liner when
installing the head.
Fig. 7-19 Tightening Order
NOTE: Before installing the cylinder
head. be sure that the faces are clean. Check that the rocker assembly oil
passage in the cylinder head is not restricted.

7 -4.2 To Install the Cylinder Head

(1) Put the cylinder head gasket carefully in position on the pylinder block face
(the gasket is marck "TOP FRONT" to indicate how it mus~ be installed {Fig.
7-181. .

t
i
(2) Lower the cylinder head into position on top of the gask~t making sure that
it is level.
(3) Lightly put oil on both cylinder head studs and nuts, then ighten the nuts in a
three stage sequence shown in figure 7 -19 until torque is 60 f, .-Ibs. (8,3 kgf/ml.

NOTE: After the engine has been running. check the torque. If th~ bolts do not move
with the correct torque setting on the torque wrench. 100~. en 30 to 60 0 and
tightentothecorrecttorque. Check the first 1 0 positionsag in after allthebolts
have been tightened to make sure they are at the correct t rque (Fig. 7 -19).

(4) Install the push rods in their locations then carefully fit the rocker shaft
assembly, noting that the valve adjusting screw ends are in the push rod cups
and that the oil feed to the rocker shaft is positioned correctly.

Model 825
Revised Feb. 81 -7-8­ Service Manual
 (5) Tighten the t>il feed pipe nut just finger tight at this stage, then tighten the
rocker shaft bracket securing nuts evenly to II torque of 12 - 15 ft.-Ibs. (1,7 -- 2
kgf/m). Now tighten the oil feed pipe nut.

When correctly positioned, the oil feed pipe will be as shown in figure 7-20.

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 .012" (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.
Fig. 7-20 Rocker Oil Line
(9) Install the leak off pipe assembly and four high pressure fuel pipes to the
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.

(16) Connect the battery. Fig. 7-21 Connecting Rod Cap

7-5 CONNECTING RODS AND PISTONS

7-5.1 To Remove Pistons and Connecting Rods

(1) Remove the cylinder head assembly (Refer to page 7-2).

(2) Remove the oil sump (Refer to page 7-25).

\
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. Fig. 7-22 Removing Pistons

(4) Remove the connecting rod caps and bearing sheels (Fig. 7-21).

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 1800 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.
Modet825
-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.

There is a steel insert rolled into the top

IMPORTANT ring groove during piston manufacture,

it is part of the piston and must not be
removed from its location.
B-1868

Fig. 7-23 Regrooving Pistons

(2) Use snapring pliers to remove the snapring holding the piston pin and push
out the piston pin to release the connecting rod.

NOTE: If the pin does not come out easily. do not use force to drive it out. The
procedure is to warm the piston in a clean liquid (usually water) to a
temperature of 1Ooo·120 oF (40 o·50 0 C), the pin can then be pushed out
easily.

7 - 5.3 Inspection

(1) Thoroughly clean all the disasembled components.

(2) Inspect the pistons for scoring and any signs of ring groove damage.

(3) Check the clearance of the piston rings in their grooves by placing the ring
into the groove and USing a feller gauge between the ring and groove face.

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 8·21. B-1987

" (7) Inspect the rod bearing inserts for signs of wear or pitting. Also inspect the Fig. 7-24 Piston and Rod Numbering
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

6°0
No. 1 connecting rod assembly. Refer

~ C;;O~ (j~O&~
to figures 7 - 24 and 7 - 2 5 for
location of piston and rod numbering.
Any new components fitted must be
°0°
~ ~ ~
numbered the same as the old
components.

(1) Warm the piston in a suitable

clean liquid to a temperature of
0=' 'C) 0 2 16 1 0
100-120oF (40·50 0 C) until the
piston pin can be easily pushed 0000°000
into the piston bore when the
piston and rod have correct
alignment.
Fig. 1-'25 Loc~tion of Piston Numooring

Model 825
Revised Feb. 82 -1-10- Service Manual
 (2) Position No, 1 piston on its head, noting the position of the '"F'" mark
indicating '"F RaNT". (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 snaprings 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.

(6) Repeat this procedure for the other three pistons and connecting rods.
Fig. 7-26 Piston Pin Retainer

7-5.5 Installing the Piston Rings

The piston rings should be fitted to the piston in the following order: (Fig. 7-27)

(1) Slotted oil control·· below the piston pin (fifth groove) (Item 1).

(2) Slotted oil control·· above the piston pin (fourth groove) (Item 2).

(3) Internally stepped compression {third groove) (Item 3).

-' ~
(4) Internally stepped compression (second groove) (Item 4).

NOTE:
(5) Plain parallel faced compression (top groove) (Item 5).

All of the above rings can be fitted by means of an expanding tool of the type
~~, rsJa'0
'0
shown in figure 7-23. These rings are made of ca~t Jm!:I <I(1d are brittle, so
when fitting, be careful not to expand any ring m""Or~ than ii, necessary to just
clear the piston.

NOTE: The in!ernally stepped compression rings must be installed with th~

7-5.6 To Install Rings

B-1985

Fig. 7-27 Piston Flings

(1) Hold the connecting rod, with
piston, in a vise.

(2) Install the bottom (5th) slotted

oil ring in the groove below the Top Ring~
piston pin. (Either side up.)
~nd & 3rd Ring
(3) Install the 4th slotted oil ring .--- (Step Up)
in groove above piston pin. (Either I 11

)0;10;",.
side up.)

(4) Install the 2nd and 3rd internal

step ring in the next 2 slots, with
the step up (Fig. 7-28).
.1
@ Tl
(5) Install the 1st (Top) ring. ;.

(Either side up.)

Position the gaps of the

around the piston.
rings evenly
~ ~ '­

A-239S
Oil the rings in their grooves and see that
they can move freely in their locations. Fig. 7-28 Location of Piston Rings

Model 8~5
-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
fitlur'e 7-29 until all the rings have entered the cylinder bore.
:1 " , i
"~-

(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
crankpin.

(6) Fit the lower half bearing shell to the connecting rod cap, putting the tag in
the machined slot, add oil to bearing and fit the cap to the crankpin, making sure
that the numbers on the rod and cap are in alignment as shown in figure 7--24.

(7) Fit the two connecting rod fastening bolts and tighten evenly to 38 ft.-Ibs.
(5,8 kgf/m) torque.

NOTE: Locking tabs are not fitted to these bolts.

(8) Use the same procedure for No.4 piston and connecting rod assembly.

(9) Rotate the crankshaft to bring numbers 2 and 3 crankpins to bottom dead
.;:.~>
It<-, ,_ ": center.
$:'
,..,' ".

'.2:" (10) Follow procedures 2 . 7 to fit the other two assemblies.

(11) Install the oil pan (Refer to page 7-25).

(12) Install the cylinder head assembly (Refer to page 7-8).

7-5.8 Installing New Pistons

With new pistons extra material is given on the top of the piston to let the necessary
material be".,,~oved with a lathe so that when fitted, the piston height above the
cylinder block top face will be within the limits indicated on page 8-1.

To find what amount needs to be removed from the piston crown, the piston, connecting
rod and bearing assembly will have to be fitted to its cylinder bore as described earlier.
(This includes tightening the connecting rod screws to the correct torque to prevent the
possibility of getting a wrong reading.) The piston height above the cylinder block top
face must be measured with the piston at top dead center. This piston height can be
measured with a depth gauge. Do this for each new piston to be fitted and mark each
piston with the number of the cylinder bore it will belong to (not on the top as any
marking here will be removed by the machining) possibly a temporary mark on the side
with pencil. When each piston has been machined, it should be checked again when
finally installed to make sure that the new piston fitted is within the limits quoted. Once
the piston hlilight is correct, mark any such piston on the top with the number of its
bore (Fig, 7-25), Fig. 7-29 l'i<fOn In<",lIaTion

Model 825
-7-12- Service Manual
~ ..____ll''--_._ _ _ _ _ _
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 Iiners 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.

(6) Lightly add lubricant to the outside of the liner with clean engine oil.

(7) The liner must be slightly above the cylinder block top face and not be
pressed fully down when fitted correctly. use a solid large washer of correct
thickness to give the correct liner height.

NOTE: The limits for liner height are given on page 8-1 and may be checked as shown
in figure 7-31.

This height should be checked in four 900 positions for correct height of top
face of liner with top face of cylinder block.

(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. Fig. 7-30 Liner Removal

(10) Follow same procedure for other liners.

(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 bat and cylinder block face. Such a plate
must be thicker than 0.027 in. (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.)

7-6 CRANKSHAFT AND MAIN BEARINGS

7 -6.1 Description

The crankshaft uses three aluminum tin lined bearings. Crankshaft end float is controlled
by thrust washers located on each side of the rear main bearing. These give 1800 and
3600 thrust faces to the crankshaft at the front and rear of this bearing. 0.0075 in. (0.19
mm) oversize thrust washers are available which if used on one side of the rear main
bearing only will reduce crankshaft end float by 0.0075 in. (0,19 mm) and by 0.015 in.
(0,38 mm) if used on both sides. The Iirnits for the crankshaft end float are given on
page 8-2. Fig. 7-31 Liner Protrusion Check
Model 825
-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.

7-6.2 To Install Main Bearings and Thrust Washers

When installing new main bearings, also check the crankshaft for wear. Removal of the
main bearings and thrust washers can be done without removing the crankshaft by the
following procedure:

(1) Remove the oil pan and suction pipe assembly.

(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.

(6) Rotate the bearing shell on the crankshaft until it is in correct location with
the tab in the machined slot.

(7) Locate the lower half bearing shell in the main bearing cap, add lubricant and
install.

(8) Tighten the two fastening bolts to position the bearing shells, then loosen.

(9) Follow items 3 - 8 for the other two bearings.

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.-Ibs. (11,5 kgf/m) torque.

7-6.3 To Install Thrust Washers

(1) Remove the two capscrews which hold the two housings for the rear main
bearing oil seal as shown in figure 7-33.

(2) Remove the rear bearing cap bolts.

NOTE: When both thrust washers and main bearing shells are being installed, both
4!' 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 af the rear moin bearinll cap as dt'!s,crib"d and install the
cap. Fig. 7-32 FWmoving Bearing Insort

Model 825
-7-14- Service Manual
 (6) Tighten the bolts evenly to 85
h.-Ibs. (11,5 kgf/ml torque.

(7) Check that the crankshaft end

play is within the limits given on
page 8-2 using a feeler gauge as
shown in figure 7-37. If incorrect,
install oversize thrust washers to give
an overall reduction of 0.015 in.
(0,38 mm). (Refer to page 8-2).

(8) Install two bolts to hold the

rear main oil seal half housing.

NOTE: If any leakage of oil is noted Fig. 7-33 Rear Main Seal Removal Fig. 7-34 Thrust Washer Removal
from this seal, then install new
seals to the half housings as
described under the heading
"Crankshaft Rear End Oil Seal".

(9) Reinstall the suction pipe assembly and oil pan.

7-6.4 To Remove the Crankshaft

Any components removed must be marked to identify them to their original locations
when they are later installed.

(1) Remove the starter motor, flywheel and flywheel housing. (Refer to page
7-17).

(2) Remove the crankshaft front pulley, timing case cover, timing gears and fuel Fig. 7-35 Thrust Washer Position
pump drive hub. (Refer to page 7-19).

(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 7-25l.

(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.

(6) Remove all the main bearing ~er Thrust/

bolts. Washer Half

NOTE: The rear seal half housing

fastening bolts must be removed
before the rear main bearing cap
can be removed (Fig. 7-33),

(7) Lift out the crankshaft for

inspection and put it where it will
not be damaged.

(8) Remove the top half main

bearing shells, and mark them if
they are to be used again.

(9) Remove the top half oil seal

housing to complete the
disassembly. Fig: 7 -36 Thrust Bearing Installation Fig. 7-37 Crankshaft End Float
Model 825
-7-15· Service Manual
 7-6.5 To Reinstall the Crankshaft

{11 First clean the crankshaft and

check that all the oilways are clear.

(21 Clean the bearing housings, put

the three top bearing shells in
position then give them lubrication
with clean engine oil.

NOTE: Unless a new set of mdn

bearings is being fitted, return
removed bearings to their
original locations.

(3) Put the crankshaft carefully in

position.
B·1993
(4) Locate the upper thrust washer
Fig. 7-38 Crankcase
in position as shown in figure 7-36.

(5) Clean the bore in the main bearing caps, fit the three lower bearing shells,
then give them lubrication with oil.

(6) Fit the three main bearing caps in their correct locations.

NOTE: Be sure that the two lower thrust washer halves are positioned correctly either
side of the rear main bearing when cap is fitted.

(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.-Ibs. (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 8-21.

(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 crankpins, 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--251.

(13) Install the oil pan using new seals and gaskets. {Refer to page 7-251.

(14) Install the timing case back plate, fuel pump drive hub, timing gears, timing
'i' cover and cran kshaft front pulley. (R efer to page 7-21 for their reassembly).

(15) Install and make correct alignment of the flywheel housing as described on
page 7-18.

(16) Install the flywheel and starter motor.

Model 825
.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.

NOTE: When traces of oil is noticed

from behind the flywheel and a
faulty rear oil seal is expected,
first make sure that the
crankcase is vented correctly.
Any build up in crankcase
pressure could cause oil to be
forced past the rear sealing

~
assembly. If crankcase pressure is
normal and new seals need to be
installed, the following procedure
should be followed with the ~
crankshaft in position.

(1) Set up a half housing in a vise

with the sea I recess.
Fig. 7-39 Seating New Seal " B-1986

(2) Press about 1 in. (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 in. (0,25/0,50 mm)
beyond the half housing face.

(3) With the thumb or finger press the remainder of the strip into the groove,
working from the center, then use a round bar to force the strip into position by
rolling and pressing its inner diameter as shown in figure 7-39.

(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
gas'ket treated with a good sealing material.

(6) Put sealing material on the faces of the housing.

(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
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 backsaw 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.
Model 825
-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 4800 F.
(2500 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.

7-7.3 To Reinstall the Flywheel

It is important that the crankshaft flange face is clean and free from burrs, also the
Fig. 7-41 Flywheel Alignment
mating face of the flywheel before installing the flywheel.

The flywheel can only be installed in one position due to the spacing of the bolt holes.

(1) Turn a short stud into the crankshaft flange just finger tight, so that when the
flywheel is installed, this stud can take the weight of the flywheel as the fastening
bolts are installed. This stud can then be removed and the fifth bolt installed.

(2) Tighten the bolts to .60 ft.-Ibs. (8,3 kgf/m) torque. Do not lock the tab
washers at this stage.

(3) Install a dial indicator with the base against the rear face of the flywheel
housing and the gauge rod at right angle to the flywheel. Turn the crankshaft and
check the run indicator out, the flywheel should run true within 0.012 in. (0,30
mm) (Fig. 7-41).

(4) When the flywheel is correctly aligned, lock the bolts with the tab washers.

7-7.4 To Install the Flywheel Housing

(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.

(3) When the housing is correctly aligned, tighten the fastening bolts.

(4) Install the flywheel as described on page 7-17.

7-8 TIMING CASE AND DRIVE

7-8.1 To Remove the Timing Case Cover

(1) Loosen the alternator fastening bolts, remove the adjusting arm bolt and
remove the fan belt.

(2) Remove the fan blade.

(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_
Model 825
-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.

7-8.3 To Install the Timing Case Cover

(1) Thoroughly clean the faces of the timing case front cover and the timing case
back plate.
Fig. 7-42 Idler Gear
(21 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.

(3) Loosely install the front cover bolts and nuts.

(4) Install the crankshaft pulley to center the seal, then tighten the cover screws
and nuts.

(5) Install the crankshaft pulley holding bolt and washer and tighten to 150 ft.-Ibs
(20,5 kgf/ml torque.

(6) Install the fan belt and make adjustment for 3/8" deflection.

7-8.4 To Remove the Idler Gear and Hub

Fig. 7-43 Idler Gear Timing Marks
(1) Remove the timing case front cover as described earlier in this section.

(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 insert the gear and hub for signs of heavy wear, cracks,
etc.

7-8.5 To Install the Idler Gear and Hub

(1) After making sure that oilways in the hub and gear are clear, hold the gear in
position with the timing marks in correct alignment as shown in figure 7~43.

(2) Install the hub as shown in figure 7-42 so that the holes in the hub and the
cylinder block are in alignment. Fig. 7-44 Backlash Check

(3) Fasten with the two bolts.

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 playas shown in figure 7-45, the limits are
given on page 8-5. Fig. 7-45 Idler Gear End Play

Model 825
·7-19· Service Manual
 (7) Lock the idler gear hub bolts
with the tabwashers.
'0

NOTE: When the timing gears are

correctly aligned, they should be
as shown in figure 7-46.

(8) Install the timing case front

cover, etc., as described earlier in
th is section.

7-8.5 To Remove the Camshaft Gear

(1) Remove the timing case front

)
cover as described earlier in this
section.

(2) Remove the three bolts

carefully and pull the gear away
from its location on the end of the
camshaft (Fig. 7-47).

(3) Clean and thoroughly inspect

the gear for signs of wear, cracks,
pitting, etc.

7-8.6 To Install the Camshaft Gear

(1) Remove the idler gear and hub

as described earlier in this section.

C-1811
(2) Remove cylinder head cover
and rocker shaft (if not earlier Fig. 7-46 Alignment of Timing Marks
removed).

(3) Install the gear to the camshaft making sure the "0" marks on the gear and o
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.-Ibs. (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 "0"
marks are in alignment.

(5) Install the idler hub and gear, timing case front cover, etc., as described earlier
in this section.

B-1884
7-8.7 To Remove the Fuel Pump Gear
Fig. 7-47 Cam Shaft 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.

(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.

7-8.8 To Install the Fuel Pump Gear

(1) Install the fuel pump gear so that the timing marks on the gear and hub are in
alignment as shown in figure 7-48.

(2) Install tM three bolts and tighten to a torque of 19 - 21 ft.-Ibs. (2,6 - 2,9
kgf/m)*. . Fig, 7-48 Fuel Pump Gear

Model 825
-7-20- Service Manual
 (3) Install the idler gear and hub, timing casc front covcr, 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.

(2) Remove the fuel pump gear 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 snapring with a pair of snapring pliers (Fig. 7-50).

(6) Remove the drive hub from its bearing (Fig. 7-49).

(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.

7-8.10 To Install the Fuel Pump Drive Hub

(ll Install the drive hub in the bearing and locate with the snapring as shown in
Hub
figure 7-50.

(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.

(3) Install the fuel pump as described on page 7-32.

(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.
0° ) ./

Fig. 7-49 Pump Drive Hub

7-8.11 To Remove the Timing Case Back

Plate

(1) Remove the timing case front

cover and timing gears as described
--=;-­
( "---..... -

~r
'"
~~ ~r I
,II
-r,;\ ­
~/
-"'"

earlier.

(2) Remove the fuel pump and

drive hub as described earlier.

(3) Remove the plate bolts.

(4) L;ft the timing case back plate

clear from the camshaft hub and
crankshaft gear.

NOTE: The crankshaft gear is a tight fit

on the crankshaft. When its
removal is necessary, then this
must be done with a puller. Fig. '7-50 Fuel Pump Drive Retainer " "","'-,.

Model 825
,7-21- Service Manual
7-8.12 To Install the Timing Case Back
Plate

(1) Make sure that both the

cylinder block and timing case back
plate faces are clean. I nstall the
tim ing case back plate to the
cylinder block using a new gasket 0
0
and sealing material. o

o ""
(Jlo I
(2) Install the bolts.
o
(3) Install the fuel pump drive hub Camshaft
and fuel pump as previously
detailed.
Fig. 7 -52 Removing Camshaft

(4) Install the timing gears, timing

case front cover, etc., as previously
detailed.

7-8.13 To Remove the Camshaft and Fig. 7-51 Cam Thrust Plate
Tappets

Camshaft end play is controlled by two 1800 thrust plates which are positioned in a
groove machined in the front face of the cylinder block. One of the plates is positioned
on a dowel to prevent rotation. These thrust plates are held in position by the timing
case back plate.

(1) Remove the cylinder head cover, rocker shaft and push rods. o o o
(2) Remove the timing case front cover and timing gears as described earlier. A·2345

Fig. 7-53 Removing Tappets

(3) Remove the fuel lift pump, tappet inspection cover and operating push rod for
fuel lift pump.

(4) Turn the engine block over so that the crankcase is up.

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
cal]lshaft 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. 7-53j.

(10) Thoroughly clean the camshaft and tappets, then inspect for signs of wear,
surface cracks, pitting. etc.

7-8.14 To Install the Tappets and Camshaft

(1) Add lubricant to the tappets and return them to their locations.

(2) Carefully install thl'! camshaft into thl! cylinder block.

Model 825
-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 of the camshaft
hub, when correctly located the
camshaft can be pushed fully in and
will appear as in figure 7-51.

(4) Install the timing case back

plate as descri bed earl ier.

(5) Install the lubricating oil pump

assembly and sump as described on Fig. 7-54 Cam Thrust Plate Position Fig. 7-55 Fuel Lift Pump
page 7-27.

(6) Turn the engine block over so /0

that the cylinder block top face or
cylinder head is up.

(7) Install the timing gears, timing

case front cover, etc., as described
on page 7-19.

(8) Install the operating push rod

for fuel lift pump (Fig. 7-55),
tappet inspection cover and fuel lift
pump.
)
(9) Assemble the remainder of the
engine components as described in
the instructions given for each
specific part of this section.

7-8.15 Timing Marks

When the engine is originally timed at the

factory. certain marks are stamped on the
gears, so that if for any reason the engine
timing has to be changed, then setting to
the original timing is easily done.

Fig. 7-56 Alignment of Timing Marks

To Reset the Engine to the Original
Timing

If the cylinder head assembly is still in

position, it is best to remove the injectors
and rocker shaft to make timing easier.

(1) Turn the engine until the

keyway in the front of the
crankshaft is up as shown in figure
7-56 (This will bring Nos. 1 and 4
pistons to T.O.C.).

(2) Fit the camshaft gear to its

hub, making sure that the "0"
B·1884
marks are correctly aligned (Fig.
7-57). Fasten with the three bolts. Fig. 7-57 Cam Shaft Gear

Model 825
-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.

(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.
Fig_ 7-58 Fuel Pump Gear

(6) Gear play adjustment should be done as described on page 7-19.

7-8.16 Timing Pin

A timing pin is installed at the bottom of the timing case cover on the left hand side.
When it is unscrewed, it positions in a hole machined in the rear face of the crankshaft
pulley (as shown in Fig. 7-59), when Nos. 1 and 4 pistons are at T.D.C.

Always return this pin to its normal position as soon as T.D.C. check has been made and
before starting the engine.

7-8.17 Checking Valve Timing

To check the valve timing use procedure as follows:

(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 in. (1 Fig. 7-59 Timing Pin
mm).

(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
No.1 inlet valve push rod between the thumb and the forefinger.)

(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 7-23.1

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! corrE!ct figure also to return the timing pin to its correct location if it has been
USE!d to ch@ck T.O.C.
Model 825
-7-24­ Manual
S\;lr\,i~\}
7-8.18 Adjusting Valve Clearance

Using the following procedure check the

valve clearances by using the correct size
feeler gauge between the valve stem and
the rocker lever end, if any adjustment is
necessary, loosen the locknut and turn the
adjustment screw clockwise to decrease or
counterclockwise to increase the clearance
as shown in figure 7-60. When a sliding
fit between the surfaces is obtained with
the feeler gauge, lock the adjustment
screw and check the clearance again, when
satisfactory, proceed to the next valve in
the adjustment sequence.

7-8.19 Valve Adjustment Sequence

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 Fig. 7-60 Adjustment of Valve Clearance
"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 No.4 cylinder;
then with No. 3 cylinder valves in the "valve overlap", make adjustment of valves of No.
2 cylinder; with No. 4 cylinder valves on "valve overlap", make adjustment of clearances
of No. 1 cylinder and finally with No. 2 cylinder valves on "valve overlap", make
adjustment of clearances of No. 3 cylinder.

7-9 LUBRICATION SYSTEM

7-9.1 The Lubricating Oil Pump

The oil pump fits into a machined bore in the cylinder block and is fastened by a screw
locked by a tab washer.

7-9.2 To Remove the Sump

(ll Remove the oil pan drain plug and empty out all the oil.

(2) Remove the dipstick and put somewhere safe.

(3) Remove the oil pan fastening screws and remove the pan carefully. Thoroughly
clean the pan before installing.

7-9.3 To Install the Oil Pan

(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.
Model 825
-7-25­ Service Manual
7-9.4 To Remove the Oil Pump

(1) Empty the engine oil from the

oil pan.
I • Strainer
(2) Remove the oil pan fastening
screws and carefully remove the pan.

(3) Remove the strainer from the

1 <;'0... YL<t1&..-- Oil Suction Pipe

end of the oil suction pipe (Fig. ·~····rl········~
7--61 ).

(4) Remove the del ivery pipe

bolding nut on the cylinder block
and the bolt holding the suction
pipe assembly to the rear main
bearing cap.

(5) Bend back the washer locking

the position bolt.

(6) Remove the oil pump assembly

from the cylinder block as shown in
figure 7-62.

7-9.5 To Dismantle the Oil Pump

(1) Remove the delivery and

suction pipes. Fig. 7-61 Oil Suction Strainer

(2) Remove the drive gear with a

puller.

(3) With the pump held in a vice,

remove the four fastening bolts and
remove the end cover assembly.

NOTE: This end cover assembly also

holds the pressure relief valve
housing.

(4) Pull out the drive shaft

complete with inner rotor.

NOTE: It is best not to remove the

inner rotor from the shaft
because this item is not available
as a separate part.

(5) Pull out the outer rotor.

7-9.6 Inspection

(1) Thoroughly clean all the parts

and inspect for signs of wear,
cracks, pitting, etc. Fig. 7-62 Lube Oil Pump Removal

Model 825
-7-26­ Servil;e Manual
 (2) Install the drive shaft complete with inner rotor, then the outer (driven) rotor
making sure that the face which holds the tappered 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).

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).

7-9.7 To Assemble the Oil Pump

(1) Install the outer rotor making sure that the face which holds the tapered edge
enters the pump body first (Fig. 7-63).

(2) I nstall the drive shaft complete with inner rotor into the pump body.

(3) Install the end cover assembly and install the four bolts. Be sure of correct A-2311
positioning SO that the suction and delivery pipes will fit correctly. 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.

7-9.8 To Install the Oil Pump

(1) Connect the suction and delivery pipes but do not tighten the pipes at this
time.

(2) Put the lubricating oil pump assembly in position, install the securing screw
and lock it by bending the washer.

(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.
Fig. 7-64 Checking Rotor Clearance
(5) Carefully install the sump as described earlier and fasten with the bolts.

(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
A-2346
oil pan when the oil pressure goes above
the spring pressure setting. Fig. 7 -65 Checking Outer Rotor Clearance Fig. 7-66 Oil Pump Rotor Clearance

Model 825
-7-27­ Service Manual
7 -9.10 To Dismantle the Oil Pressure
Relief Valve

(1) Empty the engine oil from the

oil pan.
Plunger

J
(2) Remove the oil pan fastening
bolts and carefully remove the oil Spring Cap
pan.

(3)Continue by removing the oil

pump as described earlier.
Split Pin---....,.../
~
Spring
I
tZil
U1?
(4) Remove suction and delivery B-1877
pipes.
Fig. 7-67 Oil Pressure Relief Valve

(5) Remove the four bolts and

remove the end cover assembly.

(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 767.

(7) Thoroughly clean the parts, inspect for wear or damage and install new when
necessary.

7-9.11 To Assemble the Oil Pressure Relief Valve

(1) Install the plunger, spring and spring cap, then fasten with the split pin.

(2) Fasten to the lubricating oil pump body with the four bolts.

(3) Continue as described for installing the lubricating oil pump.

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.

7-10 COOLING SYSTEM

The engine is cooled by water circulation through the cylinder block and cylinder head.
Circulation is by thermo-syphon action, with aid of an impeller type water pump, belt
driven from the crankshaft pulley.

7-10.1 Fan Belt

Wrong adjustment of the fan belt will result in wear or failure of the "V" belt, and can
overload the bearings in the water pump or alternator if adjustment is over tight. If the
adjustment is loose, engine overheating will result because of slipping fan belt.

7-10.2 Adjustment of Fan Belt

Fan belt adjustment is made by changing the position of the alternator.

(1) Loosen the alternator adjustment lever bolt.

(2) Loosen the two alternator bracket fastening bolts.

(3) Move the alternator either towards or away from the engine to loosen or
tighten the belt.

(4) Hold the position by tightening the alternator adjusting lever bolt.

(5) Tension is correct when the belt has 3/8" (10 mm) freeplay at a point halfway
between water pump pulley and crankshaft pulley.

(6) When tension is correct, tighten the two alternator bracket fastening bolts.

Model 825
-7-28­ Service Manual
NOT Ii:: When a new belt has been
Installed, check the adjustment
again after a short running
period.
1. Pump Body
7-10.3 Water Pump 2. Seal
3. Shaft Bearings
The water pump shaft rotates within two 11_1~ !i 4. Retaining Circlip
bearings. The impeller aids the circulation 5. Pump Shaft
of the water through the system. Water is 6. Distance Piece
held within the impeller chamber by a 7. Flange Oil Seal Retaining
carbon·faced seal which is spring pressed 8. Retainer - Oil Seal
against the face of a phosphor bronze 9. Flange Water Pump Thrower
bearing in the pump body. Figure 7-68 10. Impeller
shows the positions of the assembled 11. Seal
parts. 12. Insert

7-10.4 To Remove the Water Pump

(1) Straighten the washer lOCks, A-235t

remove the fan bolts and remove Fig. 7-68 Water Pump Section
the fan.

(2) Remove the fan belt.

(3) Remove the four bolts which fasten the water pump and back plate to the
cylinder block.

(4) Remove the water pump and back plate.

7-10.5 To Disassemble the Water Pump

(1) Remove the pulley nut.

(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 snapring. Use a press to push out the two shaft bearings, A-2309
complete with spacer, out through the front of the pump body. Fig. 7-69 Water Pump Pulley Removal

(6) Remove the felt seal and holding flanges.

7-10.6 Inspection
(1) Clean all the components in solvent, then dry thoroughly.

(2) Insert 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 insert 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.
Model 825
-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 snapring.

(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.

(6) Lightly coat the inner diameter of the insert area and outside diameter of the
insert with sealing material. Fig. 7-70 Pump Impeller Clearance

(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 .005" to
.025" is measured between the back face of the impeller and the pump body. This
clearance can be checked as shown in figure 7-70.

(10) Press the pulley fully onto the shaft and install the nut.

7-10.8 To Install the Water Pump

(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.

(4) Install the fan belt and adjust to the correct tension.

(5) Install the fan using new lockwashers.

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 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.
Model 825
-7-30­ Service Manual
 (4) Remove the outlet connection and gasket.

(5) Lift out the thermostat as shown in figure 7 71.

7 -1 0.11 To Test The Thermostat

The thermostat can be tested in the following manner:

(1) Put the thermostat in a container of water and slowly heat. Use a
thermometer to check the temperature of the water as temperatures increases.

(2) Note the temperature at which the valve in the unit begins to open. This
temperature should be as marked on the unit.

(3) If the unit does not function properly, then a replacement thermostat will
be necessary. No adjustment of these units is possible. Fig. 7 - 71 Removing Thermostat

7 - 10.12 Replacement of The Thermostat

Replacement of the thermostat is in reverse of the removal procedure. A new gasket

must be installed between the thermostat housing and the water outlet connection.
When the radiator has been filled with coolant, check that there are no leaks.

7 - 11 FUEL SYSTEM

7 -11.1 To Test Fuel Lift Pump

(1) Disconnect the outlet pipe (lift pump to filter) leaving outlet from the pump
open.

(2) Engage the starter. There should be a flow of fuel from the outlet port once
every two revolutions.
Fig. 7 - 72 Fuel Priming Lever
(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 '1
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)

7 - 11 .2 To Remove The Lift Pump

(1 ) Disconnect the pipes from the inlet and outlet connections. Seal the ends
of the pipes to keep out dirt.

(2) Remove the two nuts and washers holding the pump to the tappet
inspection cover.

(3) Remove the pump, spacer and gasket (Fig. 7 -73).

(4) To install the pump, reverse the above procedure. Be sure to install two
gaskets, one on each side of spacer.
A-2342

Fig. 7 - 73 Removing Fuel Lift Pump

Model 825
Revised August 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.

(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.
Fig. 7-74 Removing Fuel Pump
(5) Carefully remove the fuel pump (Fig. 7-74),

7-11.5 To Install the Fuel Injection Pump

(1) Install the fuel pump fastening flange gasket.

(2) Position the pump as shown in

figure 7-74 making sure that the
spline on its shaft is correctly
positioned to engage with the female
splines in the fuel pump hub.

NOTE: This spline will only fit in the

drive hub in one position for
timing reasons.

(3) When the splines are in correct

alignment, the pump can be pushed
in until the fastening flanges contact
each other.

(4) Before tightening,. align the

timing marks marked on the fuel
pump fastening flanges as shown in
figure 7-75. Tighten the bolt and
nuts to 15 ft.-Ibs. torque.

(5) Connect the low pressure pipes

to the inlet and outlet connections. Fig. 7-75 Fuel Pump Timing Marks (External)

(6) Connect the high pressure (injector) fuel pipes.

(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.

(9) Fuel pump timing can be checked as described below.

7-11.6 Checking Fuel Injection Pump Timing

To see the internal timing marks, the manufacturers seal on inspection cover will have to
be broken.

(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 $0 that there is access to the valve springs for using a valve spring
compre~sor.

-7-32-
Model 825
Se",ice ManUM
•...
 (3) Remove the valve springs from No.1 exhaust valve and let the valve head
rest on the piston crown.

(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 .O.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
in. (3,05 mm) down the cylinder bore.

NOTE: This is equal to 1 9 0 angle movement of the flywheel B. T. O. C. and is the !

fA-2347
static timing point.
Fig. 7 - 76 Fuel Pump Timing

(6) When this static timing point has been accurately determined, the "c" line
on the fuel pump rotor must be in alignment with the straight edge of the timing
snapring (Fig. 7-77).

NOTE: Do not move the snapring in

the pump. It is set by the
manufacturer.

(7) If the timing is not correct,

proceed by either:­

a. Making necessary
adjustments at the holes in the
fuel pump gear, they are
slotted so that the drive shaft
can be turned when the
fastening bolts are loosened
(Fig.7-7S)or;

b. Loosening the two nuts

and bolt which hold the fuel
pump to the fastening flange
and turning the pump body in
the direction required.

Fig. 7 - 77 Fuel Pump Timing Marks (Internal)

(S) When the fuel pump timing
adjustment has been made, turn
the engine against the normal direction of rotation once again to a piston
displacement of 0.120 in (3,05 mm) to check that the squared end of the
snapring is now aligned with the "c" line on the rotor.

(9) When the fuel pump timing adjustment has been made, slowly turn the
engine to T.O.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 MS 67123)

(1) Remove the valve cover.

(2) Turn the engine until No.1 cylinder is a T.O.C. on the compression stroke
(Both valve of the No.4 are moving).
Fig. 7 - 78 Fuel Pump Gear

825 Loader
Revised October 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 push rod
removed. Move the rocker arm so that a valve spring compressor can be used to
remove the valve springs (Fig. 7 -78al.

(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. 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.

Engine Fuel Pump Setting Engine Checking Fuel Pump Marking!

Type Code Angle (Degrees) Angle (Degrees)
4.108 EH34E 281 290
EH39 281 290
LH30 281 292
PH23E 281 290
8·3361
PH25E (exceptions below) 281 290
PH25E500/5/2450 279-1/2 290 Fig. 7 - 78b Timing Tool

PH25E500/9/1990 279-1/2 290

PH25E500/9/2090 279-1/2 290
PH27 281 290
PH30 (exceptions below) 281 290
PH30/30/5/2450 279-1/2 290
PH30/500/6/1570 279-1/2 290
PH30/500/9!1990 279-1/2 290
PH30/500/9/2090 279-1/2 290
RH30E 279-112 290
SH33E 279-112 290
'----­

~
~~
(8) Install the shaft of the timing tool into the drive hub for the injection pump
(Fig. 7-78cl. 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.
Fig.7 7ac Installing Tool On Engine Flange

(9) Tighten the screw (Fig. 7-78b, Item 2) to hold the body and the shaft
together.

(10) Loosen the screw (Fig. 7 -78d, Item 1) and move the plate with the mark
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 1800 apart. the No.1 cylinder is not at T .D.C.

Flg.7 7Bd AlignnH>nt Of MQrK To Engine

Modl!!IB25
Revised Feb. 82 -7-33a­ Service Manual
 (' 3) 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 The
Timing Casel.

Checking the Timing Mark on the Flange of the Injection Pump

( 1) Loosen the screw (Fig. 7 - 7 Bb, Item 2) and remove the shaft from the
body of the timing tool.

(2) Loosen the screw (Fig. 7 7Bb, Item 3) and remove the plate with the
mark. Install the plate again the opposite way. Tighten the screw.

(3) Loosen the screw (Fig. 7-7Bb, 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 p.J:Imp. The tool will fit in
only one position because of special spline (Fig. 7 -7BcT.

(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.

I (B) Loosen the screw (Fig. 7 - 7Be, Item 1) and move the plate until the mark
is over the flange of the pump.

(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
-7-33b­ Service Manual
* Revised Feb. 82
 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. Fig. 7-79 Injector Position

7-11.10 Testing for Faulty Injector

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
(witI'! the engine running at approximatelv 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)

(1) Be'sure that the injector area in the cylinder head is perfectly clean.

(2) Put a new copper sealing washer in the injector bore.

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
,J<~\
'! washer.
,
~:\ii:''''~~Hold the injector squarely into its location with one hand. and install the
, :: '~:~~tening nuts on each stud. just finger tight, with the other hand.

~" NOTJ~ tigh'" tho 'Ub fully d=. 0. tl" f.....;.' nud' yo<.

,, (51.leat for the other three injectors (where applicable).

(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.

7-11.13 Fuel Pipes (High Pressure)

When making replacement of the fuel pipes. take note that no two pipes are the same,
(Ilach is shapt!d to fit an individual injer;tor po~ition. This is important when or4ering a
/ n!!plac@m@nt pips, each one has a differ@nt part number.

Model 825
-1-34­ 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" open end,

7 - 1 1 .1 3a Using C ,A. V. Thermostart Units

Be sure there is fuel getting to the

thermostart unit. If you operate the
thermostart unit without fuel. the unit
will be damaged.

ilf the engine is difficult to start in cold weather or, black smoke is coming from the
iexhaust, the thermostart unit has a defect and must be replaced,

If the engine has not been started for five (5) days or more, operate the starter until it
turns the engine several times or operate the priming lever several times to get fuel
pressure.

If (1) the temperature is below 40 0 F (3 0 - 4 0 C)' (2) the engine turns fast with the
starter, and (3) there is white smoke coming from the exhaust, but the engine does
not start, use the thermostart unit. ~

To use the thermostart system:

(1) Move the throttle to the full open (fast) position.

(2) Push and hold the preheat button for 15 to 20 seconds.

(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.

(4) Try to start the engine again.

NOTE: If the engine still does not
start. check to see that there
is fuel getting to the inlet
of the thermostart. Also check
the voltage at the thermostart ­
(There must be 12 volts). If
the fuel and the voltage are
correct. remove the air-cleaner
hose from the manifold. Then
push the preheat button and
look at the thermostart unit
to see if the heating element
gets red. If it does not get red.
the unit has a defect and must
be replaced. If fuel is not
getting to the inlet of the
thermostart, you will need to
"charge" the fuel line (See
"Charging the Fuel Line"
below). Troubleshoot the
electrical system if there is
not 12 volts at the thermostart
unit. Fig. 7 - 80 Venting Injection Pump

Model 825
RevisedAugust79 -7-35­ Service Manual
 If you use ether as a starting aid. wait
until the thermostart unit is cold before
putting ether into the manifold. Never
activate the thermostart when using
ether.

(5) When the engine starts, release the starter switch and set the throttle for
the smoothest slow running speed.

7 -11.4 Charging the Fuel System

The air must be removed from the fuel system whenever any part of the system
between the fuel tank and injection pump has been disconnected for any reason, or
when the system has been emptied of fuel.
Fig. 7-81 Bleeding Secondary Filter

The engine must not be started until the injection pump has been filled and charged
or serious damage can be caused to the pump due to lack of lubrication.

( 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 screws (Refer to Fig. 7 - 80).

(3) Loosen the vent screw on the top of the secondary fuel filter (Refer to Fig.
7-811.

(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:

(al 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). * Fig. 7 - 82 Fuel Lift Pump

(6) Set the throttle at the fully

open position.

{71 Turn the engine with the

starter until air-free oil comes out
from the loose fittings.

(8) Tighten all the injector line

fittings and start the engine.

(9) If the engine does not run

smoothly, try loosening each
injector fuel line fitting a little with
engine idling, to release any air
still in the inj@ctor lim!!. "Fig, 7 - 83 Injgctors I'ittings
Model 825
• Revised Feb. 82 -7 36­ Svrvlce Manual
 SPECIFICATIONS

Paragraph Page
Number Number

COO LI NG SYSTE M 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
SPECIF ICATIONS 8-1 8-1
TIMING GEARS 8-2 8-5
TORQUE SPECIFICATIONS 8-8 8-7

SPECIFICATIONS

Model 825
Service Manual
 8 - 1 SPECIFICATIONS
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 . . . . . . . . . . . . 1.78411. 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. ,375179,400 mm)
--_~
I Height of Liner in Relation to Cylinder
Top Face. . . . . . . . . . . . . . .. ..0.023/0.027 in. ( 584/0,686 m~

8-1.3 Pistons

Piston Height in Relation to ~

Cylinder Block Top Face ...... .0.0 0.006 in. 0,051/0, 152 mm)~
Bore Dia. for Piston Pin . . . . . . . . . . 1. 625511.06275 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)
Oil Control Ring Groove
Width - Fourth . . . . . . . . . . . . . . . . . . . 1.126/0.127 in. (3,200/3,225 mmJ
Oil Control Ring Groove
Width Fifth . . . . . . . . . . . . . . . . . . . . . 0.19010.191 in. (4,826/4,851 mm)

I
NOTE: There is a 0.030 in. (0.762 mm) x 0.14810.152 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 . . . . . . . . . . 0.077110.0781 in. (1 ,958/1,984 mm)

Ring Clearance in Groove . . . . . . . . . . . . . 0.0024/0.0044 in. (O,051/0,1 02 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 . . . . . . . . . . . . . 0.002 .00 . 0,063/0.1 14 mm)
Ring Gap - (Cast Iron) . . . . . . . . . . . . . . . . . . 0.009/0.020 in. (0,23/0,51 mm)
(Chrome) . . . . . . . . . . . . . . . . . .. .012/0.023 in (0,31/0,59 mm)

The above ring gap is for a bore diamter 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. (0,011410.0178 mmJ

B-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 mml
Connecting Rod Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . 0.375 in. (3/8 in.1 U.N.F.
Connecting Rod End Float . . . . . . . . . . . . 0.0065/0.0105 in. (0,165/0,267 mml

Model 825
Revised Feb. 82 -8-1­ Service Manual
8-1.6 Connecting Rod Alignment

large and small edn bores must be square and parallel with e.ach other within the limits of i
0.010 in. (0,25 mm) measured 5 in. (1'27 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 iO.Ol 0 in.
(0,25 mm) is reduced toiO.0025 in. (0,06 mm).

Crankshaft

Main Journal Diameter Nos. 1 and 2 . . . . . . . . . . 2.248&2.2485 in. (57,099/57,112 mml

Main Journal Diameter No.3
Main Journal length No. 1
Main Journal length No.2
Main Journal length No.3
Main Journal Fillet Radii
Crankpin Diameter .
Crankpin Length . . . . .
Crankpin Fillet Radii ..
Surface Finish· . All Journals
Main Journal and Crank pin Regrind Undersizes .0.010,0.020,0.030 in (0,25,0,51,0,76 mm)
Oil Seal Helix Diameter
Oil Seal Helix Width . . . . _ . . . . . . . . . .
Oil Seal Helix Depth
Flange Diameter .. .
Flange Width . . . . .
Spigot Bearing Recess Depth
Spigot Bearing Recess Bore
Crankshaft End Float . . . . .
· . . . . . . . . . 2.2475/2.248 in. (57,086/57,099 mm)
· . . . . . . . . 1.40625 in. (35,719 mm)
· . 1.496/1.504 in. (38,075/38,151 mml
. . . . . . . . 1.499/1.502 in. (38,075/38,151 mm)
... 0.125/0.141 in. (3,175/3,581 mm)
· .1.9995/2.000 in. (50,787/50,800 mm)
· .1.1875/1.1895 in. (30,969/4,366 mm)
. . . 0.15625/0.17187 in. (3,969/4,366 mm)
. . . . . 8 .. 16 m icro·in. (0,2 - 0,4 micron)
. . 2.2107512.21175 in. (56,153/56,178 mm)
.0.050/0.080 in. (1.270/2,032 mm)
. . . . . . . 0.004/0.008 in. (0,102/0,203 mm)
· . . . . . . . 3.9985/3.995 in. (101,562/101,587 mm)
· . . . . . . . . . . . . . . . . . . 0.500 in. (12,700 mm)
· . . . . . . . . . . . . . . 0.875 in. (22,225 mm)
·........~002/
..
· ....... .
:~o in (31,750 mm)
..025 in. ,0508/0,381 mm)

NOTE: This crankshaft is hardened by the "Tuffride" process. When regrinding, only very
light cuts should be taken, especially in the region of the fillet radii and
adequate cooling should be ensured during grinding operations. After regrinding
the crankshaft it should be crack-detected and de·magnetised, then retreated by
this "Tuffride" process after which the crankshaft should again be crackdetected
and de-magnetised. Where facilities are not available to re-harden the crankshaft
by this process, a factory replacement crankshaft should be obtained. Fillet radii
and surface finish must be maintained during crankshaft regrinding. Length of
No. 3 main journal not to exceed 1.516 in. (38,506 mm) after regrinding. Where
necessary, use oversize thrust washers to bring crankshaft end float within the
col"ect limits.

8-1.8 Crankshaft Thrust Washers

Type . . . . . . . . . . . . · . . . . . Steel Backed . Lead Bronze Faced

Position in Engine
Thrust Washer Thickness (STD)
Thrust Washer Thickness (DIS) ..
Thrust Washer Outside Diameter
Thrust Washer Inside Diameter . . . . .
. . . . . . . . . . . . . . Rear Main Bearing
· .. 0.089/0.091 in. (2,261/2.311 mm)
· .0.0965/0.1005 in. (2,451/2,553 mml
3.245/3.255 in. (82,423/82,677 mm)
· . 2.59012.600 in. (65,786/66,040 mm)

8-1.9 Main Bearings

Shell Width . . . . . . · . . . . . . . . . 1,245/1.255 in. (31,623/31.877 mm)

Outside Diameter of Main Bearing · . . . . . . . . . . . . . . . . . 2.3955 in. (60,846 mml
Inside Diameter of Main Bearing . · . . . . 2.25Q51Zd~(57.163/57,188 mml
Running Clearance - .. Nos. 1 & 2 · . . . . .(O.0(}21'o.0035 i~~,051/0,089 mm;
Running Clearance No.3 . . . . . . . . . . ~~~~~~~y,063/0,102 mm,

8-1.10 Connecting Rod Bearings

Shell Width . . . . . . . . . . . . . . . . . . . . . . . . . . 0.870/0.880 in. (22,098/22,325 mm)

Outside Diameter of Connecting Rod Bearing , .. , ......... 2.1465 in. (54,521 mm)
Inside Diameter of Connecting Rod Bearing ... 2.0015/2.QOO&.m.-~38/50,863 mm)
Running Clearance . . . . .. .~.0015io.003 i~_._.~38/0.076 mml
"-- -.~-,.-. --.. ~
Mod..1825
-8-2­ S@rvic@ Manual
8-1.11 Camshaft

No.1 Journal Diameter . . . . . . . . . . . . . . 1.791/1 .792 in. 145.491/45,517 mml

No. 1 Cylinder Block Camshaft
Bore Diameter . . . . . . . . . . . . . . . . . . 1.794/1.7955 in. (45,568/45,606 mml
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 . . . . . . . . . 1.78411. 787 in. (45,314/45,390 mml
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. 145, 110/45,161 mm)
No.3 Journal Running Clearance . . . . . . . . . 0.00210.005 in. (0,051/0,127 mml
Cam Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.266 in. (6,766 mml

8 - , . , 2 Camshaft Thrust Plates

Thrust Plate Outside Diameter . . . . . . . . . 2.555/2.557 in. (64,897/64,948 mml

Thrust Plate Inside Diameter . . . . . . . . . . . . . . . . . . . . . . 1.500 in. (38,100 mml
Thrust Plate Thickness . . . . . . . . . . . . . . . . 0.160/0.162 in. (4,060/4,115 mml
Thrust Plate Height in Relation to .
Cylinder Block Face . . . . . . . . . . . . . . . . 0.001' in. (0,102 mml Above or Below
Camshaft End Float . . . . . . . . . . . . . . . . . . 0.0'03/0.013 in. (0,076/0,330 mml

8 - , . , 3 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)
Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 0
Bore in Cyinder Head for Guide ...... . 0.4995/0.5005 in. (12,687/12,7 13 mml
Bore in Cylinder Head for Combustion
Chamber Inserts . . . . . . . . . . . . . . . . . 1.250/1.252 in. (31,750/31,801 mml
Depth of Bore in Cylinder Head for ,
Combustion Chamber Inserts . . . . . . . . . . 0.373/0.376 in. (9.474/9,550 mml
Compression . . . . . . . . . . . . . . . . . . . . . . 300 - 500 PSI (2068,5 - 3447,5 kPal
With not more than 50 PSI (344,8 kPal difference between each cylinder.

8 - , . , 4 Combustion Chamber Inserts

Outside Diameter of Insert. . . . .. . .... 1.248/1.249 in. 131,699/31,724 mm)

Length of Insert . . . . . . . . . . '.~ . . . . . . . . . 0.374/0.375 in. (9.499/9,525 mm)
Height of Insert in Relation to
Cylinder Head Face . . . . . . . . . . . . . . . . 0.002 in. (0,051 mr:n) Above or Below
Clearance Fit of Insert in Cylinder Head Bore . . 0.00110.004 in. 10,025/0,102 mm)
Method of Location in Cylinder Head . By Cylinder Block Face and Expansion Washer

8 - 1.15 Valve Guides (Inlet)

Inside Diameter . . . . . . . . . . . . . . . . . . . 0.3145/0.3155 in. 17,988/8,014 mm)

Outside Diameter . . . . . . . . . . . . . . 0.50125/0.50175 in. 112,744112,757 mml
Interference Fit of Guide in
Cylinder Head Bore . . . . . . . . . . . . . 0.00075/0.00225 in. 10,019/0,057 mml
Overall Length of Guide. . . . . . . . . . . . . . . . .. . ..... 2.130 in. (54,102 mm)
Guide Protection Above ..~~:.\)f;
Top Face of Cylinder Head . . . . . . . . . . . . 0.800/0.815 in. (20,320/20,701 mm)

8-' .16 Valve GUides (Exhaust)

Inside Diameter . . . . . . . . . . . . . . . . . . . 0.3145/0.3155 in. (7,988/8,014 mm)

Outside Diameter . . . . . . . . . . . . . . 0.50125/0.50175 in. (12,744/12,757 mm)
Interference Fit of Guide in
Cylinder Head Bore . . . . . . . . . . . . . 0.00075/0.00225 in. (0,019/0,057 mm)
Depth of Counterbore . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.380 in. (9,650 mm)
Overall Length of Guide . . . . . . . . . . . . . . . . . . . . . . . . . 2.440 in. (61,980 mm)
Guide Protection Above
Top Face of Cylinder Head . . . . . . . . . . . . 0.800/0.815 in. {20,320/20,701 mml

Model 825
Revised Feb. 81 -8-3­ Service Manual
8-1.17 Valves Unled

Valve Stem Diameter . . . . . . . . . . . . . . . . . . . . . . 0.312/0.313 in. (7,92517,950 mml

Clearance Fit of Valve Stem in Guide . . . . . . . . . . 0.0015/0.0035 in. (0,038/0,089 mml
Valve Head Diameter . . . . . . . . . . . . . . . . . . . . 1.410/1.414 in. (35,814/35,916 mm)
Valve Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
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. (7,91217,937 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 0
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 Ibf..! 2 Ibf (13,0 kgf.± 9,91 kgf)
Fitted Position . . . . . . · . . . . . . . . . . . . . . . Damper Coil to Cylinder Head

8-1.20 Outer Valve Springs

Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . 1.780 in. (45,212 mm)

Load at Fitted . . . . . . . . . . . . 56.0 Ibf + 2.8 Ibf (25,4 kgf.± 1.27 kgf)
Fitted Position . . . . . . . . . . . . . . . . . . . Damper Coil to Cylinder Head

8-1.21 Rocker Levers

Inside Diameter of Rocker Lever Bore . . . . . . . . 0.71825/0.71950 in. (18,243/18,275 mm)

Outside Diameter of Rocker Lever Bushing . . . . . . 0.7205/0.7215 in. (18,301118,326 mm)
Finished Inside Diameter of Rocker Lever Bushing . 0.6245/0.62575 in. (15,862/15,894 mm)

8-1.22 Valve Clearances

Clearance between Valve Stem Tip and Rocker Lever (Valve Lash) .. 0.010 in. (0,25 mm) Hot
0.012 in. (0,30 mm) Cold

8-1.23 Rocker Shaft

Outside Diameter of Shaft . . . . . . . . . . . . . . 0,62225/0,62375 in. (15,805/15.843 mm)

Lubrication . . . . . . . . . . . . . . . . Oil Feed from Cylinder Head through Central Passage
to Individual Rocker Levers

8-1.24 Push Rods

Overall Length . . . . . . . . . . 8.527/8.560 in. (216,58/217,42 mm)

Outside Diameter . . . . . . . . . . . . . . . . . .0.250 in. (6,350 mm)

8-1.25 Lifters

Overall Length . . . . . . . . . . . . . . , .• , . . . . . , . . . . . . . . . 2.250 in. (57,150 mm)

Outside Diameter of Tappet Shank. . .. . . . . . . . 0.560/0.561 in. (14.224/14,249 mm)
Cylind@r Block T.. pp@t Bore Diameter . . . .. _ .. 0.562/0.56325 in. (14.275/14,307 mml
Outsid9 Diam@t@r of T.. ppet Foot . . _ . . . . _ 1.245/1.255 in. 131.623/31.877 mm)
MOdel 825
i;:
-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 CrankshDft 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/ldler and

Camshaftlldler Gears . . . . . . . . . . . . . . . 0.0015/0.003 in. (0,03810,076 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 litre/min.)

Pump Clearances

Inner Rotor to Outer Rotor . .. . ....... 0.0005/0.0025 in. (0,013/0,063 mm)

Outer Rotor to Pump Body . . . . . . . . . . . . . . . . 0.011/0.013 in. (0,28/0,33 mm)
Inner Rotor End Clearance . . . . . . . . . . . . 0.0015/0.0003 in. (0,038/0,076 mm)
Outer Rotor End Clearance . . . . . . . . . . . . 0.0005/0.0025 in. (0,013/0,063 mm)
Inside Dia. of Bore for Pump Shaft ...... . 0.50010.501 in. (12,700/12,725 mm)
Outside Dia. of Pump Shaft . . . . . . . . . 0.4983/0.4986 in. (12,655/12,664 mm)
Running Clearance, Shaft in Bore ...... . 0.0014/0.0027 in. (0,036/0,069 mm)

8 3.2 Lubricating Oil Pump Drive Gear

Interference Fit of Gear on Shaft ...... 0.0013/0. 'h 0021 in. (0,033/0,053 mm)
Lubricating Oil Pump Drive gear Backlash .. . 0.0155/0.019 in. (0,394/0,483 mm)

8-3.3 Relief Valve (Lube Oil)

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring Loaded Plunger

Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . 50/65 PSI (3.5/4,6 kgf/cm2)

8 - 3.4 Lubricating Oil Filter

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full FLow

Element Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper
By-Pass Valve Setting . . . . . . . . . Opens Between 13 17 PSI (0,91 ·1,2 kgf/cm2)
Pressure Differential
Type of Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring Loaded Ball

8 - 4 COOLING SYSTEM

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Cooled

Cylinder Block and Head . . . . . . . . . . . . . . . . . Thermo-Syphon Impeller Assisted
Engine Water Capacity (Less Radiator) . . . . . . . . . . . . . . . 7.2 U.S. pints (3,4 litre)
Radiator Cap Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 PSI (48,27 kPa)

B-4.1 Thermostat

Opening Temperature ..... . . . . . . . . . . . . . . . . 175 182°F (79.5 - 83.5°C)

Fully Open At. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 205°F (93,5 - 96°C)

8 - 5 FUEL SYSTEM

Fuel Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #2 Diesel

Model 825
Revised Feb. 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/cm 2 )
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/cm 2 )

8-5.3 Fuel Injection Pump

Make . . . . . . . . .C.A.V.
Type. . . . . . . . . • D.P.A .
Rotation . . . . . . Clockwise
Plunger Diameter . . . . . . . . 6mm
Timing Letter .. . .... :~
No. 1 Cylinder Outlet
Static Timing Point . . . . ::::1'8~
Piston Displacement From T.D.C. at 190 · . 0.109 in. (2,75 mm)

8-5.4 Injectors

Make · . • . . . . . . . • Roto-Diesel or C.A.V.

Holder Type . . . . . . • . · . . . . . . . BKB 40 SO 5147V
Nozzle Type . . . . . . . . . . • . . . .BDN 12 SO 6236
Identification Code Letter · . . . . . . . . . . . . . . . "B~'
Minimum Working Pressure · . . ..2000 PSI (140 k9fj~)
Setting Pressure . . . . . .. . . . . . . . .2200 PSI (155 kgf/cm )

8-5.5 Starting Aid

Make . . . . . . . . . . .C.A.V.
-Type ... · Thermostart Type 357
Voltage . · . . . . . . . . . 12 Volt
Maximum Current Consumption . 12.9 Amperes at 11.5 Volts

8-6 SERVICE WEAR LIMITS

fThe fOllowing "wear limits" indicate the condition when items should be serviced or
replaced:
Cylinder Head Bow . . . . . . . . • . . • . . . . . . . . . . . Longitudinal 0.006 in. (0,15 mm)
Transverse 0.003 in. (0,08 mm) concave
0.005 in. (0,13 mm) convex
'Maximum Bore Wear (when new liners are necessary) . . . . . . . • . . . 0.006 in. (0,15 mm)
Crankshaft Main and Big End Journal . . . . . . . • • . . . .Wear - - 0.001 in. (0,03 mm)
Ovality - - - 0.0005 in. (0,01 mm)
Maximum Crankshaft End Float • . . . • . . . . . . . . . . . . . . . . 0.020 in. (0,51 mm)
Val*,&T-em to Guide Clearance. . . . • . . . . . . . • Inlet 0.005 in. (0,13 mm)
~.. , Exhaust - - - 0.006 in. (0,15 mm)
Valve Head Thickness at Outer Edge. . . . . • • . • . . . • • . . 0.025 in. (0,64 mm)
Rocker Clearance on Shaft . . . • . . . . •. . • . . . . . • . . . . . . • • 0.005 in. 10,13 mm)
Camshaft Journals· . Ovality and Wear . . . . . . . . . . . . . . . . . . . 0.002 in. (0,05 mm)
Camshaft End Float. ...................... 0.020 in. (0,51 mm)
Idler Gear End Float . . . . . • • . • • • • • . • • . • . • • . . . . . . . . . 0.010 in. (0,25 mm)

Model 826
I' Revised January 11 -8-& Service Manual
8 - 7 DE·RA TING FOR ALTITUDE

When engines are operated in high altitude areas, such engines 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.
Maximum Fuel Delivery De-rating
Altitude Measllred at 800 RPM Pump Speed
0 - 2,000 feet (600 meters) No Change
2,000 - 4,000 feet (1,200 meters) 6%
4,000 - 6,000 feet (1,800 meters) 12%
6,000 8,000 feet (2,400 meters) 18%
8,000 10,000 feet (3,000 meters) 24%
10,000 12,000 feet (3,600 meters) 30%

Any necessary adjustments in this respect to the fuel pump should be carried 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. (Nml
Cylinder Head Nuts (81 )
Connecting Rod Bolts
Main Bearing Bolts
Flywheel Bolts
¢.is
/-"'42
( -.?.--
60
(57)
(1151
(81 )
Idler Gear Hub Bolts 32 (43)
Crankshaft Pulley Bolts 1 50 (203)
Injector Fastening Nuts 12 (16)
Generator Pulley Nut 20 (27)

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" 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 Lug Nuts 90-100 (122 136)
Final Drive Idler: 3/4 Bolt 125-145 (170-197)
1/2 Bolt 45 55 (170-197)
Gearbox-to-Frame Bolts 220 230 (298-312)

I Axle Housing to Upright Bolts

Axle Housing to Frame Bolts
Bushings Through Frame Walls for
Steering Shaft
240-280
125 140

100-120
(325-380)
(170 190)

(136 1631
5/8 Nut on the End of Steering Shaft 50- 70 (68-95)
Piston Nut for the Lift Cylinder

I (1 1/2" Rod)
(1-1/4" Rod)
Piston Nut for the Tilt Cylinder
200
160
160
(271,2)
(216,9)
(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 2.26" - 2.34"
(57,5 - 59,4 mm)

Model 825
·8-7­ Service Manual
 STANDARD TORQUE SPECIFICATIONS FOR BOLTS

The above illustration shows the most common hex screw head markings 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.

THREAD GRADE-2 GRADE-5 GRADE-8

SIZE DRY LUBE DRY LUBE DRY LUBE

1/4 Coarse 45-60 35-45 75-95 55-70 115-145 85-105

(5.08-6.78) (3.95-5.08) (8.47-10.73) (6.21-7.91 ) (12.99-16.38) (9.6-11.86)
I
N 1/4 - Fine 55-70 45-60 95-120 65-85 135-165 95-120
C (6.21-7.91) (5.08-6.78) (10.73-13.56) (7.34-9.60) (15.25-18.64) (10.73-13.56)
H
5/16 - Coarse 105-130 75-95 160-200 125-155 240-300 175-215
L (11.86-14.69) (8.47-10.73) (18.08-22.60) (14.12-17.51) (27.12-33.90) (19.77-24.29)
B
S. 5/16 Fine 115-145 85-105 180-225 135-165 260-325 190-240
(12.99-16.38) (9.60-11 .86) (20.34-25.4) (15.25-18.64) (29.40-36.72) (21.47-27.12)
(Nm)
3/8 - Coarse 190-250 145-180 25-30 18-23 35-45 25-30
(21.47-28.25) (16.38-20.34) (33.9-40.7) (24.4-18.6) (47.5-61.0) (33.9-40.7)

3/8 Fine 220-275 160-200 30-35 20-25 40-50 30-35

(24.86-31.07) (18.08-22.60) (40.7-47.5) (27.1-33.9) (54.2-67.8) (40.7-47.5)

7/16 - Coarse 25-30 15-20 40-50 30-35 55-70 45-55

(33.9-40.7) (20.3-27.1 ) (54.2-67.8) (40.7·-47.5) (74.6-94.9) (61.0-74.6)
F
T. 7/16 - Fine 30-35 20-25 45-55 35-40 65-80 50-60
(40.7-47.5) (271-33.9) (61.0-74.6) (47.5-54.21 (88.1-108.5) (67.8-81.4)
L
B 1/2 Coarse 40-50 30-35 60-75 45-55 90-110 65-80
S. (61.0-74.6) (47.5-54.2) (94.9-115.2) (67.8-81.41 (128.8-162.71 (101.7-122.0)

(Nm) 1/2 - Fine 45-55 35-40 70-85 50-60 95-120 75-90

(61.0-74.6) (47.5-54.2) (94.9-115.2) (67.8-81.4 ) (128.8-162.7) (101.7-122.0)

9/16 Coarse 55-65 40-50 90-110 65-80 120-150 90-110

(74.6-88.1) (54.2-67.8) (122.0-149.1) (88.1-108.5) (162.7-203.3) (122.0-149.1)

9/16 - Fine 60-75 45-55 95-120 75-90 135-170 105-130

(81.4-lOLl) (61.0-74.6) (128.8-162.7 ) (101.7-122.0) (183.0-230.5) (142.4-176.3)

I 5/8 - Coarse 75-90 55-70 120-150 90-110 180-220 135-170

(101.7-122.0) (74.6-94.9) (162.7-203.3) (122.0-149.1 ) (244.0-298.3) (183.0-230.5)

5/8 Fine 80-100 75-80 145-180 105-130 195-240 145-180

(108.5-135.6) (88.1-108.5) (196.6-244.0) (142.4-176.3) (264.4-325.4) (196.6-244.0)

3/4 - Coarse 130-160 95-·120 210-260 160-200 300-380 225-280

(176.3-216.9) (128.8-162.7) (284.7-352.5) (216.9-271.2) (406.8-515) (305.1-379.61

3/4 Fine 145-180 115-140 240-300 180-220 340-420 255-320

(196.6- 244 .0) (155.9-189.8) (325.4-406.1 ) (244.0-298.3) (460.1-569) (345.1-433.9)

- Coarse 115-140 90-110 320-400 240-300 500-600 370-460

17/8
(155.9-189.8) (122.0-149.1 ) (433.9-5421 (325.4-406.8) (678-814) (502-6241

7/8 - Fine 125-155 95-120 350-440 255-320 560-660 400-500

(169.5-210.2) (128.8-162.7) (474.5-598) (345.7-433.9) (759-895) (542-678)

1 Coarse 180-200 130-160 480-580 350-440 800-900 580-680

(244.1-298.3) (176.3-216.9) (651-786) (475-598) (1085-1220) (786-922)

1 - Fine 200-250 140-175 560-660 400-490 920-1020 665-765

(271.2-338.9) (180.8-237.3) (759-895) (542-664) (1247-1383) (902-1037)

Model 825
.8-8· Service Manual
 DECIMAL AND MILLIMETER EQUIVALENTS

FRACTIONS DECIMALS MM FRACTIONS DECIMALS MM

1/64 - 0.015625- 0.397 33/64 - 0.515625-13.097
1/32 .03125 - 0.794 17/32 .53125 -13.494
3/64 - .046875- 1.191 35/64- .546875-13.891
1/16 .0625 - 1.588 9/16 .5625 -14.288
5/64 - .078125- 1.984 37/64- .578125-14.684
3/32 .09375 - 2.381 19/32 .59375 -15.081

e 5/32
7/64 - .109375- 2.778
.1250 - 3.175
9/64 - .140625- 3.572
.15625 - 3.969
11/64- .171875- 4.366
e 21/32
39/64- .609375-15.478

41/64 -
.6250 -15.875
.640625-16.272
.65625 -16.669
43/64- .671875-17.066
3/16 .1875 - 4.762 11/16 .6875 -17.462
13/64- .203125- 5.159 45/64 - .703125-17.859
7/32 .21875 - 5.556 23/32 .71875 -18.256

e 9/32
15/64 - .234375- 5.953
.2500 - 6.350
17/64- .265625- 6.747
.28125 - 7.144
19/64- .296875- 7.541
e 25/32
47/64- .734375-18.653
.7500 -19.050
49/64- .765625-19.447
.78125 -19.844
51/64- .796875-20.241
5/16 .3125 - 7.938 13/16 .8125 -20.638
21/64 - .328125- 8.334 53/64 - .828125-21.034
11/32 .34375 - 8.731 27/32 .84375 -21.431

e 13/32
23/64 - .359375- 9.128
.3750 - 9.525
25/64 - .390625- 9.922
.40625 -10.319
27/64 - .421875-10.716
e­ 29/32
55/64 - .859375-21.828
.8750 -22.225
57/64 - .890625-22.622
.90625 -23.019
59/64- .921875-23.416
7/18 .4375 -11.112 15/16 .9375 -23.812
29/64 - .453125-11.509 61/64 - .953125-24.209
15/32 .46875 -11.906 31/32 .96875 -24.606

e 1 mm =
31/64 - .484375-12.303

.03937"'
.5000 -12.700
0 .001" =
63/64- .984375-25.003

.0254 mm
1.000 -25.400

U.S. TO METRIC CONVERSION

TO CONVERT INTO MULTIPLY BY

LINEAR Miles Kilometers 1.609
MEASUREMENT Yards Meters 0.9144
Feet Meters 0.3048
Feet Centimeters 30.48
Inches Meters 0.0254
Inches Centimeters 2.54
Inches Milimeters 25.4
AREA Square Miles Square Kilometers 2.59
Square Feet Square Meters 0.0929
Square Inches Square Centimeters 6.452
Acre Hectare 0.4047
VOLUME Cubic Yards Cubic Meters 0.7646
Cubic Feet Cubic Meters 0.02832
Cubic Inches Cubic Centimeters 16.39
WEIGHT Tons (Short) Metric Tons 0.9078
Pounds Kilograms 0.4536
Ounces (Avdp.) Grams 28.3495
PRESSURE Pounds/Sq. In. Kilopascal 6.895
WORK Foot·pounds Newton-Metre 1.356
LIQUID VOLUME Quarts Liters 0.9463
Gallons Liters 3.785
LIQUID FLOW Gallons/Minute Lite rs /M in ute 3.785
TEMPERATURE Fahrenheit Celsius 1. Subtract 32 0
2. Multiply by 5/9

Model 825
-8-9- Service Manual
8-9 SPECIAL TOOLS

PO lC Valve Guide Remove and Replacer

With this tool, all valve guides can be removed and replaced provided puller bars are
available.

PO 1 C-l Puller Bars

Two bars are supplied for use with PO lC to suit 5/16 in_ and 3/8 in. 1.0. valve guide
bores.

PD 1C-2 Valve Guide Replacing Stop

When the valve guide is replaced using one of these stops, it will ensure that the guide
protrudes the correct amount above the top face of the cylinder head.

PO 150 Cylinder Liner Remover and Replacer

PD 150-5 Adaptors for PO 150

316X Valve Seat Cutter Handle

This tool is required for the operation of all cutters and pilots.

316-10 Valve Seat Cutter Pilot

This pilot is suitable for all guides that have a nominal 5/16 in. I.D. bore.

PO 317·22 Valve Seat Cutter Inlet

PO 317-G19 Glaze Breaker Exhaust

PO 317-G22 Glaze Breaker Inlet

Remarks: See PO 317-23

FC9900 Atomizer Tester

This is a portable tester fitted with a paper filter element.

335 Connecting Rod Alignment Jig

Enables a quick check to be made on the alignment of connecting rods various adaptors
are required as follows: ­

PO 336-102 Adaptor

This adaptor is fitted into the big end bore when checking alignment.

6118B Valve Spring Compressor

This valve spring compressor has been designed to remove valve springs without removing
the cylinder head, providing the adaptors are available.

PD 6118·1 Valve Spring Compressor Adaptor

The adaptor is fitted to the rocker shaft securing studs.

Model 825
·8-10· Service Manual
 825 LOADER SPECIFICATIONS

/:
; :",
. ,
1
f I--­ 60

<6 .
I
... , ;-".,J '".. .
.-..;:------'I! I I " ««««< (1524)
: ';-~~ .. ~~)~.j-"'\ " 155
,,: /-------,,>.. __ u_:___<~ (3937)
,/,' II '-" 'L ,
I L I ", ,

III /1/>;/ ",)___38 SO 131.5

. - - - - - - ; ,...... /.i;;>;:;;;/~;/;;;;'<;;;!',_,!!'1;<,_"",",A' 7~4~~ r--I~ I t

94.25 120
(3340)

(2394) (3048)

85 113
(2159) (2870)

8)

PI·1829

SPECIFICATIONS

Weights:
Operating Weight " . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 780 Ibs. (2624 kg)
Rated Operating Capacity (SAE Rating) . . . . . . . . . . . . . . . . 1500 Ibs. (681 kg)
Tipping Load (SAE Rating) ........................................ 3100 Ibs. (1407 kg)
Travel Speed:
WorkRange ...................................... Ot04.4MPH(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.-Ibs. (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 cm 3 )
Cooling System ................................................... Liquid
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure System W/filter
Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Open
Air Cleaner .................................. Dry replaceable paper element

Model 825
Revised Feb. 82 -8-11- Service Manual
SPECIFICATIONS (Cont'd)

LOADER HYDRAULICS

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine driven, gear type

Pump Capacity . . . . . . . . . . . . . . . . . . . . 12.5 GPM (47,3 Umin.) @2500 RPM
System Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 2100 PSI (14478 kPaJ
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 (21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .' 1.25 (31,8)
Stroke
Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . 31.00 (787 A)
Tilt Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.13 (435,11
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
Move Bucket to Dump Position . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 seconds
Move Bucket to Retracted Position . . . . . . . . . . . . . . . . . . . . . . . . 2.1 seconds

ELECTRICAL

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt driven, 22 amp. enclosed

Battery ... 12 volt, 435 cold cranking amps. @ OaF (-1 7.8°C) 1 25 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 (PIN 6563328 [5 gal. package]) If fluid is not
available use 10W-30 or 1 OW-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 LI
Engine Lubrication W/Filter. . . . . . . . . . . . . .. . . . . . . . . . . . . . . 6 qts. (5,7 Ll
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 gal. (102 L)
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 gal. (102 L)

TIRES

Standard . . . . . . . . . . . . . . . . . . . . . . 8.25 x 15, 6-ply Rating, Nylon WI Bar Lug

Pressure:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 PSI (310 kPa)
Flotation •••.•.......••••••............ 45 50 PSI(31 0 - 345 KPal

Model 825
Revised Feb. 82 -8-12­ Service Manual
lenuel/ll a:J!"JaS
SZ8 lapol/II
X30NI
lV'JI.l38V'HdTv
l-6 X30NI 1'v'JI.l38'v'Hdl'v'
X30NI 1~JI.l38~Hdl~
9-1 ALPHABETICAL INDEX

Subject Page Subject Page

Axle Bearing & Seal Replacement . . . . . . . . . . . . . . . . . 4-6 Final Fuel Filter Specifications .8-6
Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Flushing Cooling System . . . .1-7
Flywheel Housing Installation 7-18
Bob-Tach 1-16 Flywheel Installation 7-'Q8
Bob-Tach Removal .5-1 Flywheel Removal . . . . . . . 7-17
Fuel Injection Pump . . . . . 7-32
Camshaft Gear Installation 7-20 Fuel Injection Pump Specifications .8-6
Camshaft Gear Removal . 7-20 Fuel Lift Pump . . . . . . . . 7-31
Camshaft Specifications . . .8-3 Fuel Lift Pump Specifications .8-6
Camshaft & Tappet Installation 7-22 Fuel Oil Specifications . . . . .8-5
Camshaft & Tappet Removal . 7-22 Fuel Pipes (High Pressure) .. 7-34
Camshaft Thrust Plate Specifications . .8-3 Fuel Pump Drive Hub Installation 7-21
Combustion Chamber Inserts . . . . . .7-4 Fuel Pump Drive Hub Removal 7-21
Combustion Chamber Insert Specifications .8-3 Fuel Pump Gear Installation 7-20
Connecting Rod Alignment . . . . . . . · .8-2 Fuel Pump Gear Removal 7-20
Connecting Rod and Pistons . . . . . . . · .7-9 Fuel Specifications .1-7
Connecting Rod Bearing Specifications .8-2 Fuel System . . . . . . .1-8
Connecting Rod Specifications .8-1 Fuel System, Charging .1-9
Control Linkage .3-6 Fuel System, Servicing .. 1-9
Control Pedals . .2-9 Fuel Tank Removal .. 5-2
Control Valve .2-6
Cooling System 7-28 Gear Pump . . . . . . . .2-4
Cooling System Specifications .8-5 Gear Pump Assembly . .2-6
Crankshaft and Main Bearings 7-13 Gear Pump Disassembly .2-4
Crankshaft Gear Specifications .8-5 Generator Output .6-3
Crankshaft Installation . . . . . 7-16 Generator Service . .6-4
Crankshaft Oil Seal, Front .. . 7-19
Crankshaft Oil Seal, Rear End 7-17 Hydraulic Cylinders 2-10
Crankshaft Removal . . . . . . . 7-15 Hydraulic Fluid, Check 1-11
Crankshaft Specifications . . . . .8-2 Hydraulic Fluid Filters 1-11
Crankshaft Thrust Washer Specification · .8-2 Hydraulic System . , . .1-11.2-1
Cylinder Block Specifications · .8-1 Hydraulic Tubelines. Hoses, Fittings .2-1
Cylinder Head Installation .. . 7-8 Hydrostatic Drive System .3-1
Cylinder Head Maintenance . .7-2 Hydrostatic Motor Installation 3-12
Cylinder Head Specifications .8-3 Hydrostatic Motor Removal .. 3-12
Cylinder Liners . . . . . . . . . 7-13 Hydrostatic Pump Installation. 3-11
Cylinder Liner Specifications .8-1 Hydrostatic Pump & Motor Assembly 3-14
Hydrostatic Pump & Motor Disassembly 3-13
De-Rating for Altitude . . . . .8-7 Hydrostatic Pump Removal 3-11
Diode Trio . . . . . . . . . . . .6-5 Hydrostatic System Check .3-7
Draining Hydraulic Fluid Reservoir . 1-12 Hydrostatic Transmission 1-13
Drive Chain Adjustment . .4-2
Drive Chain Idler Removal .4-3 Idler Gear Disassembly . .4-3
Drive Chain Installation .4-4 Injector . . . . . . . . . . 7-33
Drive Chain Removal .4-4 Injector Pump Gear Specifications .8-5
Injector Specifications . . . . . . .8-6
Electrical Circuitry · .6-1 Inner Valve Spring Specifications .8-4
Electrical System · .6-1
Electrical System Maintenance 1-10 Lift Arm Removal . .5-2
Engine Air Cleaner .1-6 Lift Valve Spool .. .2-8
Engine Cooling System . . . . . .1-7 Lifter Specifications .8-4
Engine Maintenance . . . . . . . .1-4 Loader Serial Number .1-1
Engine Oil and Filter Replacement . 1-5 Loader Specifications 8-11
Engine Overhaul .. . .7-1 Lubrication 1-15
Engine Removal .. . .7-1 Lubrication System . .8-5
Engine Serial Number .1-1
Main Bearing Specifications .8-2
Fan Belt . . . . . . . . .6-3,7-28 Main Frame . . . . . . . . . . .5-1
Fan Belt Adjustment .1-7. 7-28
Fifty (50) Hour Inspection .1-2 Oil Cooler. .1-1
Final Drive Chain . 1-14 Oil Filter Lubrication .8-5
Final Drive System . . . . . .4-1 Oil Pan Installation . 7-25
Model 825
-9-1­ Service Manual
9-1 ALPHABETICAL INDEX (Cont'd)

Subject Page Subject Page

Oil Pressure Relief Valve . . . . . . . . 7-27 Starting Aid .8-6

Oil Pressure Relief Valve Assembly 7-28 Stator Check .. 6-4
Oil Pressure Relief Valve Disassembly 7-28 Steering Control Linkage .. 3-7
Oil Pump Assembly . . . . . . . . . 7-27 Symbols . . . . . . . . . . 1-1
Oil Pump Disassembly . . . . . . . 7-26
Oil Pump Drive Gear Lubrication .. 8-5 Ten (10) Micron Filter 3-10
Oil Pump Installation 7-27 Thermostat . . . . . . . 7-30
Oil Pump Lubrication . . . . . . . . .7-25, 8-5 Tilting the ROPS .1-4
Oil Pump Removal . . . . . . . . . 7-26 Timing Case Back Plate Installation 7-22
Outer Valve Spring Specifications .8-4 Timing Case Back Plate Removal 7-21
Timing Case Installation 7-19
Piston Pin. Bushing Specifications .8-1 Timing Case Removal 7-18
Piston Ring Installation .. 7-11 Timing Gear Backlash .8-5
Piston Ring Specifications .8-1 Timing Marks . 7-23
Piston Specifications .8-1 Timing Pin . . . . 7-24
Pre-Delivery Inspection . .1-2 Tires . . . . . . . . 1-14
Preventive Maintenance . · 1-3 Tire Maintenance 1-15
Push Rod Specifications .8-4 Tire Replacement 1-15
Tire Rotation . . . 1-15
Rear Grill . . . . . . . . . · 1-4 Torque Specifications .8-7
Rectifier Check .6-5 Troubleshooting Hydraulic System .2-2
Reduction Housing Assembly .4-2 Troubleshooting Hydrostatic System .3-1
Reduction Housing Disassembly .4-1
Reduction Housing Removal .4-1 Valve Adjustment Sequence 7-25
Regulator . . . . . . . . . . . .6-3 Valve Clearance Adjustm,mt 7-25
Relief Valve Specifications . .8-5 Valve Clearances . . . . . . . .8-4
Rocker Levers Specifications .8-4 Valve (Exhaust) Specifications .8-4
Rocker Shaft Disassembly . · 7-6 Valve Guide (Exhaust) Specifications .8-3
Rocker Shaft Specifications .8-4 Valve Guide (Inlet) Specifications .8-3
ROPS Removal . . . .5-1 Valve (Inlet) Specifications .8-4
ROPS Tilting Motor .5-2 Valve Installation .7-7
Rotor Check . . . . .6-4 Valve Removal . . . .7-3
Valve Seat Inserts .7-5
Serial Number Identification · 1-1 Valve Timing Check 7-24
Service Wear Limits . .8-6 Valve & Valve Seat Reconditioning .7-5
Special Tools . . . . . 8-10
Speed Range Linkage .3-6 Water Pump 7-29
Starter Service . . . . .6-6 Wheel Torquing 1-15

Model 825
·9-2· Service Manual
CLqRK=:' •• bobcat 825-001

26 JUNE 79

-SERVICE BULLETIN ­
ROUTE TO
BOBCAT LOADER
ATTENTION

825
,-vVf
""'"
. ""V'
16089 AND BELOW

BYPASS HOSE FOR OIL COOLER

PROBLEM:
Bypass hose is breaking on Hydraulic Oil Cooler.

CAUSE:
Hydraulic pressure at cooler inlet is above the pressure rating of the hose.

CORRECTION:
Install new hose (Fig. 1) PIN 6591285. Order hose from Chicago Central Parts.

POLICY:
Melroe will give warranty compensation for the hose and Y, hour labor for loaders in
warranty period.

REMOVE PAGE PUT IN PAGE

2-11 2-11

Fig. 1 By-Pass Hose Location

BULLETIN STATUS
Refer To
Bulletin No.lsl Printed in U.S.A. NON CURRENT D
CU~RK==:' ~bobcat 825-002

28 AUGUST 79

.. SERVICE BULLETIN ..
BOBCAT LOADER
ROUTE TO
ATTENTION
_~. ~!t

(i,ti4~ft9~

REVISION TO THE SERVICE MANUAL

The attached pages are a revIsion to the 825 Service Manual (PIN 6549899
[4-7811. There are 21 pages to this bulletin, check to see if you have them all.

The list of the following Service Bulletins have been added or are already in the
Service Manual.

Bltn. No. Date Bltn. No. Date Bltn. No. Date

75-32 Dec. 75 007 Jan. 77 058 Aug. 78

76-2 March 76 011 April 77 063 Oct. 78
76-5 March 76 015 Oct. 77 086 Nov. 78
76-8 March 76 033 Dec. 77 087 Nov. 78
76-10 April 76 034 Dec. 77 100 Feb. 79
76-13 June 76 052 May 78
76-18 Aug. 76 055 June 78

Remove the following pages in the Service Manual and put in the revised or added
pages, as follows:

Remove Put In
1 Revised January 77 1-1
1 3 Revised July 78 1-3
1 5 Revised March 78 1 5
1 - 1 5 Revised January 77 1-15
3 - 11 Revised January 77 3-11
3-12a
4 5 Revised January 77 4-5
4-7 Revised January 77 4-7
7-3 7-3
7 31 Revised March 79 7 31
7 - 35 Revised April 79 7-35

BULLETIN STATUS
Refer To
Bulletin No.ls)
Printed in U.S.A. NON CURRENT D
CLQRK:= ~bobcat
~QCIQ!3.EB]~

4iiliIi SERVICE BULLETIN-­

ROUTE TO
ATTENTION
BOBCAT LOADER

825

6549899

REVISION TO THE SERVICE MANUAL

The attached pages are a revision to the 825 Service Manual (PIN 6549899
[4-78]).

This will up-date the Service Manual to show the timing procedure using the Timing
Tool, because the snapring used as a timing procedure in the pump is not always in
the correct position you will have to use the Timing Tool.

Remove the following pages in the Service Manual and put in the revised or added
pages as follows:

REMOVE PUT IN

7-33 7-33
7-33a
7-33b
7 34 7 34

Printed in U.S.A.

Refer To BULLETIN STATUS

Bulletin No.ls) NON CURRENT D
CLQRK:= ~bobcat 825-004

1 APRIL 80

..SERVICE BULLETIN ­
BOBCAT LOADER
ROUTE TO
ATTENTION
825

6549899

ELECTRICAL GROUND WIRE TO THE MAINFRAME

PROBLEM:

The ground wire will burn through the insulation.

CAUSE:

Connecting the clamp to the mainframe when using an extra battery (jump start) to
start the engine. The ground wire between the starter and mainframe is not heavy
enough to take the extra current load.

CORRECTION:

Connect the clamp directly to the engine when using an extra battery (jump start) or
install a number 4 gauge ground wire between the starter and the mainframe (See
page 6-1 Fig 6-1 Item 1). Do not put the ground wire through the harness clip.

Remove the following pages in the Service Manual (6549899 [4-781 2nd Edition
and put in the revised pages.

REMOVE PUT IN

6 1, Revised Jan. 776-2 Revised April 80 6-1

Revised Jan. 77 6-2

POLICY:

Melroe will NOT give warranty compensation for parts or labor.

BULLETIN STATUS
Refer To
Bulletin No.(s)
Printed In U.S.A. NON CURRENT D
CLqRK ......• ~bobcat 825·005

15-APRIL·80

.. SERVICE BULLETIN . .
BOBCAT LOADER ~ ~"-"~"""""~ "~"" ~~"" "--"-""""-"

825

6549899

REVISION TO .THE SERVICE MANUAL

The attached pages are a revision to the 825 Service Manual IP/N 6549899
[4-78)).

This will up-date the Service Manual to show inlet charge pressure and gasket
replacement on the transmission.

Remove the following pages in the Service Manual and put in the revised pages as
follows:

REMOVE PUT IN

3-5,3-6 3-5, Revised 3-6

3 7.3-8 3-7, Revised 3-8

BULLETIN STATUS
Refer To
Bulletin No.(s)
Printed In U.S.A. NON CURRENT D
CLqRK==:n .. -bobcat
825-1
Revision Number

1 MAY 1981
Date
SERVICE MANUAL
REVISION ROUTE TO
AFFECTING: ATTENTION

~
PARTS MANAGER
Product BOBCAT LOADER SERVICE MANAGER
Model __~===-___________________________________ SALES MANAGER D
D
Manual No. 6549899 (4-78}

Additional information about this

subject is found in the following:

The attached pages are a revision to the 825 Service Manual {PIN 6549899 Service Letter ________
[4-7811. Service Bulletin _______
B.T.I. Bulletin _ _ _ _ _ __
There are 22 pages in this revision, check to be sure that you have all of them. Installation Inst.

Section TWO has changes to WARNING and NOTE, torque on hydraulic cylinder.
Section THREE has additions of Checking Charge Pressure, Charge Pump Inlet
Pressure, specfications on rotating group and pumplmotor assembling procedures.
Section FOUR changes add torque specifications on the reduction housing drive
chain adjustment, and axle and bearing seal replacement. Additions to Section FIVE
include ROPS Removal procedure and Pivot Pin and Bushing Replacement. Section
Six includes the addition of two Electrical Wiring Diagrams. Section SEVEN has
changes to Starting Procedures, Thermostart Units, and Charging the Fuel System.
Section EIGHT has changes or aditions of the following: Chrome ring gap, cylinder
compression, radiator cap pressure, torque specifications and fuel capacity.

Remove and put in pages as follows:

REMOVE PUT IN CHANGES

2-3 2 3 No Change
2 -4 (Rev. Mar. 76) 2-4 (Rev. Mar. 81) Changed WARNING
2 5 (Rev. Mar. 76) 2 5 (Rev. Feb. 81) Added NOTE
2 6 2-6 No Change
2 11 (Rev. MAr. 78) 2-11 (Rev. Feb. 81) Torque Spec. Changes
2 12 (Rev. June 79) 2-12 (Rev. Feb. 81)

3 7 (Rev. Mar. 78) 3-7 (Rev. Feb. 81) Added Paragraphs 3-6.2
and 3-6.3
3-7a (Added Feb. 81) New Page
3-8 (Rev. Apr. 80) 3-8 (Rev. Feb. 81)
3-13 (Rev. Mar. 78) 3-13 (Rev. Mar. 78) No Change
3 14 3-14 (Rev. Feb. 81) Added Spec's. (Step 9)
3 15 (Rev. Mar. 78) 3-15 (Rev. Feb. 81) Added NOTE and Steps
a thru d
3 16 (Rev. Jan. 77) 3-16 (Rev. Jan. 77) No Change

4-1 (Rev. Mar. 78) 4-1 (Rev. Feb. 81) Added NOTE
4 2 (Rev. Jan. 77) 4-2 (Rev. Jan. 77) No Change
4 3 (Rev. Mar. 78) 4-2 (Rev. Feb. 81) Added Step 10, Change
Paragraph 4-4.5
4-4 (Rev. Jan. 77) 4-4 (Rev. Jan. 77) No Change
4-7 (Rev. Aug. 79) 4-7 (Rev. Feb. 81) Change Paragraph 4-8
4-8 (Rev. Aug. 79) 4-8 (Rev. Feb. 81)

6566233 (5-811-17.5C PrW"ited in U.S.A.

 5-1 5-1 (Rev. Feb. 811 Change Step 6
Added NOTE
5 2 (Rev. Mar. 78) 5-2 (Rev. Feb. 81) Change Paragraph 5-6.1,
5-6.2 and 5-7
5-3 (Added Feb. 811 New Page

Put in Overhead Guard

Wiring Diagram and
Engine Wiring Diagram
after the Electrical
Tab page.

7 -1 (Rev. Jan 77) 7 -1 (Rev. Feb. 81) Change Paragraph 7 - 2

7 2 (Rev. Jan. 77) 7-2 (Rev. Jan. 771 No Change
7-7 7-7 No Change
7-8 7 -8 (Rev. Feb. 81) Added NOTE after Step 3
7-35 (Rev. Aug. 79) 7-35 (Rev. Aug. 79) No Change
7 -36 (Rev. Aug. 79) 7-36 (Rev. Feb. 81)

8 1 8-1 (Rev. Feb. 81) Added Chrome Ring Gap

8 2 8-2 No Change
8-3 8-3 (Rev. Feb. 81) Added Compression
Specifications
8-4 8-4 No Change
8-5 8-5 (Rev. Feb. 81) Added Radiator Cap
Pressure
8-6 (Rev. Jan. 771 8-6 (Rev. Jan. 77) No Change
8-7 8-7 (Rev. Feb. 811 Change Torque Spec's.
Paragraph 8-8.3
8-8 8-8 No Change
8-11 8-11 (Rev. Feb. 81) Change Fuel Capacity

This Service Maual Revision includes information which was previously sent to you
on the following publications:

Service Bulletin #825-001

CIJARK ......... Melrae
~bobcat 825-2
Revision Number

9 Februa!y' 1982
Date
SERVICE MANUAL
REVISION ROUTE TO
AFFECTING:
ATTENTION

~
PARTS MANAGER
Product BOBCAT LOADER SERVICE MANAGER
Model 825
SALES MANAGER D
D
Manual No. 6549899 (4-78)

Additional information about this

subject is found in the following:
The attached pages are a revision to the 825 Service Manual (PIN 6549899
(4-78)). Service Letter _ _ _ _ _ _ __
Service Bulletin _ _ _ _ _ __
There are 65 pages in this revision, check to make sure you have them all. B.T.!. Bulletin _ _ _ _ _ __
Installation Inst.
Remove and put in the pages as follows:

REMOVE PUT IN

Preventive Maintenance Contents Preventive Maintenance Contents (Rev. Feb. 82)

1-1 (Rev. Aug. 79),1-2 (Rev. Aug. 79)
1 3 (Rev. July 78), 1 -4 (Rev. Aug. 79)
1 -5 (Rev. Aug. 79), 1-6 (Rev. Aug. 79)
1 -7 (Rev. Jan. 77), 1-8
1 -9 (Rev. Mar. 76), 1 10
1-11 (Rev. Mar. 78), 1-12
15 (Rev. Jan. 77), 1-16 (Rev. Aug. 79)
Add System Operations Sheet before Hydraulic Flow Charts
Add Hydraulic Flow Chart (PI-2 511) Before Page 2-1
2-1 (Rev. Jan. 771. 2 2 2-1 (Rev. Feb. 82), 2 2 Add Hydrostatic Flow Charts
3 1 (Rev. Jan. 77), 3-2 (Rev. Mar. 76)
3 -7 (Rev. Feb. 81 I. 3-7a (Added Feb. 81)
3-8 (Rev. Feb. 81)
3 -9 (Rev. Mar. 76), 3 10
3-12a (Rev. Aug. 79)
3 13 (Rev. Mar. 78), 3-14 (Rev. Feb. 81)
3-15 (Rev. Feb. 81), 3-16 (Rev. Feb. 81)
4 1 (Rev. Feb. 81), 4-2 (Rev. Jan. 77)
4-3 (Rev. Feb. 81), 4-4 (Rev. Feb. 81)
4-5 (Rev. Apr. 79), 4-6 (Rev. Aug. 79)
5 1 (Rev. Feb. 81), 5-2 (Rev. Feb. 81)
5-3 (Rev. Feb. 81)
Electrical System Contents
6 1 (Rev. Apr. 80), 6-2 (Rev. Jan. 77)
6-3 (Rev. Jan. 77), 6-4 (Rev. Jan. 77)
7 1 (Rev. Feb. 81), 7-2 (Rev. Jan. 77)
7 33 (Rev. Oct. 791. 7-33a (Added Oct. 79)
7-33b (Added Oct. 79)' 7-34
7 35 (Rev. Aug. 79), 7-36 (Rev. Feb. 81)
8-1 (Rev. Feb. 81), 8-2
8-5 (Rev. Feb. 81), 8-6 (Rev. Feb. 81)
8-11 (Rev. Feb. 81)
1-3 (Rev. Feb. 82), 1-4 (Rev. Feb. 82),
1 -4a (Added Feb. 82)
1-5 (Rev. Feb. 82), 1 6 (Rev. Aug. 79)
1 -7 (Rev. Jan. 77), 1 8 (Rev. Feb. 82)
1-9 (Rev. Feb. 82), 1-10 (Rev. Feb. 82)
1 11 (Rev. Feb. 82), 1 12
1-15 (Rev. Feb. 82), 1 16 (Rev. Aug. 79)
(PI-2512 & PI-25131 Before Page 3-1
3-1 (Rev. Feb. 82), 3-2 (Rev. Mar. 76)
3-7 (Rev. Feb. 82), 3-7a (Rev. Feb. 82)
3-8 (Rev. Feb. 82)
3-9 (Rev. Feb. 82). 3-10
3-12a (Rev. Feb. 82)
3-13 (Rev. Feb. 821. 3-14 (Rev. Feb. 82)
3-15 (Rev. Feb. 82), 3-16 (Rev. Feb. 82)
4-1 (Rev. Feb. 821, 4-2 (Rev. Jan. 771
4-3 (Rev. Feb. 82), 4-4 (Rev. Feb. 81)
4-5 (Rev. Feb. 82), 4-6 (Rev. Aug. 791
5-1 (Rev. Feb. 81 I. 5-2 (Rev. Feb. 821
5-3 (Rev. Feb. 821
Electrical System Contents {Rev. Feb. 821
6-1 (Rev. Feb. 82), 6- 2 (Rev. Jan. 771
6-3 (Rev. Feb. 82)' 6 4 (Rev. Feb. 82)
7-1 (Rev. Feb. 82), 7-2 (Rev. Jan. 77)
7-33 (Rev. Oct. 791, 7-33a (Rev. Feb. 821
7 33b (Rev. Feb. 82), 7-34
7-35 (Rev. Aug. 79), 7 36 (Rev. Feb. 82)
8-1 (Rev. Feb. 821. 8-2
8-5 (Rev. Feb. 821, 8-6 (Rev. Deb. 811
8-11 (Rev. Feb. 82), 8 12 (Added Feb. 821