825 6549899 SM 12-83

8
2
Service
Manual
Dealer Copy -- Not for Resale

5
6549899 (12–83) Printed in U.S.A. © Melroe Company 1983
1 of 176
2 of 176
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
B-10731a B-12365 B-7469

Never service the Bobcat Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.
WRONG WRONG WRONG

B-11799 B-15231 B-15280
Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
B-6590 B-6580 B-6589

B-16102 B-16102
Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW01-0805
3 of 176
4 of 176
FORWARD PREVENTIVE
This manual provides instruction for proper routine service and adjustment of the Bobcat, and
MAINTENANCE
detailed overhaul instructions of the power train, loader hydraulic/hydrostatic system and
general mainframe components.
Refer to the Owner’s Manual for general operating instructions (Starting Procedure, Daily
Checks, Bucket Operation, Minor Maintenance, etc.). HYDRAULIC
SYSTEM
A general inspection of the following items should be made whenever the machine has
undergone service or repair:
1. Check hydraulic fluid level, engine oil level and fuel supply.
HYDROSTATIC
2. Inspect for any sign of fuel, oil or hydraulic fluid leaks. DRIVE SYSTEM
3. Lubricate the machine.
4. Check battery condition, electrolyte level and cables.

MECHANICAL
5. Inspect air cleaner system for damage or leaks. Check element and make replacement, TRANSMISSION
if necessary.
6. Check alternator drive belt for condition and tension.
7. Check for loose drive chains by lifting the rear of the machine and turning the rear wheels
MAIN
by hand. FRAME

8. Check tires for wear and pressure.
9. Check the Bob–Tach attachment for condition. Inspect the wedges for damage or wear.
ELECTRICAL
10. Inspect safety items for condition (ROPS Guard, Seat Belt, Safety Treads, Lights, etc.). SYSTEM
11. Make a visual inspection for loose or broken parts or connections.
12. Operate the loader; checking all functions. ENGINE

SERVICE
Advise the owner if any of the above items are in need of repair.
SPECIFICATIONS
CONTENTS
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 ALPHABETICAL
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 INDEX
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
MECHANICAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
825 Loader
5 of 176 –1––3– Service Manual
825 Loader
PREVENTIVE MAINTENANCE PREVENTIVE
MAINTENANCE
Paragraph Page
Number Number
BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–30 1–16
DRAINING THE FLUID RESERVOIR . . . . . . . . . . . . . . . . . . 1–19 1–12
ELECTRICAL SYSTEM MAINTENANCE . . . . . . . . . . . . . . . 1–15 1–10
ENGINE AIR INLET SYSTEM (Air Cleaner) . . . . . . . . . . . . . . 1–7 1–6
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8 1–7
ENGINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 1–4
ENGINE OIL AND FILTER REPLACEMENT . . . . . . . . . . . . . 1–6 1–5
FAN BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9 1–7
FINAL DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23 1–14
FLUSHING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . 1–10 1–7
FUEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 1–8
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11 1–8
FUEL SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13 1–9
HYDRAULIC FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17 1–11
HYDRAULIC FLUID FILTERS . . . . . . . . . . . . . . . . . . . . . . . . 1–18 1–11
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16 1–11
HYDRAULIC SYSTEM LEAK CHECKS . . . . . . . . . . . . . . . . 1–20 1–13
HYDROSTATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 1–22 1–13
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 1–1
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–28 1–15
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–21 1–13

PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 1–2 1–3
REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 1–4
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
WHEEL MOUNTING NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . 1–29 1–15
825 Loader
7 of 176
Revised Feb. 82 –1––1– Service Manual
825 Loader
8 of 176 –1–0– Service Manual
INTRODUCTION
1–1.1 Symbols Serial Number
Plate
WARNING
Instructions are necessary
before operating or servicing
machine. Read Operation &
Maintenance Manual,
Handbook and signs (decals)
on machine. Follow warnings
and instructions in the
manuals when making repairs,
adjustments or servicing.
Check for correct function
after adjustments, repairs or B–02969R
service. Failure to follow Fig. 1–1 Loader Serial Number Plate
instructions can cause injury
or death [A].
W–2003–0797

Serial
IMPORTANT Number
This notice identifies

procedures which must be
followed to avoid damage to
the machine.
I–2030–0284
1–1.2 Serial Number Identification

It is important to make correct reference
to the serial number of the loader when
making repairs or ordering parts. Early or
later made models (identification made B–02144
either by Lot or serial number group) Fig. 1–2 Engine Serial Number Plate
sometimes use different parts, or it may
be necessary to use a different procedure
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. 1–1). Two types of serial numbers are used. Early loaders use
a serial number with a lot code and a four number production sequence. Later
machines use a five number production sequence.
The serial number is made up as follows for early loaders.
4970 A 1001 M
Plant Location
Production Sequence
Lot Code
Model, Engine Version
The serial number is made up as follows for later loaders.

4970 M 11001
Production Sequence
Plant Location
Model, Engine Version
825 Loader
9 of 176
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).
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 delivery to the
customer.
The pre–delivery inspection also lets the factory know when something is wrong
with the loader so that the action can be taken to prevent the problem from
happening in the future.
All items on the inspection form (Fig. 1–3) must be completed according to
specification in this manual.
One copy of the completed form is to be mailed to the attention of Quality Control,
Melroe Division.
*Fig. 1–3 Pre–Delivery Inspection Form
1–1.6 30 Hour Inspection

The 30–hour inspection must be completed soon after the first 30 hours of

operation.
The purpose of the 30–hour inspection is:
1. For adjustment and inspection after first work period
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 specification in this manual.
When the 30 hour inspection has been completed, the form must be signed by the
mechanic that completed the inspection, dealer person and owner or operator.
One copy of the completed form is for the owner of the loader. Another copy is to
be sent to the attention of Service Department, Melroe Division. The remainder Fig. 1–4 30 Hour Inspection Form
copy is for the dealer.
825 Loader
10 of
Revised Feb. 82176 –1–2– Service Manual
SERVICE SCHEDULE
Maintenance work must be done at regular intervals. Failure
to do so will result in damage to the Bobcat loader or the
engine. The SERVICE SCHEDULE is a guide for correct
maintenance of the Bobcat loader. DO NOT change this
SERVICE SCHEDULE unless you increase the frequency of
service when the Bobcat loader is operated in very hot, cold, Never go under or reach under lift arms or a lift
dusty or corrosive conditions. cylinder without an approved lift arm stop
installed, or you could be crushed.
W–2060–0887
ITEM SERVICE REQUIRED 8–10 50 100 200 500 1000

Engine Oil Check the oil and add oil as needed.
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.
Tires Check tires for damage and for correct air pressure.
Seat Belt, Operator Check the condition of the seat belt. Check the operator
Guard & Seat Bar guard fastening bolts to make sure they are tight. Check
the seat bar for correct operation.
Safety Signs (Decals) Check for damaged decals. Replace any decals that are

not in the correct location.
All Pivot Pins Add grease to all the fittings.
Hydraulic Fluid Check fluid level and add recommended fluid as needed.
Water Filter Remove the trapped water.
Wheel Nuts Tighten wheel nuts to 120 ft.–lbs. (163 Nm) torque
(Check every 8 hours for the first 20 hours).
Engine Oil and Filter Change oil and filter.
Transmission Fluid Check fluid level and add fluid as needed.
Battery Check the battery cables and the water level.
Control Pedals and Check both for correct operation. Make repairs and
Steering 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 & Check condition and tension of the belt.
Water Pump)
Drive Chains Raise the loader and check the tension in the chains.
Hydraulic Tubes & Hoses Inspect for damage and leaks and replace as needed.
Spark Arrestor Muffler Empty spark chamber.
Fluid Filter (25 Micron) Replace the filter element.
Fluid Filter (10 Micron Replace the filter element.
[External])
Final Fuel Filter Replace the filter element. Remove air from the system.
Transmission Fluid Remove condensation, check level and add as needed.
Reservoir
U–Joint (Hydrostatic & Add grease to the fittings (3)
Engine)
Seat Bar Lubricate the detent mechanism.
Transmission Fluid Drain the reservoir and fill with the correct fluid.
Reservoir
Transmission Fluid Filter Replace the filter element.
(10 Micron [Internal])
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 REAR GRILL
825ServiceManual#6549899–PreventiveMaintenanceSectionPages1–4
Grill
The rear grill is opened by pulling forward Handle
and up on the rubber fastener (Fig. 1–5).
Lift up the engine cover, pull up on the
handle to release the grill. Pull the grill
open (Fig. 1–6).
1–4 TILTING THE OPERATOR GUARD Latch
The ROPS (Roll Over Protective

Structure) can be tilted, when desired to
make more space when servicing the
Bobcat.
To tilt the Operator Guard (S/N 19126 &
Below):
1. Remove the retaining nuts at the

left and right rear corners of the A–02278 B–01793
ROPS (Fig. 1–7). Fig. 1–5 ReleasingEngine Cover Fastener Fig. 1–6 Opening Rear Grill
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 (S/N 19127 & Above):
Retaining
Nuts
1. 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.
1–7).
5. The hex bolt for the mechanical tilt is located on the right side of the loader B–01796
between the wheels (Fig. 1–8A). Use a rachet and socket (Fig. 1–8a) and Fig. 1–7 ROPS Retaining Nuts
tilt the operator guard into the full forward position (Fig. 1–9).
NOTE: DO NOT exceed 50 ft–lbs. (68 Nm) torque on the hex bolt used to
raise or lower the operator guard. Raise
WARNING
Tilt
DO NOT raise or lower the Switch
operator’s guard with the
engine running.
W–2303–0298
To lower the operator guard, use the

above procedure in the reverse order.
Lower
B–01781 B–03626
Fig. 1–8 Cab Tilt Switch Fig. 1–8a Lifting The Operator Guard
825 Loader
12 of
1–4.1 ROPS Tilt Motor
To seal out water from the ROPS tilt
motor, clean the area (Fig. 1–9a, Item
1). Seal electric wire opening the R.T.V.
(Room Temperature Vulcanizing) type
compound. 1
1–5 ENGINE MAINTENANCE

B–01809
1–5.1 Engine Oil Fig. 1–9 Tilting The ROPS
1. Check oil level every eight hours of operation.

B–02419
2. On new machine check the oil level every four hours during the first 50 hours Fig. 1–9a ROPS Tilt Motor
of operation.
3. Oil level must always be kept between the Min and Max marks on the dipstick
(Fig. 1–10 & 1–11).

Keep Oil Level
Between These
1–5.2 Specifications Marks
Use good quality detergent motor oil that meets the API service classifications.
(See Chart.)
Max.
Min.
A–01528
Fig. 1–10 Dipstick
Fill Pipe
Dipstick
B–01789
Fig. 1–11 Engine Oil Dipstick/Fill Locations
825 Loader
13 of 176
Revised Feb. 82 –1–4a– Service Manual
825ServiceManual#6549899–PreventiveMaintenanceSectionPages4a–4b
825 Loader
14 of 176 –1–4b– Service Manual
NOTE: Do not use synthetic lubricating oils.
Use oil of correct SAE viscosity for expected temperature conditions at the time
of starting, not for the highest temperature expected during the working day.
RECOMMENDED SAE VISCOSITY NUMBER

(LUBRICATION OILS FOR ENGINE CRANKCASE)
C°–34 –29 –23 –18 –13 –7 –1 +4 +10 +15 +21 +27 +32 +38 +43 +49 +54 +60
SAE 40 or 20W–50
SAE 10W–30/40
SAE 15W–40
SAE 5W–30
SAE 30W
SAE 20W/20
SAE 10W
F°–30 –20 –10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +110 +120 +130 +140
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, remove 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.
Drain Plug
3. Put oil on seal and turn new element on to filter head. Tighten the element
until hand tight.
Start the engine and run it for a few minutes, and check for leaks at the filter. Stop
the engine, check the oil level and add oil if necessary. Fill to the full mark on the
dipstick. Do not overfill, as this causes oil foaming, oil consumption, high engine
temperature and oil leaks at the engine seals.
A–02275
Fig. 1–12 Engine Oil Drain Plug
825 Loader
15 of 176
1–7 ENGINE AIR INLET SYSTEM (AIR
CLEANER)
Correct maintenance of air inlet system Dust Cap
is necessary for long engine life. A small
leak in the system can destroy an
engine in a few minutes. Set up a
schedule for inspection and follow it
regularly. To service the filter, follow
these steps:
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. A–02283
1–14). Fig. 1–13 Removing Dust Cap
3. Before installing the new cartridge, wipe all foreign material from the filter
housing.
4. Install clean cartridge carefully to be sure of good seal. Be sure that the Reset Button
cartridge gasket is in good condition and the new plastic washer is correctly

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.
Window
Air cleaners must be inspected regularly for leaks or damage. A damaged air
cleaner can badly effect the performance of an engine.
The following air cleaner service procedures can be taken when the engine is to
be serviced in the field:
1. Check all connections for tightness, making sure that the air cleaner outlet
pipe and air inlet hose are complete. Indicator
2. If the air cleaner has been damaged, check all connections immediately.
Check the internal cartridge seal areas. Make replacement of the air cleaner A–02291
body if necessary. Fig. 1–14 Condition Indicator
3. In the case of leakage, if

adjustment does not correct the
trouble, make replacement of the
necessary parts, hoses, or
gaskets.
NOTE: The seal surface of the filter

element must seal correctly
or dust will enter the engine
causing engine failure.
Element
4. Inspect the intake manifold gasket
for damage or looseness which
can cause dirty air to enter the
engine.
B–01791
Fig. 1–15 Removing Air Cleaner Element
825 Loader
16 of 176
1–8 ENGINE COOLING SYSTEM Radiator
Cap
Correct coolant level must be kept to cool the engine or overheating will result.
Check the coolant level in the radiator daily and fill to 2.0 inches below the filler
neck when level is low (Fig. 1–16). Remove radiator cap carefully, after engine has
cooled. The cooling system is under pressure. The pressure rating of the cap is
7 PSI. During freezing temperatures, a correct mixture of Ethylene Glycol and
water must be used to protect coolant from freezing. The capacity of the cooling
system is 10 U.S. quarts (9.46 liters).
The radiator grill area must be kept free from debris for good cooling. Use an air
or water pressure nozzle and blow from the outside to remove foreign material.
Remove the oil cooler if necessary to remove debris deposits between the engine
radiator and oil cooler (Fig. 1–17).
B–01808
Fig. 1–16 Checking Radiator Level
Use safety goggles when using air or water

under pressure. Do not use cold water to clean
a hot engine. Failure to obey warnings can
cause serious injury.
W–2064–1285

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).
A–02289
Fig. 1–17 Cleaning Engine Radiator
2. Loosen the generator bracket fastening bolt above the generator (Item 2).
3. Move the generator towards or away from the engine to either loosen or
tighten the belt. Make adjustment of belt tension to give 0.375 inch of play Mounting
at the middle point between the pulleys (Item 3). Bolt
4. When belt tension is correct, tighten the adjustment bolt and fastening bolt.
1–10 FLUSHING THE COOLING SYSTEM

Regularly, at least once each year, the complete cooling system must be flushed 0.375”
and filled with clean coolant and conditioner. When flushing the system, back
flushing 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. Install a new gasket Set
when installing the thermostat housing. Screw
A–02287
Fig. 1–18 Adjusting Fan Belt
825 Loader
17 of 176
Revised January 77 –1–7– Service Manual
1–11 FUEL SYSTEM
WRONG
Stop and cool the engine before

adding fuel. NO SMOKING!
Failure to obey warnings can
cause an explosion or fire.
W–2063–0887
The fuel fill pipe is located at the rear of

the Bobcat to the left of the engine (Fig.
1–20, Item 1).
1. Use a clean, approved safety

container to add fuel.
Fig. 1–19 Fuel Fill Warning
X B–03756

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).
B–01794R
Fig. 1–20 Fuel Fill Pipe Location
1–12 FUEL SPECIFICATIONS

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 the fuel tank:
1. Keep the filler cap in place.

Plug
2. Always fuel after machine has been stopped. (Water can increase overnight
in an empty fuel tank).
3. Regularly remove the fuel tank plug (Fig. 1–21), and remove water.
B–01811
B–01812
Fig. 1–21 Fuel Tank Drain
825 Loader
18 of
1–13 TO SERVICE THE FUEL
SYSTEM 3
1
The engine is equipped with two fuel
filters; a filter which holds water and a Secondary
secondary filter (Fig. 1–22). The filter Filter
element (Fig. 1–22, Item 1) must be
replaced every 250 hours of operation.
Clean the water filter (sediment bowl)
(Fig. 1–22, Item 2) at regular intervals
(See SERVICE SCHEDULE).
2
To replace the filter element: Water And

Sediment Trap
B–01790
1. Clean the area around the filter Fig. 1–22 Fuel Filters (Primary And Secondary)
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. 1
4. Lubricate and install a new O–ring.
Loosen
5. Install the new filter element in
position and install the bolt. Do not
over–tighten the bolt.
2
6. After the new filter is installed, the

air must be removed from the fuel
system.
A–02290
Fig. 1–23 Venting Injection Pump
1–14 REMOVE 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). 1
3. Loosen the bolt (Fig. 1–24, Item 1) on the top of the final fuel filter.
Loosen
B–01798R
Fig. 1–24 Fuel Filter Bolt
825 Loader
19 of 176
4. Operate the lever on the fuel lift pump (Fig. 1–25) pushing the fuel and air
through the vent plugs.
NOTE: If the lift pump will not pump fuel, rotate the engine a small amount.
5. When solid flow of fuel flows from the vent plugs (no air bubbles), tighten all
the vent plugs in the following order:
(a) Final fuel filter bolt (Fig. 1–24, Item 1).
(b) Injector pump housing side plug (Fig. 1–23, Item 2).
(c) Injector pump housing top plug (Fig. 1–23, Item 1).
6. Loosen the fittings on the high pressure lines of the injectors (Fig. 1–26).
7. Move the throttle to half open position. Turn the engine with the starter until B–03873
no air bubbles show at the fittings of the injectors. Tighten all the high Fig. 1–25 Fuel Lift Pump
pressure fittings.
8. Tighten the two 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 injector lines.
1–15 ELECTRICAL SYSTEM

MAINTENANCE
1–15.1 Electrical System
The Bobcat is equipped with a 12 volt
generator charging system. Maximum Loosen fittings
B–03948
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 0.375 inch play at the middle
point between pulleys (Fig. 1–18).
4. Check the condition of the wiring to the warning indicators (Alt., Trans–Hot, Sender
Wire
Trans–Fit, Eng–Hot and Eng–Oil). Check the Trans–Hot and Eng–Hot
indicators regularly to see if they are in working condition. The Trans–Hot
sender switch is located at the top of the oil cooler and the Eng–Hot sender
switch is located on the engine head beside the thermostat housing. To
check these warning indicators, turn the ignition switch at the dash panel to
ON, remove the wire from the sender switch and put it against the frame. The
indicator must light when the wire is in contact with frame (Fig. 1–27). The
other warning lights must always light up whenever the ignition switch is
turned on and go out after the engine has started. Warning lights that still
have light while engine is running are an indication of a malfunction in the
system. If this happens, stop the engine immediately and troubleshoot.
A–02288
Fig. 1–27 Grounding Sender Wire
825 Loader
20 of
1–16 HYDRAULIC SYSTEM
1–16.1 Hydraulic/Hydrostatic Transmission Fluid
Use Clark hydraulic/hydrostatic transmission fluid (P/N 6563328). This fluid is
available at Chicago Central Parts. 10W–30 or 10W–40 SAE Motor Oil API Class
SE or SF can also be used. Dipstick
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
building. 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). A–02284
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 Transmission
Fluid).
To check and/or add fluid:
1. Place a machine on a level surface.

2. Lower the lift arms and tilt the
Bob–Tach fully back.
3. Remove the dipstick and read the

fluid level. Hydraulic Oil
Fill Pipe
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 Current Models B–02638
Early Models B–01794
filter (10 Micron) is installed in the return Fig. 1–29 Hydraulic Reservoir Fill
line to the pump. This filters 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.
Hydrostatic
Make replacement of the filters after Transmission
each 250 hours of operation, or sooner, (10 Micron)
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 Suction
replacement of the return line filter (10 (25 Micron)
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 B–01802
replace this filter. (See Final Filter page Fig. 1–30 Hydraulic And Hydrostatic Filters
3–10).
825 Loader
21 of 176
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.) Throw away oil element.
4. Clean the filter housing and check

the seal ring for condition. Make
replacement of the seal ring if it has 25 Micron
defect. Add lubricant to the seal Filter
ring before installing filter.
A–02285
5. Install the new element and turn it Fig. 1–31 Removing Hydraulic Filter
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.
1–18.2 Replacement Of The Return

Line Filter (10 Micron):
2. Thoroughly clean the exterior of the Drain

filter.
3. Use a filter wrench to remove the

10 micron filter element. Throw A–02279
away the old element.
Fig. 1–32 Hydraulic Reservoir Drain Plug
4. Lower the ROPS cab, set the throttle at about 1/2 throttle, set steering
controls in neutral and start the engine.
5. With the engine running, check the filter housing area for any indication of
leaks.
6. Slowly move the steering levers to activate the transmission. Drive forward
and backward at slow intervals. Continue to drive the loader until all
indication of air is out of the system.
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.)
825 Loader
Regularly (depending on humidity and/or
temperature change) lift the rear of the
loader and let stand overnight. Loosen
the drain plug to allow water, if any, to run
out. A large quantity of water in the sump
may cause permanent damage to the
hydraulic and transmission system.
1–20 LEAKS
Regular inspection must be made to find
leaks at tube fittings, hose connections,
lift and tilt cylinders, filters, etc. A leak in
the hydraulic system must not be
permitted. Even a small leak can amount
to a large loss of fluid in a short period of
time. Most leaks are easily repaired.
Sometimes, tightening a fitting or hose
clamp is all that is necessary. Do not over
tighten tube fittings, as this can cause a
greater leak. A tube fitting that still leaks B–01803
after it has been properly tightened must Fig. 1–33 Cleaning The Oil Cooler
be disconnected and checked for foreign
particles or damaged joint. If the seat is
cracked or has deep scratches, the part
must have replacement made.

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).
Use safety goggles when using air or water

under pressure. Do not use cold water to clean
a hot engine. Failure to obey warnings can
cause serious injury.
W–2064–1285
3. Use a thin soft (plastic or wood) rod to help remove material. Also clean the
engine radiator.
A high temperature warning switch is installed at the top of the oil cooler. If the
hydraulic system overheats, the switch closes and lights the Trans–Hot indicator
on the dash panel. Be sure the wire is correctly connected to the switch.
1–22 CARE OF THE HYDROSTATIC TRANSMISSION
Good preventive maintenance practice is an important item in adding to the life
of the transmission. When adding fluid to the reservoir, be sure that the fluid is very
clean. Do not let dirt fall into the reservoir, fill pipe, and be sure to install the filler
cap. Use only correct oil when filling the reservoir. (See Transmission Fluid, page
1–11).
825 Loader
23 of 176
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). 0.250” Max.
3. Start the engine and run at 1/2

throttle.
4. Operate controls a few times for

several minutes until they operate
smoothly.
C–01759
Fig. 1–34 Checking Drive Chain Freeplay
1–22.2 Cold Weather Start–Up
Allow additional warm–up time during low temperature conditions. Run the engine
at low RPM and activate the cylinders and control valves for several minutes until
the oil is warm to the touch.

1–23 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. 1–34). If there
is more than 0.250 inch of free play measured at the tire tread, the chain
needs adjustment. Check the free play at each side of the loader. See
Section 4 for drive chain adjustment.
1–24 TIRES
Several types of tires are available to fit the use of the Bobcat. It is very important
that the Bobcat be equipped with the correct tires for its use. The following basic
tires are recommended for use indicated:
8:25 x 15 – 6 ply, standard . . . . . . . . . . Standard, regular construction loading,
excavation, quarry, mine
12:00 x 16.5 – 6 ply, flotation, . . . . . . . . . . . Flotation and traction, mud, swamp,
coal mine, bar lug tread sand
825 Loader
24 of 17677
Revised January –1–14– Service Manual
NOTE: Do not use ballast in tires.
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–01250
Fig. 1–35 Tire Rotation
1–27 TIRE REPLACEMENT
The tires on the Bobcat Loader are
specially designed for it. Exchanging
them with any other tire tread, or size, CODE FOR SYMBOLS

can result in poor loader performance.
When exchanging a damaged or worn GREASE AIR FILTER ENGINE OIL
tire, it is important that the replacement FILTER
tire be of the same size as the tire still on
the Bobcat. Two different size tires on FUEL FILL HYDRAULIC
the same side of the machine will cause COOLANT
OIL FILTER
drive chain and tire wear, and loss of
power. If two new tires are used for HYDRAULIC OIL
replacement of two worn ones, put both ENGINE OIL FUEL FILTER
RESERVOIR
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
engine throttle pivot. Use medium
engine oil for this purpose. Also remove (Early)
the seat and put grease on the seat rails
to keep them working smoothly. (Current)
1–29 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 will result
in wear of the stud holes and can cause
loss of wheel. Correct wheel nut torque
is 120 ft.–lbs. (163 Nm). B–01813
C–01756
Fig. 1–36 Lubrication Chart
825 Loader
25 of 176
1–30 BOB–TACH
825ServiceManual#6549899–PreventiveMaintenanceSectionPages5–16
Unlocked
Check the Bob–Tach locking lever
and wedges for wear or damage. The
lever springs must compress enough
to hold the levers in over–centered
(lock) position when the levers are
pushed down (Fig. 1–37, 1–38).
Spring tension adjustment is Locked
possible. Check the wedges for
condition and move locking levers to
see that the wedges move far enough
to correctly engage a bucket or
attachment. Bent or broken wedges
must have replacement made.
If new style Bob–Tach is to be
installed on a Bobcat with old style
cylinder, (Serial Number 12000 & Wedges
Below) it will be necessary to cut off
0.625 inch from each end of the rod B–01508
end trunnion (Fig. 1–38a). Fig. 1–37 Bob–Tach (Old Style)
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 lever will go over center into the
lock position (Fig. 1–39).
NOTE: If the brake lever hits the

left steering lever install a
new left hand steering
lever. (See Bobcat
Technical Information
Bulletin Number 135), (See
3–5 Steering Control
Linkage) for removal.
D–01246
Fig. 1–38 Bob–Tach (New Style)
Tighten
Lock
0.625” 0.625”
A–02427 A–02464
Fig.1–38a Cutting Old Style Cylinder Rod Fig.1–39 Park Brake
825 Loader
26 of 176
HYDRAULIC SYSTEM
Paragraph Page
Number Number
CONTROL PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9 2–9
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7 2–6 HYDRAULIC
GEAR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4 2–4 SYSTEM
GEAR PUMP DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5 2–4
HYDRAULIC CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10 2–10
HYDRAULIC CYLINDER REPAIR . . . . . . . . . . . . . . . . . . . . . 2–11 2–10
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 2–1
HYDRAULIC SYSTEM TROUBLESHOOTING . . . . . . . . . . . 2–3 2–2
INSPECT PARTS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . 2–6 2–5
LIFT VALVE SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8 2–8
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12 2–12
TUBELINES, HOSES, FITTINGS . . . . . . . . . . . . . . . . . . . . . . . 2–2 2–1
825 Loader
825 Loader
29 of 176
30 of 176
31 of 176
32 of 176
33 of 176
34 of 176
35 of 176
36 of 176
37 of 176
38 of 176
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 on 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 available in most shops, the
following procedure can be used when tightening flare fittings.
825 Loader
39 of 176
Fitting Size Rotate No. of Hex Flats Mark a Line on Nut
and Adapter Before Torquing
1/2 inch 2
5/8 inch 1–1/2 – 2
3/4 inch 1
7/8 inch 3/4 – 1
1 inch 3/4 – 1 Misalignment of Marks Shows
Amount to Tighten
(See Chart)
1. Tighten the nut hand tight with a wrench until it contacts the seat.
2. Mark a line on the length of the nut and the adapter (Fig. 2–2).
3. Use a wrench to rotate the nut to tighten to the amount shown in the chart.
If the fitting leaks after tightening, disconnect it and inspect the seat area for A–01897
damage. Make replacement of the part if it is damaged. Fig. 2–2 Tightening Flared Fittings
2–2.2 Straight Thread O–Ring Fitting (Elbows, Adapter, 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.
O–Ring
2–2.4 Tubelines And Hoses

Make replacement of tubelines 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 PROBLEM ANALYSIS

PROBLEM
No Hydraulic Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Slow Hydraulic Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A O–Ring
Rough Hydraulic Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B
No Lift Hydraulic Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
No Tilt Hydraulic Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
No Auxiliary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
A–01852
Fig. 2–3 Straight Thread Seal
825 Loader
CHART A
NO OR SLOW HYDRAULICS
Check Check If
Check Check Defect Make Repair
Suction If Pump If Pedal Or
Fluid Level Output Linkage
And Type Side Fittings Is Replacement
(Of Pump) Good Page 2–4 Good Page 2–9 Of Linkage
Found
If Not If Fittings If Output If No Defect

Correct Are Loose Is Low Is Found
Make If Make Repair

Add Fluid Or Replacement Check Seals Defect
Make Make Or
Repair of 25 Micron In Cylinder
Replacement Page 2–11 Replacement
Filter Page Is Of Seals
1–12 Found
If Output If No Defect
Is Still Low Is Found
Check Check If
Pump Release Pressure Make Repair

Output Pressure Or Adjust
Page 2–4 Page 2–6 Is Not As Needed
Correct
If Output If Pressure
Is Still Low Is Correct
If
Make Repair Defect Make Repair
Check Valve Or
Or Assembly
Replacement Is Replacement
Page 2–6 Of Valve
Of Pump Found
CHART B CHART C
ROUGH ACTION OR NO ACTION NO LIFT, NO TILT OR NO AUXILIARY
OF HYDRAULIC CYLINDERS
Check If No If No
Check If Check Defect Check Defect Check
Fluid Level Suction Side Cylinder Seals Linkage Rods Valve Section
And Type Of Pump For Page 2–11 Page 2–9 Page 2–6
Correct Air Leaks Is Is
Found Found
If Not If Defect If Defect If Defect

Correct Is Found Is Found Is Found
Add Or Make Add Or Make Make Repair Make

Replacement Replacement Of Linkage Replacement
Of Fluid Of Seals Rods Of Valve
Section
825 Loader
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. 2–4.)
5. Lower ROPS until steering levers

are centered.
6. Turn the pressure control valve on B–02242

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
WARNING raised position.
W–2304–0298
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 12.5 GPM.
10. If an indication of 12.5 GPM and/or 2100 PSI is not present, check for air
leaks. If, after checking for air leaks, there is still not 12.5 GPM at 2100 PSI,
remove and make pump repairs.
2–4.2 Removal B–02166

Fig. 2–5 Removing Gear Pump
2. Remove transmission case cover.
3. Remove hydraulic lines and 6

protect them with poly bags. 1
2 4
4. Remove two fastening bolts and 8 11 3
remove pump assembly (See Fig. 12 13 9 10
2–5). Do not force anything 14
between the two surfaces. Use a
soft hammer to loosen the pump,
if necessary. 7
16 5
Reverse the above procedure to install.
Tighten the fastening bolts to 33 ft–lbs. C–01090
torque. Fig. 2–6 Gear Pump Breakdown
825 Loader
42 of
2–5 DISASSEMBLY OF GEAR PUMP (Fig. 2–6)
1. Clean outside of pump thoroughly.
2. Clamp pump in vise, shaft down.
3. Remove four tie bolts (Item 1).
4. Remove two tie bolts (Item 2).
5. Use a sharp tool to mark across front place, body and back plate. This will
aid in correct assembly.
6. Remove the pump from the vise. Hold the pump in both hands and hit the
shaft against a wooden block to separate the front plate (Item 3) from the
back plate (Item 4). The body (Item 5) will hold to either the front plate or the
back plate.
7. To separate the body from the section it is with, put drive gear (Item 6) in the
bearing and hit the end with a plastic hammer.
8. Remove the O–ring (Item 7) from the back plate assembly.
9. Remove the diaphragm (Item 8) from the front plate by using a sharp tool.
10. Remove the springs (Item 9), two each, and steel balls (Item 10), two each,
from the front plate.
NOTE: Some pumps only have one spring (Item 9) and ball (Item 10). Make
sure they are installed in the correct location (pressure side of the
gears).

11. Lift the back–up gasket (Item 11) and protector gasket (Item 12) from the
front plate.
12. Lift the diaphragm seal (Item 13) from the front plate.
13. Remove the shaft seal (Item 14) from the front plate.
2–6 TO INSPECT PARTS FOR WEAR
2–6.1 General
1. Clean and dry all parts.
2. Use an emery cloth to remove scratches from all parts.
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 then 0.685 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.924
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 180 degrees apart. This puts the oil grooves
closest to the respective dowel pin holes.
2. If I.D. of bearings in front plate or back plate are more than 0.691 inch, the
front or back plate needs replacement. (Bearings are not available as
separate items.)
825 Loader
43 of 176
3. Bearings in front plate must be flush with lands in groove pattern.
4. Check for wear on face of back plate – if wear is more than 0.0015 inch, back
plate needs replacement.
2–6.3 Body
1. Check inside gear pockets for wear.
2. Body needs replacement if I.D. of gear pocket is more than 1.719 inch.
2–6.4 Assembly Of Gear Pump (Fig. 2–6)

1. The diaphragm, back–up gasket, diaphragm seal, protector gasket, O–ring
and shaft seal must have replacement made as new parts.
2. Put diaphragm 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) 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 O–ring (Item 7) in groove in back plate (Item 4).
11. Slide back plate over gear shafts until dowel pins are engaged.
12. Install bolts (Items 1 & 2) and tighten evenly to 23 ft.–lbs. torque.
13. Install shaft seal over drive gear shaft taking care not to cut rubber sealing
lip. (Put oil on seal before assembly.)
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.
2. 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. Hydraulic
Tester
5. Increase engine to full RPM. C–01823
Fig. 2–7 Testing Relief Pressure
825 Loader
6. Activate auxiliary pedal so
pressure goes over relief
setting. 4
3
7. Correct pressure is 2100–2150
PSI.
8. If pressure is not correct, make 1

replacement of valve.
2–7.2 Internal Leaks

To find an internal leak in valve
assembly, first check condition of
cylinders. If lift arms or bucket still 4
drift after cylinders are found to be
good, then check the control valve for
the following: 6
1. Spool not centering in the valve
body when pedal is released.
Check for broken centering
spring by removing the bonnet
at the back of the valve section.
Center the spool to neutral and 5
make pedal adjustment to fit the 2
spool position.

2. Poppet in the valve section
(Fig. 2–8, Item 1) leaking.
Remove the check plug on the
top of the valve section, also
remove and clean the poppet B–01539
parts.
Fig. 2–8 Lift Control Valve
3. Leak in the valve because of
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.
3. Disconnect control rods from
valve bank.
4. Disconnect tubelines at valve
bank and protect with poly
bags.
5. Remove bolts which hold valve Valve Bank
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.
2. Mark each valve section (1, 2,
3, 4 etc.) for identification. Bolts
B–02240
Fig. 2–9 Removing Valve Bank
825 Loader
3. Remove the nuts (1) from the three
thru bolts which hold the valve
sections together (Fig. 2–10). Cover Aux. Aux. Lift Tilt Inlet
4. Remove each section by sliding it

off the thru bolts. Hit lightly with a
soft hammer if necessary, to loosen
the seal between sections. Throw
away the used O–rings. Clean the
O–ring counterbores and the
machined surface of each section.
5. If a valve section is to be
disassembled, place it in a vise. Be B–01511R
careful not to clamp the machine
surface in the vise jaws. Fig. 2–10 Hydraulic Control Valve Breakdown
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 (Fig. 28, Item 2).
NOTE: When disassembling the lift valve section, remove the snap ring
from the float detent rod at the end of the bonnet before removing
the bonnet. The detent rod must be with the spool assembly or the
four steel balls will fall out of their holes. A restrictor is also located
in the B (rear) tubeline opening, on top of the valve section (Fig. 2–8,

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).
10. 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 Spool
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.
2. Make lubrication of parts with oil and install in the valve body section.
B–02094
Fig. 2–11 Removing Detent
825 Loader
NOTE: Install the rear O–ring seals
and seal retainer on the spool
before installing spool in the Valve Section
valve section. Push the spool
into the rear of the valve
section (Fig. 2–12). Retaining Washer
3. Make lubrication of new O–rings O–Ring Seal

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.)
Back–Up Seal
5. Install the seal plate at the front end
of the valve section.
A–01799
6. Install the load check valve Fig. 2–12 Installing Valve Spool With Seals
poppets, springs and hex plugs.
Use new O–rings, lubrication made
with oil, on the plugs.
7. Install new O–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. 2–13).
9. After all the control valve sections have been assembled, install the thru bolts
and the nuts. Tighten the nuts to 20 ft.–lbs. torque. Do not overtighten.
10. With the control valve clamped in a vise, check the operation of each spool
for free movement and centering.
If any spool restriction is noted and spool does not displace properly, try rotating
the spool 180°. If this does not help, loosen the three thru bolt nuts and check spool
movement. If spool movement is now normal, use care in tightening the thru bolt
nuts. To install the valve back into the machine, reverse the removal procedure.
A–01924
Fig. 2–13 Reassembly Of Valve
2–9 CONTROL PEDALS

2–9.1 Adjustment STEP 3
Adjust Yoke
Adjustment of pedals so that the spool
has full movement and centers correctly.
To make adjustment, turn the yoke at the
pedal end (Fig. 2–14).
STEP 4
NOTE: Make adjustment to fit
operator.
STEP 1
Remove
Pin
0.250”
STEP 2
Loosen Nut
D–01170 A–02385
Fig. 2–14 Adjustment Of Control Pedals
825 Loader
2.9.2 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).

Side Plate
6. Remove pedal assembly.
B–01817
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 correctly.
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 than four drops per minute must come out of opening.
2–10.2 Removal Of Lift Cylinder (Fig. 2–16) B–02652
1. Lift the lift arms and hold with a Fig. 2–15 Brake Lever Removal
support or hoist.
2. Disconnect hydraulic hoses and
protect ends with plastic bags. Pin
2
3. Remove pivot pins. 1
4. Remove cylinder.
To install, reverse removal procedure.
3
2–10.3 Removal Of Tilt Cylinder (Fig.
2–17)
1. Tilt Bob–Tach forward to the floor.
2. Shut off engine and activate lift and B–02270

Lift Cylinder B–02241
tilt pedal to release hydraulic
pressure. Fig. 2–15.2 Foot Pedal Spacer Fig. 2–16 Lift Cylinder Removal
3. Disconnect hydraulic hoses and 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 cylinder 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 Lift Cylinder
can cause damage to cylinder head seals. Carefully remove scratches on B–02239
a cylinder shaft with a fine carborundum stone (Fig. 2–18). Fig. 2–17 Tilt Cylinder Removal
825 Loader
48 of 176
Revised March 1978 –2–10– Service Manual
2. Pin holes at either of the cylinder fittings can cause external leakage.
Pinholes can be welded shut by gas or electric arc welding. When welding Stone
the cylinders at the pivot (base) end, the shaft must be extended to prevent
heating and weakening the piston seals. When welding cylinders at the head
(rod) end, the cylinder must be disassembled to prevent damage to the head
seals.
3. A bent cylinder case can cause the piston to be worn flat and result in internal
leakage.
If a cylinder case has been bent and the piston worn flat, make replacement
of the cylinder.
4. Foreign material on the cylinder case can cause damage to the cylinder wall PI–01221B
and result in internal leakage. Use caution when opening hydraulic lines or
making replacement of the filter element. Do not allow dirt to get into the Fig. 2–18 Removing Scratches
system, as it will circulate through the system and cause wear to the
hydraulic pump, control valve and cylinders.
Cylinder
2–11.1 To Disassemble A Hydraulic Lift Or Tilt Cylinder Head
1. Remove the cylinder from the machine (To remove the lift cylinder, remove
both pivot pins first, move the cylinder forward and remove the hydraulic
lines).
2. Use a special spanner wrench to remove the head from the cylinder (Fig.
2–19).

3. Pull the shaft and piston assembly from the cylinder case.
NOTE: If the piston comes loose from the cylinder rod, it can have the Spanner Wrench
A–01896
wrong piston or nut. The piston should be made of aluminum, not
zinc. The nut should be 0.625 inch (16 mm) thick (Fig. 2–19.1) Fig. 2–19.1 Locking Nuts
0.625” (16 mm)

2–11.2 To Replace The Cylinder Seals
1. File or grind a bevel on the shoulder at the piston end of the cylinder shaft,
if it does not have one (Fig. 2–20). This will allow the seals to be installed over
the shoulder without damaging them. Remove all scratches from the shaft
(Fig. 2–18). Do not use a power grinder or file for removing scratches.
2. Put the Teflon piston seal in warm oil or water for several minutes before
installing it. This will make it softer and easier to install.
A–02425
Fig. 2–19.1 Locking Nuts
2–11.3 To Assemble The Hydraulic Cylinder
1. Install the cylinder head seals and

put the cylinder head carefully
onto the cylinder shaft (Fig. 2–21). O–Ring Seal
Rod Seal
2. Install the spacer on the shaft (lift File Inside
cylinder only).
3. Install the piston seals and put the

piston onto the end of the cylinder
shaft.
Back–Up
4. Install the piston locking nut and Seal Wiper Seal
tighten to 150 – 160 ft.–lbs. (203 –
217 Nm) torque. PI–01221A A–01898
Fig. 2–20 Beveling The Shoulder Fig. 2–21 Installing Cylinder Head
825 Loader
49 of 176
2–12 OIL COOLER
825ServiceManual#6549899–HydraulicSystemSection
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 By–Pass Valve

cooler and protect open ends
with plastic bags.
2. Remove wire to temperature

sending unit.
3. Remove fastening bolts and lift

B–01794R
oil cooler out.
Fig. 2–22 By–Pass Valve Location
To install, reverse procedure for
removal.

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.
2. Remove valve (Fig. 2–23, Item

1).
D–01168
To install as shown in figure 2–22 & Fig. 2–23 Removal Of By–Pass Valve
2–23.
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.)
825 Loader
50 of
HYDROSTATIC SYSTEM
Paragraph Page
Number Number
ADJUSTMENT OF SPEED RANGE LINKAGE . . . . . . . . . . . 3–4 3–6
CHECKING HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . 3–6 3–8
CHECKING RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7 3–9
CONTROL LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3 3–6
HYDROSTATIC DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 3–1 3–1
HYDROSTATIC MOTOR INSTALLATION . . . . . . . . . . . . . . . 3–13 3–12
HYDROSTATIC MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . 3–12 3–12 HYDROSTATIC
HYDROSTATIC PUMP INSTALLATION . . . . . . . . . . . . . . . . 3–11 3–11 SYSTEM
HYDROSTATIC PUMP & MOTOR ASSEMBLY . . . . . . . . . . 3–16 3–14
HYDROSTATIC PUMP & MOTOR DISASSEMBLY . . . . . . 3–14 3–13
HYDROSTATIC PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . 3–10 3–11
HYDROSTATIC TRANSMISSION
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 3–1
INSPECT PARTS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . 3–15 3–14
STARTING PROCEDURE, AFTER REPAIR . . . . . . . . . . . . 3–17 3–15
STEERING CONTROL LINKAGE . . . . . . . . . . . . . . . . . . . . . . 3–5 3–7
TEMPERATURE & PRESSURE SWITCHES . . . . . . . . . . . . . 3–9 3–10
10 MICRON FINAL FILTER REPLACEMENT . . . . . . . . . . . . 3–8 3–10
825 Loader
825 Loader
3–1 HYDROSTATIC DRIVE SYSTEM
3–1.1 Description
The hydrostatic system is made up of a charge pump (geroter), two hydrostatic
pumps and two hydrostatic motors. See the colored Flow Charts PI–02512,
PI–02513 and System Operation description for the full operation the Hydrostatic
System.
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
825 Loader
CHART A– NO DRIVE
SYSTEM PRE–CHECK
Turn On If Check If Light
Check If Ignition & Light Start Engine TransFilt Light Will Operate
Oil Check & Run At (Max. 5 Sec. Lift Arm
Level Correct TransFilt Is 1/2 Throttle For Light To Not Control
Light On Go Out) Go Out
If Level If Light If Light

Is Low Is Off Goes Out If Lift
Arms
Operate
Correctly
Make
Repair Go To
Add Oil On Light Chart C
System
If Machine If Lift Operate Lift Charge

Hydraulic If Lift
Go To Now Operates Arms Arms To Full Arms
Chart C Return To Height & Over System & Repair
Air Leaks Page Will Not
Service Operate Relief Valve Operate
Correctly 3–15

If Lift Arms Will
Not Operate
Go To
Chart B
CHART B – NO DRIVE
GEAR PUMP CHECK
Check If
Output Of Gal/Min Go To
Implement Chart C
Pump Is
Page 2–4 Correct
If Gal/Min
Is Low
Make If
Replacement Of Gal/Min Check
25 Micron Filter Pump If Pressure
& Recheck Pressure Is Low
Is
Gal/Min Correct
If Gal/Min If Pressure
Is Low Is Correct
Make If System If System

Replacement Operates Does Not Go To
Of Implement Normally Chart C
Pump Return To Operate
Service Correctly
825 Loader
54 of 176
Revised March 1976 –3–2– Service Manual
CHART C
NO DRIVE
Check If If Inspect If
Pressure Check Stroked Pressure Defect
Charge Charge Pressure Components Install New
Pressure Page 3–8 & Case Drain Component
Page 3–8 Is Correct Is Low Page 3–14 Is Found
If Pressure If Pressure If No Defect

Is Low Is Correct Is Found
Install If System Inspect If

External Operates Charge Defect Make Repair
10 Micron Correctly Return Relief Spring Of Spring
Filter To Service Page 3–14 Is Found
If No Defect
Is Found
Check Install
Charge Internal
10 Micron

Pressure
Filter
CHART D
DRIVE WITH WARNING LIGHT ON
Check If Check If Check If Change

Charge Pump Pressure 50–60 PSI Pressure 20 PSI Pressure Internal 10
Inlet Pressure Is Low Valve Low Is Still Valve Is Still Micron Filter
Page 3–8 Low Low
If Pressure
Is Correct
If System
Now Operates
If Pressure Correctly If Pressure
Is Correct Return To Is Correct
Service
825 Loader
CHART E
NO DRIVE ON ONE SIDE
If No If
Inspect Defect Check Stroked Pressure Inspect
Control Is Charge Pressure Is Drive
Linkage Found Page 3–8 Correct Chain
If Defect If Pressure If Defect Is

Is Found Is Low Found
Make Check Case If Make Repair

Repair Of Drain Of Both Flow Or Install
Linkage Pump And Is New
Motor Correct Drive Chain
If Flow Is Large In
Motor Or Pump

Install New
Component
CHART F
LOADER PULLS TO ONE SIDE
Inspect Linkage If Check Wheel If Inspect Tire

(Two–Speed Adjustment RPM In High RPM Pressure
And Control Is And Low Is And
Lever) Correct Range Correct 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
825 Loader
CHART G
LOADER OPERATES ONLY ONE DIRECTION – ONE SIDE
Inspect If No Inspect High Inspect Charge

Control Defect Pressure Relief Relief Valves
Linkage Is Valves Page 3–9
Found Page 3–9
If Defect If Defect If Defect

Is Found Is Found Is Found
Make Install Install

Adjustment New New
And/Or Valve Valve
Repair
CHART H
SYSTEM OVERHEATING

If No If No If No
Check Inspect Defect Inspect Defect Check For Leak
Oil Level If Oil Fan Suction
Correct Is Is
And Type Cooler Found Belt Found Air Leak Is
Found
If Low Or If Defect If Defect If Leak

Wrong Type Is Found Is Found Is Found
Make Make
Add Or Make Repair Make
Replacement Repair
Or Of Belt Repair
Of Oil Clean
Check For If No Inspect

Install New If In Cooler
Low Loader Being Defect
Transmission Operated In Is By–Pass
Assembly Range Valve
High Range Found
Page 2–12
If In High If Defect
Range Is Found
Make
Operate In Repair Or
Low Range Install
New Valve
825 Loader
3–3 CONTROL LINKAGE
3–3.1 Adjustment Of Steering
Linkage
1. Lift and block loader so all
wheels are off floor, or pull out
transmission gear box levers
(Fig. 3–10). Lever
2. Tilt ROPS and remove

transmission cover.
3. 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 Gasket

position.
7. Loosen lock nut and turn swivel

linkage rod until eye of swivel is Steering
in alignment with bolt in pump Linkage
arm.
C–01829
8. When alignment is correct,
fasten swivel with bolt and Fig. 3–2 Removing Drive Linkage
tighten lock nut on swivel.
Tighten nut for swivel bolt to 10
ft.–lbs. (14 Nm) torque.
9. Install a new gasket before 3

putting transmission cover on.
3–4 ADJUSTMENT OF SPEED

RANGE LINKAGE
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 2) between high and low
range.
There is no other adjustment of the
speed range linkage.
1 2
If wheel RPM is different between left
and right side of loader, first check for
correct adjustment of the steering
control linkage. (Control lever travel,
equal from vertical (center) position
to low and high ranges.) If wheel
RPM between sides is within 20%, no
adjustment is necessary.
Also check for loose bolts on linkage 6 5
bar and motor control arms. Check 4
for hose or tubelines in wrong
position and stopping movement of
linkage.
C–01754
Fig. 3–3 Adjustment Of Linkage Rod
825 Loader
58 of80
Revised April 176 –3–6– Service Manual
To remove speed–range linkage:
825ServiceManual#6549899–HydrostaticSystemSectionPages1–7
1. Remove the bolt holding the

linkage to the arm on the rear
motor (Fig. 3–4).
Rear
2. Remove the bolts holding the Motor
linkage to the arm of the front
motor and bellcrank (Fig. 3–5).
3. Remove the bolts holding the Linkage

bellcrank and linkage rod (Fig.
3–3, Item 3).
B–01905 Linkage
4. Remove nuts (Fig. 3–3, Items 4
& 5), control arm (Item 6) and Fig. 3–4 Removing Rear Motor Linkage
control lever (Item 2).
C–01826
3–5 STEERING CONTROL Fig. 3–5 Removing Front Motor Linkage

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. Support

Nut
5. Remove the steering levers
(Fig. 3–6).
6. Disconnect linkage.
Steering
7. Loosen the support nuts (Fig. Lever
3–7).
B–02209 B–02207
8. Slide left hand shaft over to Fig. 3–6 Removing Steering Lever Fig. 3–7 Steering Lever Support Nuts
welded bracket.
9. Remove left hand support nut.
10. Remove left hand rod.
11. Remove right hand support nut.
12. Raise left hand end of shaft and

remove assembly from
transmission (Fig. 3–8).
Control Lever
Shaft
B–01906
Fig. 3–8 Removing Control Lever Assembly
825 Loader
59 of 176
100 – 120 ft.–lbs.
(136 – 162 Nm)
25 – 28 ft.–lbs. 50 – 70 ft.–lbs.
(34 – 38 Nm) (68 – 94 Nm)
180 – 200 in.–lbs.

(21 – 23 Nm)
25 – 28 ft.–lbs.
(34 – 38 Nm)

10 – 15 ft.–lbs.
(14 – 20 Nm)
25 – 28 ft.–lbs.
(34 – 38 Nm) D–01357
Fig. 3–8.1 Steering Assembly Bolt And Nut Torque
NOTE: Put LOCTITE sealant on the threads of the bolts for the pintle levers
during assembly.
Use the above procedure in reverse order to install the steering linkage. See figure
3–8.1 for the correct torque.
NOTE: All 825 Bobcat loaders between serial number B–1000 and C–1000
have a spacer inside the steering levers (Fig. 3–8.2, Item 1). The
spacers must be in place or the levers will not operate correctly.
3–6 CHECKING HYDROSTATIC SYSTEM

3–6.1 Test Kit
1. 0 – 300 PSI gauge.
2. 200 PSI pressure gauge
825 Loader
60 of 176
825ServiceManual#6549899–HydrostaticSystemSectionPage7a–7b
825 Loader
3–6.2 Charge Pressure Check
Steering Levers In Neutral Position:
1. Remove the sending unit from the Pressure Gauge

1
right rear of the tank and install
0–300 PSI pressure gauge (Fig.
3–9).
The transmission must not be

disengaged with the loader
parked on a slope.
W–2305–0298
B–02267 C–01821
Fig. 3–8.2 Steering Lever Spacer Fig. 3–9 Checking Charge Pressure
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). Pull Out

2. Install a gauge with approximately 4 foot hose (101,6 mm) in location shown
in Figure 3–11, Item 1 ).
3. Push transmission levers in (Fig. 3–10).
4. Lower the ROPS. Position the hose so it will not be damaged (pinched) when
lowering the ROPS.
5. Fasten the gauge to the side of the ROPS so it can be seen when operating
the Bobcat.
6. Install the ROPS bolts and tighten.
7. Operate the machine under load at full RPM and check pressure on the
gauge. 100 PSI (689 kPa) is the minimum acceptable reading. B–02949R
Fig. 3–10 Trans. Disengagement Lever
3–6.3 Charge Pump Inlet Pressure
Steering Levers in Neutral Position:
1. Install 200 PSI gauge at the left rear

of the frame (Fig. 3–11, Item 2). 2
2. Pull out the transmission gear box 1

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
PSI (28 kPa).
B–02167
Fig. 3–11 Checking Inlet Pressure To Charge Pump
825 Loader
62 of
3–7 CHECKING RELIEF VALVES
Cup
3–7.1 Charge Relief Valve
NOTE: See Bobcat Technical Information Bulletin #162 for more
information on the Charge Relief Valve.
Spring
To check condition of charge relief valve it must be removed from unit and visual
inspection made as follows:
1. Remove inlet line to charge pump.

Spacer
2. Use a screwdriver and compress spring. Snap Ring
B–02173
3. Use snap ring pliers to remove snap ring.
Fig. 3–12 Removing 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 Hydrostatic
valve from unit. Transmission
(10 Micron) Charge Inlet
2. Connect compressed air line to Relief Valve
each end of valve to see if air goes
through.
Suction
3. Air must go only one way. Filter Relief (25 Micron)
Valve
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. B–01802
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). Lift Arm
Stop
3. Clean transmission housing area. Relief

Valve
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 Spring
valve with defect. Hex Plug
C–01961 B–02175
Fig. 3–14 Lift Arm Cylinder Stop Fig. 3–15 Removing Relief Valve
825 Loader
63 of 176
3–8 10 MICRON FINAL FILTER
ELEMENT REPLACEMENT (Fig.
3–16)
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. 10 Micron Filter
7. Disconnect linkage rods and

remove pedal assembly.

NOTE: CLEAN LOADER FLOOR C–01878
AREA THOROUGHLY Fig. 3–16 10 Micron Final Filter Location
(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).
The charge pressure switch (1) is set

to activate when pressure goes
below 65 PSI.
C–01828
Fig. 3–17 Removing Pump Suction Hose
825 Loader
The charge pump inlet switch (2) is set
to activate when pressure goes below
4 PSI.
The temperature inlet switch is set to
activate when temperature goes
above 210°F (99°C).
3–10 REMOVAL OF HYDROSTATIC

PUMP ASSEMBLY
1. Tilt or remove ROPS (See

Section 5–2).

cylinder stops (Fig. 3–14).
3. Steam clean the loader

thoroughly.
4. Remove fluid from

transmission and remove the
transmission housing cover.
5. Remove all hoses from fittings

on pump assembly (Figs. 3–17
& 3–18). Protect ends of hoses
with plastic bags. Put caps on
open fittings (Fig. 3–20).
C–01827
6. Disconnect steering linkage Fig. 3–18 Removing Pressure Hose
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).
Steering
Linkage
C–01829
Fig. 3–19 Disconnecting Steering Linkage
825 Loader
65 of 176
3. Connect steering linkage to
pump control arms.
4. Connect hoses.
5. Install new cover and gasket.
3–12 REMOVAL OF
HYDROSTATIC MOTOR
1. Tilt or remove ROPS (See B–02022

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


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 B–01901

motor to reduction gear housing Fig. 3–21 Removing Pump Fastening
(Fig. 3–23). Bolts
9. Remove the motor. Weight is

22 pounds.
Remove
Bolts
Rear
Motor
B–01905
C–01819
Fig. 3–22 Removing Speed–Range
Linkage Fig. 3–23 Hydrostatic Motor
825 Loader
66 of 176
3–13 INSTALLING HYDROSTATIC
MOTOR
1. Install elbows and hoses (right

hand motor) (Fig. 3–23a). Hose
Hose
2. Install motor in reduction housing
and fasten with bolts.
3. Connect 2 speed linkage to control

arm on motor.
3–13.1 New Hydrostatic Pump & C–01752

Motor 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. Check to see
which unit you have 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.
Front
Pump
Motor
Rear
ID. No. Pump ID. No.
B–02670
Fig. 3–23b Checking Hydrostatic Units
825 Loader
67 of 176
825ServiceManual#6549899–HydrostaticSystemSectionPages12a–12b
825 Loader
3–14 HYDROSTATIC PUMP OR
MOTOR DISASSEMBLY (Fig. 3–24)
The inner parts of hydrostatic pumps
and motors are similar. The following
procedure for pump disassembly can be 23
used for disassembly and assembly of 22
22A*
motor. (Do not do the steps which belong 21
to pump disassembly.) 18 19 20
To disassemble the pump, begin by: 14
12 24 25
1. Remove pump assembly from the 10
transmission housing. Put plugs in 13
all fluid openings to keep out dirt. 11 10
12 38 48
2. Separate pump from the 39 14
7 45 50
assembly. 49
5 11
3 8 9 15
To disassemble motor, begin by: 1 35 44 41
33 40
1. Remove the motor from the 4
transmission housing. 6 34 50
4
2 33 43
2. Remove the back plate from the
motor.
34
Continue to disassemble the pump or

motor by: 32
30
3. Clamp the end of the drive shaft in * In Motor Only
a protected jaw vise with the body * See The Parts Microfiche For The Correct Kit P/N
of the pump up and remove the four ** Some Pumps Do Not Use This Bearing (See BTIB #162) C–01958
bolts (Fig. 3–24, Items 48 and 50) Fig. 3–24 Hydrostatic Pump Breakdown
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 15), the two O–rings (Item 12), the one inner race (Item 11) and the
two bearings (Item 10). The camplate can now be pushed to one side and
removed. The two camplate pivot bearings are a loose fit into the housing.
Revised Feb. 82 825 Loader

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.
4. Inspect the needle bearing (Item 49) inside the charge pump adaptor housing, if the needles are free of loose play
and are in the bearing cage there is no need to make replacement of the bearing. (Later Model pumps do not use
this bearing, See BTIB #162).
5. Inspect the check ball assembly (Item 38). Make sure the ball seat is in good condition and the ball is free to move.
6. Inspect the flat surfaces of the back plate (Item 32), the finish on the gerotor side must show no damaged surface.
The finish on the piston block side must be smooth and free of grooves or metal deposit. The back plate will need
replacement if it shows any wear above. The cam stop must be tight in the back plate.
7. The pistons (Item 20) must move freely in the piston block bore. If they are tight in the bore, inspect the bore for
damage.
8. Inspect the outside diameter of the pistons for finish condition. They must not show wear or deep scratches. The
shoes must fit well on the ball end of the pistons with no more than 0.003 inch (0,076 mm) end play. The flat surfaces
of the shoes must be flat, smooth and show no sign of loose metal or metal deposit. The minimum thickness of the
shoe can not be less than 0.148 inch (3,759 mm). Do not machine the piston shoes.
9. Inspect the spider (Item 21). It must be flat, no cracks and no signs of wear in the pivot area.

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.
3–16 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) on the jaws of the vise, then put the drive shaft of the front pump in the vise
with the drive shaft down.
(b) Install the adapter plate and the four bolts. Tighten the four bolts with your hand only.
(c) Install the connector (for the drive shaft), then install the rear pump and fasten with two bolts.
(d) Tighten the four bolts to 27–31 ft.–lbs. (37–42 Nm) torque.
(e) Tighten the two bolts to 90–100 ft.–lbs. (122–136 Nm) torque.
3. Install a new O–ring (Item 18) on the camplate trunnion. Put camplate into housing (Item 9). Put the needle bearings
(Item 10) and the bearing inner races (Item 11) over the shaft and slide into the housing. The chamfered inside
diameter of the race must be inward.
4. Install new O–rings (Item 12) around the outside diameter of the cam pivot bearings. Install sleeve cover (Item 13)
and fasten with snap ring (Item 14).
5. Install trunnion cover (Item 15) and fasten with snap ring (Item 14).
6. Install snap ring (Item 4) on shaft (Item 7). Install the thrust washer (Item 5), thrust bearing (Item 6) and second thrust
washer (Item 5). Fasten with second snap ring (Item 4).
825 Loader
70 of 82
7. Install shaft in housing and install washer (3), shaft seal (2) and hold with
snap ring (1).
8. Clamp this assembly in a vise with the open end of the housing up.
9. Compress the pin keep (24) and install the spline. Install the three pins (25)
with the head to the inside of the block. Install the wave washer (Fig. 3–24.1).
Install pins in the special grooves of the piston block spline.
10. Install the pivot (22), spider (21) and the piston assemblies (20) in the piston
block. Install this assembly in the housing assembly, the piston shoes must
be in contact with the camplate. Be sure all the parts are in their correct
position.
B–02648
11. Install and tighten the back plate to give a preload to the wave washer. Fig. 3–24.1 Install Wave Washer (Motor)
Remove the back plate (motor only).
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.

Nut
16. Install the outer geroter gear (41) over the inner geroter gear (40). Use oil
to lubricate the outer gear.
B–02949R
NOTE: On the new adaptor plate (Item 43) the bearing has been removed. Fig. 3–25 Gearbox Lever
When installing this type of adaptor plate (Item 43) use the following
procedure for correct alignment.
(a) 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.–lbs. (149–156 Nm) torque.
(d) The four bolts in the adaptor plate can now be tightened to 27–31
ft.–lbs. (37–42 Nm) torque. This procedure will insure the correct
alignment between the two pump assemblies.
17. Install a new O–ring (34) on the relief valve assemblies (35) and install seats
(33) and relief valves in the back plate (32).
3–17 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.
825 Loader
71 of 176
3. Connect the pressure line to the
implement pump.
Temperature
Sender
To clean and charge the system, use the
following procedure:
1. Put the gearboxes in neutral
position by removing the nut and
pulling out on the gearbox levers
(Fig. 3–25).
The transmission must not be

disengaged with the loader
parked on a slope. B–01794
W–2305–0298
Fig. 3–26 Oil Cooler Temperature Sender
2. Tilt the ROPS fully forward.
3. Remove the temperature sender from the oil cooler (Fig. 3–26) and install
a 1–100 PSI (0–700 kPa) gauge.

4. Remove the outside 10 micron filter (Fig. 3–27, Item 1) and install a 3 micron
filter (P/N 6511278) in its place.
5. Loosen and disconnect the tubeline (Item 2) from the 25 micron filter. Turn
the tubeline away from the filter. Put a cap (Item 3) on the filter fitting where
the tubeline was removed. Connect a hose (Item 4) from the tubeline to the
reservoir filler tube.
6. Remove the hydraulic pressure
sender from the right side of the 5
loader. Install a 0–200 PSI (0–400
kPa) gauge at this location (Item 5).
7. Lower the ROPS. Start the engine

and run at idle until charge pressure
increases, then run at 2/3 throttle
for 1/2 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
hours. 1
9. Read the gauge at the right side of 4
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 3
removed from service. 2
B–02107
Fig. 3–27 Cleaning And Charging System
825 Loader
72 of
FINAL DRIVE SYSTEM
Paragraph Page
Number Number
AXLE BEARING & SEAL REPLACEMENT . . . . . . . . . . . . . . 4–8 4–6
AXLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7 4–5
DRIVE CHAIN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 4–6 4–4
DRIVE CHAIN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5 4–4
FINAL DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 4–1
REDUCTION HOUSING ASSEMBLY . . . . . . . . . . . . . . . . . . . 4–4 4–2
REDUCTION HOUSING DISASSEMBLY . . . . . . . . . . . . . . . . 4–3 4–1
REDUCTION HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . 4–2 4–1
MECHANICAL
TRANSMISSION
825 Loader
825 Loader
4–1 FINAL DRIVE SYSTEM Front Of Loader
Final Drive
4–1.1 Description (Fig. 4–1) Reduction Chain Axle (Front)
Gearcase
The final drive system is made up of
a 3–step reduction gearcase, a 100
H.E. final drive chain, axles and idler
assemblies.
4–2 REMOVAL OF REDUCTION
HOUSING
1. Tilt or remove the ROPS
enclosure (See Section 5). Idler Assembly
Clean the transmission area
thoroughly.
Axle (Rear)
2. Lift the lift arms and install the
3. Remove the fluid from the C–01842
reservoir.
Fig. 4–1 Final Drive Chain System
4. Remove the transmission
covers, hydrostatic pump
assembly and motor (See
Section 3) and the final drive
chain. Remove the lever for
engaging the drive gears (Fig.

4–3). Lift Arm
Stop
5. Connect the hoist to the
reduction housing. Remove The transmission must not be
three bolts holding the disengaged with the loader
reduction housing to the parked on a slope.
transmission housing (Fig. W–2305–0298
4–4).
NOTE: The bolts on the reduction
housing must be Gear
tightened to 220–230 Lever
ft.–lbs. (298–312 Nm)
torque when installing the
housing (Fig. 4–4).
6. Use the hoist to remove the
reduction housing from the C–01961
transmission housing (Fig.
4–5). Weight of reduction Fig. 4–2 Lift Arm Cylinder Stop
housing is 120 lbs.
4–3 DISASSEMBLY OF
REDUCTION HOUSING (Fig. 4–6) B–02949R
4–3.1 Removal Of The Intermediate Fig. 4–3 Drive Gear Lever

Gear (6)
1. Remove the bolts which hold

the detent part (1) to the
reduction housing. 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 Reduction
the shaft at this time. Housing
Bolts
4. Remove the thrust washer and
small steel ball (2).
C–01820 B–02143
Fig. 4–4 Removing Gearcase Bolts Fig. 4–5 Removing Reduction Housing
825 Loader
75 of 176
5. Remove the shaft from the housing.
6. Remove the gear (6).

20 14 19
15
16
4–3.2 Removal Of Input Drive Gear (7)
1. Remove the snap ring from the end

of the shaft (8) and snap ring 17 18
holding ball bearing (13).
1
2. Remove the gear and shaft (7) with 2
bearing (13). 3 6
3. Remove the snap ring (10) holding

needle bearing (11) and remove the
needle bearing. 4
12 8
13 7
10
4–3.3 Removal Of Output Gear (14) 11 C–01640
Fig. 4–6 Assembly Of Reduction Housing
1. Remove the snap ring (15).
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. 4–6)
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).
Snap Ring
4–4.2 Installing Input Shaft And Gear
1. Install the needle bearing (1) and snap rings (10).
C–01822
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 Spring Ball
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.
B–02176
2. Lift the lift arms and install cylinder stops (Fig. 4–2).
Fig. 4–8 Detent, Ball And Spring
825 Loader
76 of 17677
Revised January –4–2– Service Manual
3. Tilt or remove ROPS enclosure
(See Section 5–2).
4. Clean area thoroughly.
5. Remove foot pedal assembly Idler Fastening
(See Section 2). Nuts
6. Remove the floor plate.
7. Loosen idler fastening bolts and
turn the adjustment bolt (Fig.
4–9).
8. Turn the large bolt and tighten
the idler bracket until no
freeplay is present at the wheel
on the tightest place on the
sprocket. Check at several
places on the circumference of
the sprocket to prevent over Adjustment
tightening (Fig. 4–10). Tighten Bolt
the drive chain when freeplay at
the wheel reaches 0.500 inch
maximum.
9. Tighten the idler fastening
bolts.
10. Install a new gasket under the
floor plate.

11. Reverse Steps 1–7.
4–4.5 Drive Chain Adjustment B–01773

(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.–lbs. (55–75 Nm)
torque. Check at several
locations on the circumference
of the sprocket to prevent
over–tightening (Fig. 4–10b).
NOTE: Tighten the drive chain

when freeplay at the wheel B–02650
reaches 0.500 inch B–02653
Fig. 4–10a Adjusting Chain Tension
maximum. Fig. 4–10 Loosening Bolts (External)
4. Tighten idler fastening bolts to
230 ft.–lbs. (312 Nm) torque.
4–4.6 Drive Chain Idler Removal
(Internal Adjustment Type)
2. Remove the ROPS enclosure.
4. Remove the transmission
cover.
5. Remove the pedal assembly
and floor cover.
C–01817
Fig. 4–10b Checking Chain Tension
825 Loader
77 of 176
6. Remove the 10 micron (internal) filter assembly.
7. Separate the chain and remove links until end clears idler assembly.
8. Loosen the reduction gear housing fastening bolts and move the gear
housing away from the side wall of the transmission housing.
9. Remove the two fastening nuts on the idler assembly (Fig. 4–11).
10. Remove the idler assembly. Fastening

Nuts
11. Install a new gasket under the floor plate.
B–01577
12. Reverse above steps to install.
Fig. 4–11 Idler Assembly (Internal)
4–4.7 To Disassemble The Idler Gear (Internal)
1. Remove the two bolts (Fig. 4–12).
2. Separate components (Fig. 4–13).
NOTE: Spacers and bearings are a matched set. Replace as a unit.

C–01818
Fig. 4–12 Remove Adjustor (External)
4–4.8 Drive Chain Idler Removal (External Adjustment Type) Spacer

Sprocket
1. Lift the lift arms and install the cylinder stops (Fig. 4–2).
2. Tilt the ROPS enclosure.
3. Clean area thoroughly. Bearing

4. Remove the transmission cover.
5. Remove the pedal assembly and floor cover.

C–01831
6. Loosen the idler bolt (Fig. 4–10.1, Ref. 1).
Fig. 4–13 SeparatingComponents
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.

B–02649
Fig. 4–13.1 Remove Adjustor (External)
825 Loader
78 of
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.
thoroughly.
5. Remove the front transmission
cover.
6. Remove pedal assembly and
floor plate.
7. Loosen the chain idler bracket
(Fig. 4–9).
8. Remove from sprocket lock bolt B–02949R
and nut.
Fig. 4–14 Drive Gear Lever
9. Put reduction housing gears in
neutral. (Lever on outside of
transmission housing (Fig.
4–14).
10. Rotate drive chain until master
connector link (white) is in

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 B–01908
in loader.
Fig. 4–15 Removing Front Axle Sprocket
4–6 INSTALLING DRIVE CHAIN
1. Fasten wire to chain. Pull wire
around sprockets in same
position chain is to be installed Wire
(Fig. 4–17).
2. Rotate rear wheel while pulling
chain over sprockets.
3. Install front sprocket, nut and
lock bolt (Fig. 4–15).
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 Wire
until there is 0.250 inch
maximum wheel movement.
Rotate wheel several
revolutions to prevent over
tightening as a result of high C–01834 C–01835
spots on sprockets.
Fig. 4–16 Removing Drive Chain Fig. 4–17 Installing Drive Chain
825 Loader
79 of 176
6. When chain tension is correct,
tighten the fastening nuts on tighter.
7. Install chain guide (Fig. 4–18).
Axle
Nut
4–7 REMOVAL OF AXLE
4–7.1 Removal Of Rear Axle
1. Steam clean the loader thoroughly.
2. Remove the ROPS enclosure (See

Section 5–2). B–01902
3. Lift the lift arms and install cylinder Fig. 4–19 Removing Axle Nut
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 B–02208
reservoir.) Fig. 4–18 Installing Chain Guide
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).
B–01904
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.)
12. 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.
15. Tie a wire to one end of chain then

pull on other end of chain while 1.0” to 2.0” Welds
turning axle.
16. When chain is out, disconnect wire

and leave wire in loader to aid in
installation.
17. Remove the sprocket from axle 3/4” Bolts

(Fig. 4–15). (As Required)
18. Remove bolts which hold axle
housing to frame.
19. Remove axle assembly (Fig. 4–20).
4–7.2 Removal Of Front Axle

1.0” to 2.0” Welds
Use the same steps as rear axle except C–02186
omit Step 7, 8, 12, 14, 15 & 16.
Fig. 4–20a Axle Housing Mounting Repair
825 Loader
80 of 176
4–7.3 Installation Of The Axle
Bearing
Reverse the above steps to install axles. Puller
Replace the gasket between the axle
and the transmission case if damaged.
When installing the axle housing, tighten
the upright bolts (Item 3) to 240–280 Axle
ft.–lbs. (326–380 Nm) torque (Fig.
4–21). Tighten fastening bolts (Item 8) to
the frame to 125–140 ft.–lbs. (170–190
Nm) torque.
Bearing
B–02177
Fig. 4–21 Installing Axle Housing
NOTE: If repairs are being done on loaders (S/N 15640 & Below) used in
heavy work conditions or when solid tires are used also weld the
axle housing to the loader main frame (Fig. 4–20a). The welds
shown in Figure 4–20a are all that are needed. Any more than this B–01909
will cause axle housing distortion and removal will not be possible. Fig. 4–22 Removing Outer Axle Bearing
4–8 AXLE BEARING AND SEAL REPLACEMENT
1. Remove the axle assembly (axle
with housing) from the loader.
2. Remove the inner bearing and axle

from the housing.
3. Remove the outer bearing from the Bearing Seal
axle (Fig. 4–22).
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
diameter of 2.7553–2.7559
inch (69,984–69,999 mm). The
later model 825s use a wear
ring with an inside diameter
of 3.117–3.121 inch B–01941 B–01944
(79,17–79,27 mm).
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. Press
Axle
5. Install new races, outer bearing Housing
and seal in housing (Fig. 4–23,
4–24 & 4–25). Axle
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 nut (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. B–01943
Fig. 4–25 Seating Axle Seal Fig. 4–26 Installing Axle In Housing
825 Loader
81 of 176
4–9 INSTALLATION OF AXLE
SPROCKET
825ServiceManual#6549899–FinalDriveSystemSection
3
Install the axle sprockets after the axle 125 – 140 ft.–lbs.
is installed in the loader. (170–190 Nm) Torque
1
To install the axle sprockets:
2
1. Install the axle sprocket (Fig.
4–27, Item 1).
2. Install the axle nut and tighten the

nut until there is no end play to the
axle (Fig. 4–27, Item 2).
3. Hit the end of the axle and check 4

for end play.
4. Tighten the axle nut to the nearest 5

hole on the axle nut that 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.–lbs. (6,2 – 7,9 Nm).

C–01638
4–10 PARK BRAKE REMOVAL
Fig. 4–27 Installation Of Axle Sprocket
1. Lift the lift arms and install cylinder stops (Fig. 4–2).
2. Tilt the ROPS enclosure.
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.
B–02651
6. Remove shoulder screws from the case and lift out brake assembly. Use Fig. 4–28 Removing Brake Assembly
caution not to drop the actuator lever from the bottom of the brake assembly
(Fig. 4–28).
Reverse the above steps to install the brake.
825 Loader
82 of
MAIN FRAME
Paragraph Page
Number Number
BOB–TACH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4 5–1
ELECTRIC MOTOR FOR ROPS . . . . . . . . . . . . . . . . . . . . . . . 5–7 5–2
FUEL TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6 5–2
LIFT ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5 5–2
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 5–1
PIVOT PIN & BUSHING REPLACEMENT . . . . . . . . . . . . . . . 5–3 5–1
ROPS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 5–1
MAIN
FRAME
825 Loader
825 Loader
5 MAIN FRAME
5–1.1 Description (Fig. 5–1) ROPS
The loader main frame is separate from

the upright frame assembly. The main Lift Arms
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 12.0 inches
(30 cm) off the stops and hold with
blocks.
3. Tilt the ROPS forward, disconnect Grill
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 Upright
tilt assembly to the cab (Fig. 5–2 for Frame
electric tilt and Fig. 5–6 for

mechanical tilt).
Main Frame
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.

Fuel Tank
2. Connect the hoist and lift the rear of
the lift arms until it is clear of the
uprights.
E–01086
3. Remove the bushings with a driver Fig. 5–1 Main Frame
tool.
4. Use a bushing driver and install
new bushings.
NOTE: 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.
825 Loader
85 of 176
5–5 LIFT ARMS REMOVAL (Fig.
5–3)
1. Remove the Bob–Tach.
2. Remove the lift cylinder pivot

pins at rod end.
3. Remove the auxiliary and rear
tilt hose lines.
4. Attach overhead hoist and take
up all play.
Tilting
5. Remove the rear thru bolts and Assembly
pivot pins.
6. Remove the lift arm assembly.
D–01172
5–6 FUEL TANK REMOVAL Fig. 5–2 ROPS (Cab) Tilting Mechanism (Electric)
5–6.1 Removing Fuel Tank On

Loader S/N 16999 & Below (Fig.
5–1) Thru Bolt
1. Remove the engine. Bushing

2. Remove or loosen the hoses
and electrical wires.
3. Loosen the upright frame to
axle housing bolts and move Bushings
the frame about 1.0 inch toward
the rear.
4. Remove the fuel tank fastening
bolts.
5. Move the fuel tank toward the
rear and remove from under the Pivot
loader. Pins
5–6.2 Removing Fuel Tank On
Loader S/N 17001 & Above (Fig.
5–4) D–01169
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.
6. Lower the floor jack with the
belly pan to remove the gas
tank.
5–7 ELECTRIC MOTOR FOR

ROPS (Cab Tilt – S/N 19126 &
Below)
The cab tilt mechanism (Fig. 5–2) is
an electric screw jack. Do not service
this unit. If there is a defect, make a
replacement of the complete unit.
E–01086R
Fig. 5–4 Fuel Tank Removal (S/N 17001 & Above)
825 Loader
86 of
5–7.1 Removal Of Tilt Mechanism
1. Tilt the ROPS forward and hold with overhead hoist. 1
2. Remove the electrical wires to the motor.
3. Remove the fastening bolts.
4. Remove the motor.
B–02419
5. Reverse to install. Fig. 5–5 Cab Tilt Motor
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 Vulcanizing)
type compound to close the
opening (Fig. 5–5, Item 1).
5–8 MECHANICAL TILT FOR THE

ROPS (S/N 19127 & Above) D–01534
Fig. 5–6 ROPS Tilt (Mechanical)
The ROPS tilt mechanism (Fig. 5–6) is
a mechanical operated screw jack. The
mechanical jack is operated by turning
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.–lbs. (163 – 203 Nm)
torque.
B–03626
Fig. 5–7 Raising & Lowering the ROPS
825 Loader
87 of 176
825ServiceManual#6549899–MainFrameSection
825 Loader
ELECTRICAL SYSTEM
Paragraph Page
Number Number
ALTERNATOR OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4 6–3
ALTERNATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6 6–4
ELECTRICAL CIRCUITRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 6–1
FAN BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3 6–3
PROBLEM ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2 6–1
REGULATOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5 6–3
STARTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7 6–6

ELECTRICAL
SYSTEM
825 Loader
89 ofFeb.
Revised 176 82 –6––1– Service Manual
825 Loader
91 of 176
92 of 176
93 of 176
94 of 176
95 of 176
96 of 176
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
alternator, (with integral regulator),
warning indicator light (CLT) and
battery.
The starting circuit includes the
starter, solenoid and other parts Battery
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 1
the electrical system are:
1. Battery loses charge.
Alternator
2. Starter will not turn engine.
Starter
Refer to problem analysis charts to
find problem with starting or charging
circuits.
IMPORTANT
E–01108
When working on the Fig.6–1 Electrical System
electrical circuitry, first
remove the ground (negative)
cable from the battery.
I–2155–1297
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.
825 Loader
97 of 176
CHART A
BATTERY LOSES CHARGE
Check
Check Condition Charging
If If Check If Check If Output System
Generator Of Wiring Output
Drive Belt Good Good Good Works
Battery & (Page 6–3) (Page 6–3) Is Correct
Cable Correctly
If Loose If Defect If Defect If Output

Or Defect Is Found Is Found Is Not
Is Found Correct
Remove
Make If No And
Repair As Make Make Check Defect
Repair As Repair As Regulator Inspect
Needed Is Generator
(Page 6–3) Needed Needed (Page 6–4) Found (Page 6–4)
If Defect
Is Found

Remove
Generator
Make
Replacement
of Regulator
(Page 6–4)
CHART B
STARTER WILL NOT TURN ENGINE OVER
Check Wiring,
Check Check Ignition
For If Engine Condition If Check If
Starter Switch &
Engine Of Battery Good Good Circuit
Seizure Is Good & Cables (Page 6–6)
Breaker
If Engine If Defect
Has Defect Is Found
Remove
Correct And Make
Engine Repair As
Problem Needed
(Page 6–6)
825 Loader
Revised January
98 of 176 77 –6–2– Service Manual
6–3 FAN BELT
Mounting
Check the drive belt for correct tension. A loose belt can cause charging problems. Bolt
Correct tension is 0.375 inch (10 mm) play at the midway point (Fig. 6–2).
A new belt must be installed when:
1. It is worn narrow.
0.375”
2. It has cracks or is separating.
3. It has oil on it.
4. There is no more adjustment. Set

Screw
A–02287
To check wiring: Fig. 6–2 Fan Belt Adjustment
1. Turn the ignition switch on. Connect a voltmeter from chassis to: (Fig. 6–3)
No. 1 alternator connection

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

OUTPUT
1. Put the machine on safe blocks.
No. 2
2. Disconnect negative battery Terminal
No. 1
cable. Connect an ammeter in line Terminal
with the Bat terminal of the
generator. Connect the battery Bat
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.
5. If the indication is correct, the

alternator is good. If the indication
is high or low, check the regulator.
6–5 TO CHECK THE REGULATOR

Test Hole
1. Leave the ammeter connected as
in Paragraph 6–4.
B–02113
Fig. 6–3 Alternator
825 Loader
99 of 176
2. Lower the electric charge in battery. (Turn engine with starter, connect lights, Test Hole
etc.)
3. With the engine running at full throttle, connect the alternator field to chassis
with a small screwdriver or wire (Fig. 6–4).
4. Check the ammeter. The indication must be 8 – 28 amperes. If 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.
6–6 ALTERNATOR SERVICE B–02113

A–02211
6–6.1 Removal (ROPS Must Be Tilted) Fig. 6–4 To Check The Regulator
1. Disconnect negative battery cable.
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–01959
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 Opens)
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)

Check For
1. Connect an ohmmeter from one slip ring to the shaft. There must be Grounds
A–01857
maximum resistance.
Fig. 6–6 Checking Rotor Coil Wires
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
connection. If the light doesn’t come on, there is a defect in the stator.
3. Connect the test light from one of the connections to the frame of the stator.
If the light comes on, there is a defect in the stator.
Ohmmeter
(Check for Grounds) B–02108
Fig. 6–6 Checking Stator Coil Wires
825 Loader
10082
Revised Feb. of 176 –6–4– Service Manual
a
6–6.5 To Check Diode Trio (Fig. 6–8)
Insulated
1. Connect a D.C. test light from one Half
of the three connections to the
single connection. Then, reverse
the connections. The light must
come on when connected one
way, but not when connected the
other way.
A–02382
Do not use high voltage to Fig. 6–8 Checking Diode Trio

check diode trio or rectifier.
W–2306–0298
Ground Half B–02101
B–02102
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.
5. Repeat Steps 3 and 4 on both the other connections. If any of the tests are
bad, complete rectifier replacement is necessary.
B–02128
Fig. 6–10 InsulationWashers And Spacers
6–6.7 Assembly
Assembly is basically the reverse of disassembly.
If the regulator is removed, make sure the insulation washers and spacers are in
good condition on the two regulator screws (Fig. 6–10).
To install the rotor, put a piece of straight wire through the case to hold the brushes
in place (Fig. 6–11).
B–02097
Fig. 6–11 Holding Brushes
825 Loader
a
6–7 STARTER SERVICE Jumper Wire
825ServiceManual#6549899–ElectricalSystemSection
6–7.1 To Check The Starter Solenoid
1. Lift the Bobcat on safe blocks. Keep the ignition switch off. Be sure the Bat
S
battery has full charge and the connections are clean and tight. M
2. Connect a jumper wire from the S 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 Cranking
turn, do this: Motor
3. Connect the jumper from the Batt connection on solenoid to the M terminal
on starter (Fig. 6–13). If the starter will turn rapidly, the defect is in the A–01991
solenoid. If starter does not turn, the defect is in the starter. Fig.6–12 Checking Solenoid
Jumper Wire
6–7.2 To Remove Starter
Solenoid
1. Disconnect negative battery cable.
Bat
S
M
2. Disconnect the wires from starter connections.
3. Remove the bracket which holds the rear of the starter. Remove the three Cranking
nuts which hold the starter in place, and lift it out.

Motor
A–01992
6–7.3 Disassembly And Inspection Fig. 6–13 Checking Operation
1. Remove the three screws which hold the solenoid in place. Twist the
solenoid 1/4 turn and slide it off. Armature
2. Remove the thru bolts and the shift lever bolt. The starter will now come
apart.
3. Check the armature by connecting a test light from the outside of the
armature to the commutator (Fig. 6–14). If the light comes on, the defect is
in the armature.
4. Check the armature on an armature tester (Fig. 6–15).

A–01995
Fig. 6–14 Armature Testing (Grounds)
5. Check the condition of the commutator, and make repairs as needed.
6. Connect a test light from the

outside connection to each of the Armature Tester
inside connections (Fig. 6–16). If Coil
the light doesn’t come on, the field Armature
coils have a defect.
6–7.4 Assembly
Assembly is the reverse of
disassembly.
A–01994 B–02122
Fig. 6–15 Armature Testing (Shorts) Fig. 6–16 Checking Field Coil Wires
825 Loader
ENGINE SERVICE
Paragraph Page
Number Number
CONNECTING RODS AND PISTONS . . . . . . . . . . . . . . . . . . 7–5 7–9
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–10 7–28
CRANKSHAFT AND MAIN BEARINGS . . . . . . . . . . . . . . . . . 7–6 7–13
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3 7–1
FLYWHEEL AND FLYWHEEL HOUSING . . . . . . . . . . . . . . . . 7–7 7–17
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–11 7–31
INSTALLING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 7–4 7–8
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 7–1
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9 7–25
STARTING ENGINE AFTER
RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2 7–1
TIMING CASE AND DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8 7–18

ENGINE
SERVICE
825 Loader
825 Loader
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 it 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, etc., to
make clearance to cylinder head possible.
The engine must be removed when it is necessary to overhaul the block assembly.
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.
7. 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 Fig. 7–1.
9. Lift the engine up and to the rear slowly to release the drive coupling.
825 Loader
105 of Feb.
Revised 176 82 –7–1– Service Manual
7–3.2 Cylinder Head Maintenance
The number of hours run has no
effect on when to overhaul the
cylinder head on the 4.108 diesel
engine, since carbon beyond a small
quantity does not form and gather in
the combustion chambers and on the
pistons as in gasoline engines.
Easy starting and performance
should be the determining factors
and the cylinder head removed only
when it becomes absolutely
necessary.
Before starting to overhaul the
cylinder head, make sure that all
gaskets and any other parts
expected to be required are
available.
Remove any external foreign matter
from the area of the cylinder head
cover, injectors and fuel pump.
Remove the cylinder head as follows:
1. Completely empty the cooling

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
C–01832
electrical connection to the
starting aid located in the intake Fig. 7–1 Removing Engine
manifold.
7. Remove the cylinder head
cover together with the
breather pipe.
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.
11. Unscrew the small bolts on the
tops of the injectors and
remove the leak–off pipe by
turning the fitting on top of the C–01813
fuel filter. Fig. 7–2 Rocker Shaft Removal
825 Loader
10677
Revised Jan. of 176 –7–2– Service Manual
12. Remove the low pressure fuel
pipes between the fuel filter and
the fuel pump, remove the fuel
filter after disconnecting the feed
pipe from the lift pump, plug all
pipes and openings to prevent
entry of foreign particles.
13. Remove the four high pressure
fuel pipes from the fuel pump to the
injectors. Plug fuel pump outlet
ports.
14. Remove the injector fastening
nuts and carefully remove the
injectors. Plug the exposed
openings on the injectors.
15. Remove the alternator adjusting
arm.
16. Remove the cylinder head C–01810
fastening nuts and lift off the
cylinder head completely with Fig. 7–3 Lifting Cylinder Head
intake and exhaust manifolds (Fig.
7–3).
NOTE: During this final operation do not pry with a screwdriver or any
other sharp instrument between the cylinder head and block faces.
Once the head has been removed it must be placed on a flat surface,
such as wood, to prevent any damage to the machined face.

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 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: O sealing rings are fitted to
the inlet valve stems. The
inlet valve spring caps have B–01862
a deeper center portion to fit Fig. 7–4 Valve Numbering Fig. 7–5 Valve Spring Compression
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 Expansion
sequence detailed on page Washer
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
B–01856 B–01857
to prevent them from turning. The
expansion washers are fitted as shown Fig. 7–6 Fitting Expansion Washers Fig. 7–7 Seating Expansion Washers
in Figures 7–6 and 7–7.
825 Loader
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 0.250 inch (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.
A–02681
7–3.5 Cleaning Fig. 7–7a Pre–CombustionInserts (Good)
Plug all openings, oil ways, etc., where the entry of foreign matter could cause
damage to the working parts. Remove any carbon carefully from the tops of
pistons (a ring of grease between the piston and cylinder wall can help catch loose
carbon particles).
Clean the cylinder head face, being careful not to scratch the machined surface.
If the water jacket within the cylinder head shows signs of excessive scale, then
a special cleaning solution must be used. The cylinder head should be tested for A A
B
water leakage after this cleaning.
Clean all the studs on top of the cylinder head and those in the top face of the

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
A–02681
damaged threads replaced.
Fig. 7–7b Pre–Combustion Inserts (Bad)
NOTE: Studs and nuts are phosphate coated. Be sure that only genuine
parts are used as replacements.
7–3.6 Inspection
After the cylinder head has been disassembled and cleaned, the following
components should be inspected as follows:
1. Valve springs
Valve springs become weak because of the combined effects of heat and the
normal working of the springs.
It is best to install new valve springs whenever the engine undergoes an
overhaul. Where a top overhaul only is being done, the springs should be B–01887
inspected, paying special attention to squareness of ends and pressures at Fig. 7–8 Valve Guide Removal
specific lengths. The details can be found on page 8–4.
2. Valve Guides
The valve guides should be inspected for wear and if necessary replaced by
new ones.
The worn guides should be removed either by press or the valve guide
removal tool shown in Figure 7–8, being careful not to damage the bores
during their removal.
Before installing new guides, remove any burrs from the cylinder head parent
bores, then coat the bores with clean oil and either press in the new guides
or pull them in by means of the tool shown in Figure 7–9 until the guide
protrusion above the head top face is 0.800–0.815 inch.
NOTE: Be careful during this operation since guides are brittle.
825 Loader
108 of 176
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 any new valve fitted should be
marked to identify its position if removed
later. (See Fig. 7–4 for illustration of
valve numbering.) B–01863
Fig. 7–9 Valve Guide Installation
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 gauge 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.
B–01858 A–01653
Fig. 7–10 Refacing Valve Seats Fig. 7–11 Checking Valve Head Depth
825 Loader
4. Using the valve guide bore as a
pilot once again press the insert Valve Valve
in with the insert driver, this tool is Inlet Exhaust
shown fully dimensioned in
Figure 7–13. Steady pressure
should be given with either a
hand or a hydraulic press. The
purpose of the insert driver is to
get squareness when the insert is
being pressed in.
NOTE: The insert must not be driven

by hammer and lubrication B C
must not be used. A
5. Visually inspect to be sure that the Inlet Exhaust

insert has been pressed fully in A – 1.530” to 1.531” A – 1.296” to 1.297”
(flush with the bottom of the B – 0.3125” to 0.3175” B – 0.3125” to 0.3175”
recess). C – 0.015” Chamfer at 45° (Max.) C – 0.015” Chamfer at 45° (Max.)
6. Cut the valve seat at an included A–02350
angle of 90° (which will give the Fig. 7–12 Valve Insert Detail
normal 45° seat) until the valve
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. – 2.750 inch A. – 2.750 inch
B. – 2.0 inch B. – 2.0 inch
C. – 0.750 inch C. – 0.750 inch
D. – 0.309 to 0.310 inch D. – 0.309 – 0.310 inch
E. – 0.0625 inch at 45° E. – 0.0625 inch at 45°
F. – 0.0625 inch at 45° F. – 0.0625 inch at 45°
G. – 0.0312 inch Radius G. – 0.03125 inch Radius
H. – 1.238 to 1.239 inch H. – 1.018 to 0.019 inch
J. – 0.222 to 0.225 inch J. – 0.222 to 0.225 inch
K. – 1.523 to 1.533 inch K. 1.287 to 1.297 inch
7–3.10 To Disassemble The Rocker Shaft Assembly
1. Remove the snap rings from each end of the rocker shaft.
K
2. Withdraw the rocker levers, springs and support brackets from the rocker E
shaft.
3. Unscrew the oil feed pipe from the connector and remove the connector. C H
(When refitting this feed pipe, it should be noted that the end of the pipe
locates the connector position on the shaft.) J
G Rad.
After disassembly, thoroughly wash all parts in clean solvent. Inspect the rocker
A
bushings and shaft for wear. The rocker levers should be an easy fit on the rocker
B
shaft without loose side play.
If any rocker lever bushings have bad seizure onto the rocker shaft, the bushings
will have worked loose in their locations. Each rocker lever should be checked and
if any looseness is present, make a replacement of both lever and bushing.
New rocker levers are supplied complete with bushing fitted and reamed to size. F
D
B–02016
Fig. 7–13 Insert Driver
825 Loader
NOTE: When fitting new bushings, see that the oil feed holes are in Align Oil Feed
alignment before pressing in, and when pressed fully in see that the Holes
holes are in alignment (Fig. 7–14).
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.
A–02352
Fig. 7–14 Rocker Arm Bearing
7–3.12 Push Rods
Make a replacement of any bent push
rods.
Replacement of push rods may be
made without removing the rocker
shaft, as follows:
1. Ensure that the valve is closed.
2. Loosen the valve adjusting screw
until the rocker lever can be moved

sideways along the shaft.
3. Remove the old push rod and
install new rod.
4. Make adjustment of valve B–01892
clearance. Fig. 7–15 Rocker Shaft 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 snap ring 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 valve springs have a damper coil, when correctly installed this 5
coil is nearest the cylinder head top face. See note on spring caps 3
on page 8–4. Inner
Valve
5. Use a valve spring compressor, as 2 Spring
shown in Figure 7–16, to compress
the valve springs and locate the
retaining semi–conical collets. Outer
Valve
Spring
NOTE: Inlet valve stems are fitted 1
with rubber O–ring seals.
They fit inside the valve
spring cap bore and must
align with groove on the valve
stem. Assembly of the inlet 4
valve assemblies should be
carried out as follows: (Fig.
7–17). B–01862 A–02340
Fig. 7–16 Valve Spring Compression Fig. 7–17 Valve Assembly
825 Loader
6. Put spring seating washer in
position (Item 1).
7. Position the valve springs
correctly on the seating washer
(Item 2).
8. Put the valve spring cap in position
(Item 3).
9. Compress with the valve spring
compressor until the valve stem is
through the cap enough to install
the O–ring seal.
10. Install the O–ring over the valve
stem and slide it down until it
locates in the groove (Item 4).
11. Install the collets (Item 5).
7–4 INSTALLING CYLINDER HEAD Top Front

B–01990
7–4.1 Cylinder Head Gasket Fig.7–18 Installing 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 18 3 17
of a black composite material and is 8 4 7 11
12 1

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 16
that the gasket is placed correctly,
otherwise the steel beading may be
pinched between the cylinder head face 15
and the top of the liner when installing 14 9 5 10 13
the head. 2 6
B–01886
NOTE: Before installing the cylinder
head, be sure that the faces Fig. 7–19 Tightening Order
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 cylinder block face
the gasket is marked Top Front to indicate how it must be installed (Fig.
7–18).
2. Lower the cylinder head into position on top of the gasket making sure that
it is level.
3. Lightly put oil on both cylinder head studs and nuts, then tighten the nuts in
a three stage sequence shown in Figure 7–19 until torque is 60 ft.–lbs. (8,3
kgf/m).
NOTE: After the engine has been running, check the torque. If the bolts do
not move with the correct torque setting on the torque wrench,
loosen 30 to 60° and tighten to the correct torque. Check the first 10
positions again after all the bolts have been tightened to make sure
they are at the correct torque (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.
825 Loader
11281
5. Tighten the oil feed pipe nut just finger tight at this stage, then tighten the
rocker shaft bracket securing nuts evenly to a torque of 12 – 15 ft.–lbs. (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 0.012 inch (0,3 mm) as described on page
7–25.
7. Replace the alternator adjusting link and adjust the fan belt tension.
8. Install the injectors (refer to page 7–34) but do not tighten the holding nuts. B–01861
9. Install the leak off pipe assembly and four high pressure fuel pipes to the Fig. 7–20 Rocker Oil Line
injectors. Tighten the holding nuts.
10. Install the fuel oil filter and the low pressure fuel pipes between filter and lift
pump and filter and fuel pump.
11. Connect the electrical wire and fuel line to the starting aid.
12. Install the muffler onto the manifold.
13. Connect the water outlet connection at the front of the cylinder head.
14. Fill the cooling system with clean water. Check for water leaks.
15. Vent the air from the fuel system as described on page 7–35.

16. Connect the battery.
7–5 CONNECTING RODS AND PISTONS A–02344

Fig. 7–21 Connecting Rod Cap
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.
4. Remove the connecting rod caps and bearing shells (Fig. 7–21).
B–01989
Fig. 7–22 Removing Pistons
NOTE: If the bearing shells are to be used again, they should be marked to
identify them to their original locations. Identification marks should
be made on the steel (back) face.
5. Push the pistons and connecting rods carefully out through the top of the
block and remove as shown in figure 7–22.
6. Rotate the crankshaft through 180° to bring the other pair of big ends to
bottom dead center and remove them.
When piston removal has been done, keep each piston and rod assembly
separate, each to each as marked. Mark the pistons on the crown (before
removing the piston pin) to indicate the Front marking on the connecting rods.
825 Loader
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 ring groove during piston
IMPORTANT manufacture, it is part of the piston
and must not be removed from its
location.
I–2162–0298 B–01868
Fig. 7–23 Regrooving Pistons
2. Use snap ring pliers to remove the snap ring 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 100°–120°F (40°–50°C), the pin can then be
pushed out easily.
7–5.3 Inspection
1. Thoroughly clean all the disassembled 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 B–01987
8–2). Fig. 7–24 Piston And Rod Numbering
7. Inspect the rod bearing inserts for signs of wear or pitting. Also inspect the
crankpins and, if out of round, remove the crankshaft from the engine for a
complete dimensional check, to determine whether grinding or a
replacement crankshaft is necessary. For details of crankshaft removal, See
Page 7–15.
7–5.4 To Install The Pistons To The
Connecting Rods
If the original pistons are to be fitted, they
must be assembled to the same
connecting rods, i.e., No. 1 piston to No.
1 connecting rod assembly. Refer to
Figures 7–24 and 7–25 for location of
piston and rod numbering. Any new
components fitted must be numbered
the same as the old components.
1. Warm the piston in a suitable

clean liquid to a temperature of Fan
100 – 120°F (40–50°C) until the
piston pin can be easily pushed
into the piston bore when the B–01891
piston and rod have correct
alignment. Fig. 7–25 Location Of Piston Numbering
825 Loader
11482
2. Position No. 1 piston on its head, noting the position of the F mark indicating
Front. (When there is no mark, pistons can be installed either way.)
3. Hold No. 1 connecting rod with the small end between the piston pin bores
so that the word Front on the rod is towards the same side.
4. Push the piston pin into the piston to hold the connecting rod in position.
5. Install the two retaining snap rings making sure that they fit correctly in their
recesses (Fig. 7–26).
NOTE: If the engine has been in use for a long time, install new snap rings,
even if the old ones are not damaged. B–01878
Fig. 7–26 Piston Pin Retainer
6. Repeat this procedure for the other three pistons and connecting rods.
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). 5 4
3. Internally stepped compression (third groove) (Item 3).

4. Internally stepped compression (second groove) (Item 4). 2
3
5. Plain parallel faced compression (top groove) (Item 5).
1
NOTE: All of the above rings can be fitted by means of an expanding tool
of the type shown in Figure 7–23. These rings are made of cast iron
and are brittle, so when fitting, be careful not to expand any ring
more than is necessary to just clear the piston.
NOTE: The internally stepped compression rings must be installed with

the step up.
7–5.6 To Install Rings

B–01985
1. Hold the connecting rod, with Fig. 7–27 Piston Rings
piston, in a vise.
2. Install the bottom (5th) slotted oil
ring in the groove below the piston
pin (Either side up.) Top Ring
3. Install the 4th slotted oil ring in 2nd & 3rd

groove above piston pin. (Either Ring
side up.) (Step Up)
4. Install the 2nd and 3rd internal step
ring in the next 2 slots, with the step
up (Fig. 7–28). Oil Rings
5. Install the 1st (Top) ring. (Either

side up.)
Position the gaps of the rings evenly

around the piston.
Oil the rings in their grooves and see that
they can move freely in their locations.
A–02398
Fig. 7–28 Location Of Piston Rings
825 Loader
When all the rings have been fitted, they must be as shown in Figure 7–28.
7–5.7 To Install Piston And Connecting Rod Assemblies
Before installing the piston and connecting rod assemblies in their respective
cylinder bores, thoroughly clean and wash each bore with clean engine oil.
1. Turn the engine until the crankpins of numbers 1 and 4 cylinders are at
bottom dead center.
2. Use a ring clamp of the type shown in Figure 7–29 carefully compress the
rings on No. 1 piston and hold in this position.
3. With the word Front on the connecting rod facing the front of the engine,
insert the rod carefully into No. 1 cylinder bore.
NOTE: The cylinders are numbered 1, 2, 3 & 4 starting from the (water
pump) end of the engine. It is important that these components
(marked as shown in figures 7–24 and 7–25) are installed in their
original locations.
4. The piston head may be hit lightly with the shaft of a hammer as shown in
figure 7–29 until all the rings have entered the cylinder bore.
5. Pull the rod towards the crankshaft, put the top half bearing shell in position
with the tag in the machined slot and add oil lubricant. Pull the rod fully onto
the crank pin.

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.–lbs.
(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 crank pins to bottom dead
center.
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 removed 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 height is
correct, mark any such piston on the top with the number of its bore (Fig. 7–25). B–01871
Fig. 7–29 Piston Installation
825 Loader
7–5.9 Cylinder Liners
The cylinder liners are made of cast alloy iron, they are an interference fit in the
cylinder block and are of the thinwall dry type.
Boring of these liners to a larger size is not possible and new liners must be fitted
when liners have become worn.
Dimensional checks of the cylinder bore is best done with an inside micrometer.
When checking liners each one should be measured in three positions – top,
center and bottom; the readings being taken parallel and at right angles to the
center line of the cylinder block, giving six readings for each cylinder bore.
When checking the internal bore of a new installed liner, first let the liner settle for
a period of time.
7–5.10 To Install New Cylinder Liners
1. Remove all the components from the cylinder block. (Refer to the specific
sections for details of their removal.)
2. Remove the cylinder head studs from the cylinder block top face.
3. Use a liner removal tool to pull the liners carefully out through the top of the
cylinder block (Fig. 7–30).
4. Clean the bore thoroughly and remove any burrs which may be present.
5. Thoroughly clean and dry the liner after the removal of any grease or
preservative.

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 90° 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.
A–02314
10. Follow same procedure for other liners.
Fig. 7–30 Liner Removal
11. Bore and hone the liners to the dimensions quoted on page 8–1.
NOTE: The liner height may make boring difficult where boring equipment
is mounted on the top face of the cylinder block. This may be
overcome by making a parallel plate to fit between the boring bar
and cylinder block face. Such a plate must be thicker than 0.027 inch
(0,686 mm) and have holes bored in it to give clearance around the
liners.
12. Assemble the engine components to the cylinder block. (Refer to the specific
sections for assembly of these components.)
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 180° and 360° thrust faces to the crankshaft at the front and rear of this
bearing. 0.0075 inch (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 inch (0,19 mm) and by 0.015 inch (0,38 mm) if used on both sides. The
limits for the crankshaft end float are given on page 8–2. B–01874
Fig. 7–31 Liner Protrusion Check
825 Loader
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.–lbs. (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 operations would normally be done with the main
bearing cap removed.
3. Remove the rear main bearing cap and from it the two lower half thrust
washers (Fig. 7–34).
4. Remove the single upper half thrust washer by rotating it with a thin piece
of wood until it can be lifted out of its position.
NOTE: The new thrust washers should have a light lubrication with oil
before fitting. The steel faces of the lower thrust washers should
face towards the bearing cap (Fig. 7–35), the steel face of the upper
thrust washer should also face towards the cap.
5. Position the upper thrust washer half as shown in Figure 7–36, put the lower
halves on either side of the rear main bearing cap as described and install
the cap. B–01865
Fig. 7–32 Removing Bearing Insert
825 Loader
6. Tighten the bolts evenly to 85
ft.–lbs. (11,5 kgf/m) 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 inch
(0,38 mm). (Refer to page 8–2.)
Thrust
Washer
8. Install two bolts to hold the rear
main oil seal half housing.
B–01864 B–01870
Fig. 7–33 Rear Main Seal Removal Fig. 7–34 Thrust Washer Removal
NOTE: If any leakage of oil is noted 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 Thrust
locations when they are later installed. Washer

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 B–01869
pump drive hub. (Refer to page 7–19.)
Fig. 7–35 Thrust Washer Position
3. Remove the fastening bolts (also any studs fitted) and remove the timing
case back plate.
4. Remove the oil pan and lubricating oil pump, complete with suction and
delivery pipes. (Refer to page 7–25.)
5. Remove all the connecting rod bolts, connecting rod caps and bearing shells.
(Refer to page 7–9.)
NOTE: All the bearing shells must be marked (on the steel face) to indicate
Top or Bottom and number of the rod assembly.
6. Remove all the main bearing

bolts.
Upper Thrust
NOTE: The rear seal half housing Washer Half
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. B–01867 B–01866
Fig. 7–36 Thrust Bearing Installation Fig. 7–37 Crankshaft End Float
825 Loader
7–6.5 To Reinstall The Crankshaft
1. First clean the crankshaft and
check that all the oilways are clear.
2. Clean the bearing housings, put
the three top bearing shells in
position then give them lubrication
with clean engine oil.
NOTE: Unless a new set of main

bearings is being fitted,
return removed bearings to
their original locations.
3. Put the crankshaft carefully in

position.
4. Locate the upper thrust washer in B–01993

position as shown in Figure 7–36.
Fig. 7–38 Crankcase
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.–lbs. (11,5 kgf/m) torque.
9. Check that the crankshaft can be rotated freely. Check the crankshaft end
play with a feeler gauge as shown in Figure 7–37. If it is not within the limits
specified on page 8–2, then install oversize thrust washers to give the
necessary adjustment. (Refer to page 8–2.)
10. Install new seal strips to the rear main bearing oil seal housings and install
the housings as described under Crankshaft Rear End Oil Seal on page
7–17.
11. Put oil on the crank pins, install the connecting rod bearing shells, making
sure their positions are correct, then install the connecting rod caps as
described on page 7–12. The crankcase should now be as shown in Figure
7–38.
12. Install the lubricating oil pump complete with suction and delivery pipes.
(Refer to page 7–25.)
13. Install the oil pan using new seals and gaskets. (Refer to page 7–25.)
14. Install the timing case back plate, fuel pump drive hub, timing gears, timing
cover and crankshaft front pulley. (Refer to page 7–21 for their reassembly.)
15. Install and make correct alignment of the flywheel housing as described on
page 7–18.
16. Install the flywheel and starter motor.
825 Loader
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
crackcase pressure is
normal and new seals need
to be installed, the following
procedure should be
followed with the crankshaft B–01986
in position.
Fig. 7–39 Seating New Seal
1. Set up a half housing in a vise with the seal recess.
2. Press about 1.0 inch (25 mm) of the strip, at each end, into the ends of the
groove making sure that each end of the strip goes 0.010/0.020 inch
(0,25/0,50 mm) beyond the half housing face.

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
gasket 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 B–01864
then tighten the bolts to block.
Fig. 7–40 Rear Main Seal Installation
7–7 FLYWHEEL AND FLYWHEEL HOUSING
7–7.1 To Remove The Flywheel
1. Remove the transfer chaincase and clutch housing from the flywheel
housing.
2. Straighten the locking tabs on the flywheel fastening bolts.
3. Remove the bolts and carefully remove the flywheel from the crankshaft
flange.
7–7.2 To Replace The Flywheel Ring Gear
1. The flywheel ring gear is a shrink fit on the flywheel. It can be removed by
cutting partway through the gear with a hacksaw and chisel cutting it from
the flywheel. Another method is to heat the ring gear to expand it enough to
hit it loose with a hammer, evenly, from the flywheel.
825 Loader
2. The outer face of the flywheel should be thoroughly cleaned to give a smooth
fit when the new ring gear is installed.
3. Clean, then heat the new ring gear to a temperature not more than 480°F
(250°C).
4. Fit the ring gear over the flywheel with the lead on the teeth facing uppermost
(facing away from the engine when the flywheel is installed). Rotate the gear
quickly on its location as soon as it is fitted to make sure that it is laying flat,
then let cool.
7–7.3 To Reinstall The Flywheel

It is important that the crankshaft flange face is clean and free from burrs, also the B–01991
mating face of the flywheel before installing the flywheel.
Fig. 7–41 Flywheel Alignment
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.–lbs. (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 inch
(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.
825 Loader
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. B–01880
Fig. 7–42 Idler Gear
2. Using a new gasket with a light application of sealing material, put the front
cover in position being careful not to damage the rubber lip of the oil seal on
the crankshaft key.
3. Loosely install the front cover bolts and nuts. Timing

Marks
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.–lbs. (20,5 kgf/m) torque.

Timing
6. Install the fan belt and make adjustment for 0.375 inch deflection. Marks
7–8.4 To Remove The Idler Gear And Hub

B–01889
1. Remove the timing case front cover as described earlier in this section. Fig. 7–43 Idler Gear Timing Marks
2. Straighten the locking tabs and unturn the two idler hub holding bolts.
3. The bolts, idler gear and hub may now be removed together as shown in
Figure 7–42.
4. Clean and thoroughly inspect the gear and hub for signs of heavy wear,
cracks, etc.
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.
B–01881
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 play as shown in Figure 7–45, the limits are given
on page 8–5. C–01812
Fig. 7–45 Idler Gear End Play
825 Loader
7. Lock the idler gear hub bolts with
the tab washers.
NOTE: When the timing gears are

correctly aligned, they
should be as shown in figure
7–46.
8. Install the timing case front cover, Timing

etc., as described earlier in this Marks
section.
7–8.5 To Remove The Camshaft Gear

1. Remove the timing case front
cover as described earlier in this Timing
section. Marks
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.
Timing

Marks
7–8.6 To Install The Camshaft Gear
1. Remove the idler gear and hub as

C–01811
described earlier in this section.
Fig. 7–46 Alignment Of Timing Marks
2. Remove cylinder head cover and rocker shaft (if not earlier removed).
3. Install the gear to the camshaft making sure the D marks on the gear and D Marks
camshaft hub are in alignment as shown in Figure 7–47.
4. Install the three bolts and tighten to a torque of 19–21 ft.–lbs. (2,6–2,9
kgf/m)*.
NOTE: Only the round (not–slotted) holes in the camshaft gear are to be
used and these will make alignment with the tapped holes on the
camshaft hub when the D marks are in alignment.
5. Install the idler hub and gear, timing case front cover, etc., as described
earlier in this section.
B–01884
7–8.7 To Remove The Fuel Pump Gear Fig. 7–47 Camshaft Gear
1. Remove the timing case front cover as described earlier in this section.
2. Remove the idler gear and hub as described earlier in this section. Timing
Marks
3. Remove the three bolts and carefully pull the gear from its location on the
fuel pump drive hub.
4. Clean and thoroughly inspect the gear for signs of wear, cracks, pitting, etc.
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 the three bolts and tighten to a torque of 19–21 ft.–lbs (2,6–2,9 B–01883
kgf/m)*.
Fig. 7–48 Fuel Pump Gear
825 Loader
3. Install the idler gear and hub, timing case front cover, etc., as previously
detailed in this section.
*Tightening these bolts to the correct torque is more easily done after the idler gear
and hub have been installed.
7–8.9 to Remove The Fuel Pump Drive Hub
1. Remove the timing case front cover as described earlier in this section.
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 snap ring with a pair of snap ring 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
1. Install the drive hub in the bearing and locate with the snap ring as shown Snap Ring
in Figure 7–50. Hub
2. Check the drive hub end play with feeler gauges placed between the front
face of the bearing and the rear face of the drive hub. The end play limits are
given on page 8–5.
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. B–01882
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 earlier. Snap ring
2. Remove the fuel pump and drive

hub as described earlier.
3. Remove the plate bolts.
4. Lift 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. A–02310
Fig. 7–50 Fuel Pump Drive Retainer
825 Loader
7–8.12 To Install The Timing Case
Back Plate Thrust
Plate
1. Make sure that both the cylinder
block and timing case back plate
faces are clean. Install the timing
case back plate to the cylinder
block using a new gasket and
sealing material.
2. Install the bolts.
3. Install the fuel pump drive hub and Camshaft

fuel pump as previously detailed.
A–02343
4. Install the timing gears, timing Fig. 7–52 Removing Camshaft
case front cover, etc., as
previously detailed. Camshaft
7–8.13 To Remove The Camshaft B–01876

And Tappets
Fig. 7–51 Cam Thrust Plate
Camshaft end play is controlled by two 180° 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.

2. Remove the timing case front cover and timing gears as described earlier.
Tappet
3. Remove the fuel lift pump, tappet inspection cover and operating push rod A–02345
for fuel lift pump.
Fig. 7–53 Removing Tappets
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
camshaft and exercising great care to ensure that the cams and journals are
not damaged during this operation.
9. If desired, the tappets may now be removed by lifting them out of their
locations (Fig. 7–53).
10. Thoroughly clean the camshaft and tappets, then inspect for signs of wear,
surface cracks, pitting, etc.
7–8.14 To Install The Tappets And Camshaft
1. Add lubricant to the tappets and return them to their locations.
2. Carefully install the camshaft into the cylinder block.
825 Loader
3. Before the camshaft is pushed
fully in, locate the two thrust
plates (Fig. 7–54) (one of which
locates on the dowel in the
recess) in position, either side Thrust Plate
of the camshaft hub, when
correctly located the camshaft
can be pushed fully in and will
appear as in Figure 7–51.
4. Install the timing case back Push

plate as described earlier. Rod
5. Install the lubricating oil pump B–01875 B–01874

assembly and sump as
described on page 7–27. Fig. 7–54 Cam Thrust Plate Position Fig. 7–55 Fuel Lift Pump
6. Turn the engine block over so

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),
Timing

tappet inspection cover and fuel
lift pump. Marks
9. Assemble the remainder of the

engine components as
described in the instructions
given for each specific part of Timing
this section. Marks
7–8.15 Timing Marks

When the engine is originally timed at
the factory, certain marks are Keyway
stamped on the gears, so that if for
any reason the engine timing has to Timing
be changed, then setting to the Marks
original timing is easily done.
To Reset The Engine To The

Original Timing C–01811
If the cylinder head assembly is still in Fig. 7–56 Alignment Of Timing Marks
position, it is best to remove the
injectors and rocker shaft to make
timing easier.
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.D.C.).
2. Fit the camshaft gear to its hub,

making sure that the D marks
are correctly aligned (Fig.
7–57). Fasten with the three
bolts.
B–01884
Fig. 7–57 Cam Shaft Gear
825 Loader
3. Install the fuel pump gear on to the fuel pump drive hub, making sure that
the stamped timing marks align as shown in figure 5–58. Fasten with the
three bolts. Timing
Marks
4. Install the idler gear so that the double dots on the idler gear are in alignment
to the single dot on the crankshaft gear and single line (or dot) on the
camshaft gear, with the single dot on the idler gear in alignment with the
double dots on the fuel pump gear. These timing marks when correctly
positioned will appear as shown in Figure 7–56.
5. Put the idler gear with the hub and install the two retaining screws using a
new washer.
6. Gear play adjustment should be done as described on page 7–19. B–01883

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 Check 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 inch (1,0
mm).
Timing Pin
3. Turn the engine slowly in the normal direction of rotation until the clearance
of No. 1 inlet valve is just taken up. (In this condition it will be possible to rotate B–01872
No. 1 inlet valve push rod between the thumb and the forefinger.) Fig.7–59 Timing Pin
4. Nos. 1 and 4 pistons will now be at T.D.C. if the timing has been correctly set.
NOTE: If valve timing is incorrect and the camshaft gear has been correctly
fitted to the camshaft hub, the error will probably be due to wrong
alignment of the original timing marks on the drive gears (Check as
detailed on page 7–23).
When valve timing is originally set and checked during production a timing
tolerance of plus or minus 2–1/2 (flywheel) degrees is available for item (4) above.
When the timing has been correctly set, do not forget to reset No. 1 inlet valve
clearance to the correct figure also to return the timing pin to its correct location
if it has been used to check T.D.C.
825 Loader
7–8.18 Adjusting Valve Clearance
825ServiceManual#6549899–EngineServiceSectionPart1of4
Using the following procedure check the

valve clearance by using the correct
size feeler gauge between the valve
stem and the rocker lever end, if any Feeler Adjustment
adjustment is necessary, loosen the Gauge Screw
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 A–01770

Fig. 7–60 Adjustment Of Valve Clearance
Following the firing order sequence (1, 3, 4, 2) turn the engine so that the valves
of No. 1 cylinder are in the position of valve overlap (the period between the
opening of the inlet valve and the closing of the exhaust valve). In this position,
make adjustment for clearances of the No. 4 cylinder; then with No. 3 cylinder
valves in the valve overlap, make adjustment of valves of No. 2 cylinder; with No.4

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

1. 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.
825 Loader
7–9.4 To Remove The Oil Pump
1. Empty the engine oil from the oil

pan.
Strainer
2. Remove the oil pan fastening
screws and carefully remove
the pan.
Oil Suction Pipe
3. Remove the strainer from the
end of the oil suction pipe (Fig.
7–61).
4. Remove the delivery 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
B–01885
1. Remove the delivery and
suction pipes. Fig. 7–61 Oil Suction Strainer
Remove
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.
Oil Pump
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.
B–01888
Fig. 7–62 Lube Oil Pump Removal
825 Loader
2. Install the drive shaft complete with inner rotor, then the outer (driven) rotor
making sure that the face which holds the tapered edge enters the pump
body first (Fig. 7–63). Now make the three following dimensional checks:
(a) Check the clearance between the inner and outer rotor (Fig. 7–64). Outer
Rotor
(b) Check the clearance between the outer rotor and the pump body (Fig.
7–65).
(c) Check the clearance between the rotors and the end cover assembly
using a straight edge and feeler gauge (Fig. 7–66).
7–9.7 To Assemble The Oil Pump

1. Install the outer rotor making sure that the face which holds the tapered edge Inner
enters the pump body first (Fig. 7–63). Rotor
2. Install 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
positioning so that the suction and delivery pipes will fit correctly. A–02311
Fig. 7–63 Rotor And Oil Pump
4. Press the oil pump drive gear onto the shaft.
5. Rotate the pump by hand to make sure that it turns quite freely.
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.
A–02312
5. Carefully install the sump as described earlier and fasten with the bolts. Fig. 7–64 Checking Rotor Clearance
6. Fill the oil pan to the correct level with clean oil of an approved grade.
NOTE: Be careful starting the engine, since it will take a moment for the oil
pump and pipes to charge. The engine speed should be kept to a
minimum until the gauge shows enough pressure. (Oil pressure
warning light is off.)
The best way to prime the lubricating oil
pump is to crank the engine for about 10
to 20 seconds before starting the
engine.
7–9.9 Oil Pressure Relief Valve
The oil pressure relief valve is part of
the oil pump end cover, which is
fastened to the rotor housing by four
capscrews. This relief valve controls
the maximum oil pressure by moving a
spring loaded plunger and sending
extra oil back to the oil pan when the oil
pressure goes above the spring
pressure setting. A–02346 B–01879
Fig. 7–65 CheckingOuter Rotor Clearance Fig. 7–66 Oil Pump Rotor Clearance
825 Loader
7–9.10 To Dismantle The Oil Pressure
Relief Valve
Housing
1. Empty the engine oil from the oil
pan.
Plunger
2. Remove the oil pan fastening bolts
and carefully remove the oil pan. Spring Cap
3. Continue by removing the oil pump

as described earlier. Split Pin
4. Remove suction and delivery Spring

pipes. B–01877
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 7–67.
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 0.375 inch (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.
825 Loader
NOTE: When a new belt has been
installed, check the 1
adjustment again after a 12
short running period. 1. Pump Body
2 3 3 2. Seal
11 3. Shaft Bearings
7–10.3 Water Pump 4. Retaining Circlip
4
5. PUmp Shaft
The water pump shaft rotates within two 6. Distance Piece
bearings. The impeller aids the 5
7. Flange–Oil–Seal
circulation of the water through the Retaining
system. Water is held within the impeller 8. Retainer–Oil Seal
chamber by a carbon–faced seal which 9. Flange–Water Pump
is spring pressed against the face of a Thrower
phosphor bronze bearing in the pump 10. Impeller
body. Figure 7–68 shows the positions of 10 11. Seal
the assembled parts. 12. Insert
8 6
7–10.4 Remove The Water Pump 9 7
1. Straighten the washer locks, A–02351

remove the fan bolts and remove
the fan. Fig. 7–68 Water Pump Section
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 snap ring. Use a press to push out the two shaft
bearings, complete with spacer, out through the front of the pump body.
6. Remove the felt seal and holding flanges. A–02309
Fig. 7–69 Water Pump Pulley Removal
7–10.6 Inspection
1. Clean all the components in solvent, then dry thoroughly.
2. Inspect the pump body for cracks, corrosion or any other damage. Install
new when necessary.
3. Inspect the shaft and bearing assembly for wear or corrosion. Install new
when necessary.
4. Inspect the water thrower flange for damage or corrosion. Install new when
necessary.
5. Inspect the water pump seal and inspect for wear, scoring or cracks on the
sealing faces. Install new when necessary.
6. Remove rust and scale from the impeller and inspect for corrosion or other
damage. Install new when necessary.
7. Inspect the pump pulley for signs of cracks, corrosion or any other damage.
Install new when necessary.
825 Loader
7–10.7 To Assemble The Water Pump
1. Install the oil seal holder and oil seal, followed by the oil seal holding flange.
2. Fit the two bearings and spacer onto the shaft and pack the space between
the two bearings about 3/4 full of high temperature grease.
3. Press the bearing and shaft assembly into the pump body, impeller end first
and locate with the snap ring.
4. Press the water thrower flange into position on the drive shaft.
5. Thoroughly clean the insert recess and drain hole in the pump body.
A–02313
6. Lightly coat the inner diameter of the insert area and outside diameter of the Fig. 7–70 Pump Impeller Clearance
insert with sealing material.
7. After removing any traces of oil or grease from the insert, press it fully in.
Remove all extra sealing material.
NOTE: Special care must be taken during this operation not to mark the
face upon which the seal contacts.
8. Place the carbon–faced seal on the drive shaft so that this face contacts with
the insert face.
9. Press the impeller onto the shaft over this seal until the clearance of 0.005

to 0.025 inch 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 lock washers.
7–10.9 Thermostat
A thermostat is located in a housing at the front of the cylinder head, inside the
water outlet connector to the radiator.
The thermostat works by restriction of the water circulation until the water in the
thermostat housing is at a specific temperature. A valve in the thermostat then
opens and the normal coolant circulation through the system takes place.
7–10.10 To Remove The Thermostat
1. Empty the coolant from the radiator.
2. Remove the water hose from the engine water outlet connection at the front
of the cylinder head.
3. Remove the two nuts and washers which hold the outlet connection to the
thermostat housing.
825 Loader
4. Remove the outlet connection and gasket.
5. Lift out the thermostat as shown in Figure 7–71.
7–10.11 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.
Thermostat
2. Note the temperature at which the valve in the unit begins to open. This
temperature should be as marked on the unit. B–01984
3. If the unit does not function properly, then a replacement thermostat will be Fig. 7–71 Removing Thermostat
necessary. No adjustment of these units is possible.
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.
Priming Lever
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 B–01772
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
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)
Spacer Lift Pump

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).

Gasket
4. To install the pump, reverse the above procedure. Be sure to install two
gaskets, one on each side of spacer.
A–02342
Fig. 7–73 Removing Fuel Lift Pump
825 Loader
135 of August
7–11.3 Fuel Injection Pump
7–11.4 To Remove The Fuel Injection Pump
1. Remove the four high pressure pipes between the pump and the injectors
and cover all openings to keep out dirt.
2. Remove the low pressure fuel pipes from the inlet and outlet connections and
cover the openings.
3. Disconnect the stop and throttle controls and return springs. Fuel Pump
4. Remove the two nuts and the socket headed bolt which hold the fuel pump
to the fastening flange together with the spring and flat washers. B–01995
Fig. 7–74 Removing Fuel Pump
5. Carefully remove the fuel pump (Fig. 7–74).
7–11.5 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 Timing
pushed in until the fastening Marks
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–lbs. 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 so that there is access to the valve springs for
using a valve spring compressor.
825 Loader
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.D.C.).
5. When the gauge has been set at zero, turn the engine AGAINST normal
direction of rotation until the piston (and valve) have moved a distance of
0.120 inch (3,05 mm) down the cylinder bore.
NOTE: This is equal to 19° angle movement of the flywheel B.T.D.C. and is
the static timing point.
A–02347
6. When this static timing point has been accurately determined, the C line on Fig. 7–76 Fuel Pump Timing
the fuel pump rotor must be in alignment with the straight edge of the timing
snap ring (Fig. 7–77).
NOTE: Do not move the snap ring in the pump. It is set by the manufacturer.
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. 7–78) 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.
8. When the fuel pump timing

adjustment has been made, turn
the engine against the normal Timing
direction of rotation once again to Mark
a piston displacement of 0.120
inch (3,05 mm) to check that the
squared end of the snap ring is B–01982
now aligned with the C line on the Fig. 7–77 Fuel Pump Timing Marks (Internal)
rotor.
9. When the fuel pump timing adjustment has been made, slowly turn the
engine to T.D.C. in the normal direction of rotation, remove the dial indicator
and install the valve springs.
10. Install the push rod and make valve clearance adjustment.
7–11.6a Timing The fuel Injection Pump (Using Timing Tool MS67123)
1. Remove the valve cover.
2. Turn the engine until No. 1 cylinder is a T.D.C. on the compression stroke
(Both valves of the No. 4 are moving).
B–01883
825 Loader
137 of October
3. Loosen the adjusting bolt of the rocker arm on the No. 1 cylinder exhaust
valve, so that the rocker arm can be moved to the one side and the pushrod
removed. Move the rocker arm so that a valve spring compressor can be
used to remove the valve springs (Fig. 7–78a).
4. Remove the valve springs from the No. 1 cylinder exhaust valve and put the
valve head on the top of the piston crown.
5. Install a dial indicator on the top of the valve stem (Fig. 7–76). Turn the
engine backward and forward to find T.D.C. (maximum piston height) and
zero the dial indicator.
NOTE: Do not turn the engine crankshaft too far because the valve can fall
into the combustion chamber. B–03303
Fig. 7–78a Removing Valve Springs
6. Remove the fuel injection pump (See Paragraph 7–11.4).
7. Loosen the screw (Fig. 7–78b, Item 1) on the timing tool and set the gauge
as shown in the chart below. 3
1
Engine Fuel Pump Setting Engine Checking Fuel Pump Marking 2

Type Code Angle (Degrees) Angle (Degrees)
4.108 EH34E 281 290
EH39 281 290

LH30 281 292
PH23E 281 290
PH25E (exceptions below) 281 290
PH25E500/5/2450 279–1/2 290
PH25E500/9/1990 279–1/2 290 B–03361
PH25E500/9/2090 279–1/2 290
PH27 281 290 Fig. 7–78b Timing Tool
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 279–1/2 290
SH33E 279–1/2 290
8. Install the shaft of the timing tool into the drive hub for the injection pump (Fig.
7–78c). The tool will fit in only one position because of the special spline. Be
sure that the tool is tight against the flange on the engine.
9. Tighten the screw (Fig. 7–78b, Item 2) to hold the body and the shaft
together. B–03352
Fig.7–78c Installing Tool On Engine
10. Loosen the screw (Fig. 7–78d, Item 1) and move the plate with the mark Flange
close to the flange on the engine (Fig. 7–78d). Tighten the screw.
11. Turn the timing tool in the opposite direction of the normal rotation of the
injection pump so that there is no play in the gears.
12. After completing steps 1– thru 11 above, the mark on the plate must be in
alignment with the mark on the flange on the engine.
NOTE: If the marks are 180° apart, the No. 1 cylinder is not at T.D.C.
The Mark Must 1

Be In Alignment B–03354
Fig. 7–78d Alignment Of Mark To Engine
825 Loader
138 of Feb.
Revised 176 82 –7–33a– Service Manual
13. If the marks are not in alignment, make adjustments to the gear for the
injection pump (Fig. 7–78). (See Paragraph 7–8.1, To Remove Cover On
825ServiceManual#6549899–EngineServiceSectionPages33a–33b
The Timing Case).
Checking The Timing Mark On The Flange Of The Injection Pump
1. Loosen the screw (Fig. 7–78b, Item 2) and remove the shaft from the body
of the timing tool.
2. Loosen the screw (Fig. 7–78b, Item 3) and remove the plate with the mark. 1
Install the plate again the opposite way. Tighten the screw.
B–03353
3. Loosen the screw (Fig. 7–78b, Item 1) and set the gauge as shown in the
chart. Fig. 7–78e Timing Tool On Injection Pump
4. Install the timing tool on the shaft of the injection pump. The tool will fit in only
one position because of special spline (Fig. 7–78c).
5. Connect a test pump (for testing injection pumps and fuel injectors) to the
No. 1 outlet of the injection pump.
6. Operate the test pump until the pressure is 440 PSI (3033 kPa) maximum.
7. Turn the tool in normal direction of rotation (normal rotation is shown on the
plate of the pump) until you cannot turn it further.

8. Loosen the screw (Fig. 7–78e, 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
13982
Revised Feb. of 176 –7–33b– Service Manual
7–11.9 Injector Problems
The following are an indication of possible faulty injectors:
1. Misfiring (running rough).
2. Knocking in one (or more) cylinders.
3. Engine overheating.
4. Loss of power.
5. Smoky exhaust (black).
6. Increased fuel required.
Injector
B–01860
7–11.10 Testing For Faulty Injector Fig. 7–79 Injector Position
If an injector is not working correctly and it is not known which one is at fault, loosen
the pipe nut at the injector end of the high pressure fuel pipe. Do this with each
injector (with the engine running at approximately 1,000 rev/min). Tighten each
pipe nut before going to the next. The faulty injector, when checked in this manner,
will have little or no effect on the running of the engine.
7–11.11 Injector Removal
After stopping the engine, remove the nuts from the flange of the faulty injector
and pull the complete unit from the cylinder head.
7–11.12 Injector Installation (Fig. 7–79)

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 washer.
4. Hold the injector squarely into its location with one hand, and install the
fastening nuts on each stud, just finger tight, with the other hand.
NOTE: Do not tighten the nuts fully down on the fastening studs yet.
5. Repeat 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, each is shaped to fit an individual injector position. This is important when
ordering a replacement pipe, each one has a different part number.
825 Loader
The pipes must be clean (wash in clean fuel oil and blow through the fine bore with
compressed air), the fittings at each end should not be split or compressed, or
leakage will result and a new pipe will be needed.
Be sure when installing, that the pipe fits squarely at both ends and that the nuts
are tight but not over tight.
When changing an injector, always loosen both the nuts or remove the pipe
completely, do not leave one end tight and the pipe under tension. The correct size
wrench for the job is a 5/8 inch open end.
7–11.13a Using C.A.V. Thermostart Units
Be sure there is fuel getting to the

thermostart unit. If you operate the
IMPORTANT thermostart unit without fuel, the
unit will be damaged.
I–2163–0298
If the engine is difficult to start in cold weather or, black smoke is coming from the
exhaust, the thermostart unit has a defect and must be replaced.
If the engine has not been started for five days or more, operate the starter until
it turns the engine several times or operate the priming lever several times to get
fuel pressure.

If (1) the temperature is below 40°F (3° – 4°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 1
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 2
Charging The Fuel Line
below). Troubleshoot the
electrical system if there is
not 12 volts at the Injection Pump
thermostart unit.
A–02290
Fig. 7–80 Venting Injection Pump
825 Loader
141 of August
If you use ether as a starting aid, wait

until the thermostart unit is cold Secondary Filter
WARNING before putting ether into the
manifold. Never activate the
thermostart when using ether.
I–2307–0298
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.
B–01798
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. Fig. 7–81 Bleeding Secondary Filter
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.
7–81).
4. Operate the priming lever on the fuel feed pump (Refer to Fig. 7–82) and
when fuel, free from air bubbles, flows from each venting point, tighten the
screws in the following order:
(a) Filter cover vent screw (Fig. 7–81).
(b) Hydraulic head screw (Fig. 7–80, Item 2).
(c) Gear housing vent valve (Fig. 7–80, Item 1).
5. Loosen the tubeline fitting at the injector end of all the injector high pressure
lines (Fig. 7–83).
6. Set the throttle at the fully open position.
7. Turn the engine with the starter until air–free oil comes out from the loose
fittings. B–03873
Fig. 7–82 Fuel Lift Pump
8. Tighten all the injector line fittings and start the engine.
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 injector line.
Loosen Fittings
B–03948
Fig. 7–83 Injectors Fittings
825 Loader
14282
SPECIFICATIONS
Paragraph Page
Number Number
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4 8–5
DE–RATING FOR ALTITUDE . . . . . . . . . . . . . . . . . . . . . . . . . . 8–7 8–7
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5 8–5
LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 8–10 8–11
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 8–5
SERVICE WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6 8–6
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9 8–10
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 8–1
TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2 8–5
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 8–8 8–7

SPECIFICATIONS
825 Loader
825 Loader
8–1 SPECIFICATIONS
a
8–1.1 Cylinder Block
Camshaft Bore Dia. No. 1 . . . . . . . . . . . . 1.794/1.7955 in. (45,568/45,606 mm)
Camshaft Bore Dia. No. 2 . . . . . . . . . . . . . . 1.784/1,787 in. (45,314/45,390 mm)
Camshaft Bore Dia. No. 3 . . . . . . . . . . . . . . 1.776/1.778 in. (45,110/45,161 mm)
8–1.2 Cylinder Liner (Cast Iron)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry – Interference Fit
Interference Fit of Liner . . . . . . . . . . . . . . . . . . 0.003/0.005 in. (0,076/0,127 mm)
Inside Dia. of Liner after
Finish Boring and Honing . . . . . . . . . . . . . 3.125/3.126 in. (79,375/79,400 mm)
Height of Liner in Relation to Cylinder Block
Top Face . . . . . . . . . . . . . . . . . . . . . 0.023/0.027 in. (0,584/0,686 mm) ABOVE
8–1.3 Pistons
Piston Height in Relation to
Cylinder Block Top Face . . . . . . . . 0.002/0.006 in. (0,051/0,152 mm) ABOVE
Bore Dia. for Piston Pin . . . . . . . . . . . 1.96255/1.96275 in. (26,989/26,994 mm)
Compression Ring Groove
Width – Top . . . . . . . . . . . . . . . . . . . . . . . . . 0.0805/0.0815 in. (2,045/2,070 mm)
Width – Second . . . . . . . . . . . . . . . . . . . . . . 0.0645/0.0655 in. (1,638/1,664 mm)
Width – Third . . . . . . . . . . . . . . . . . . . . . . . . 0.0645/0.0655 in. (1,638/1,664 mm)

Oil Control Ring Groove
Width – Fourth . . . . . . . . . . . . . . . . . . . . . . . . 0.126/0.127 in. (3,200/3,225 mm)
Oil Control Ring Groove
Width – Fifth . . . . . . . . . . . . . . . . . . . . . . . . . . 0.190/0.191 in. (4,826/4,851 mm)
NOTE: There is a 0.030 in. (0,762 mm) x 0.148/0.152 in. (3,759/3,861 mm)
steel insert fitted into the top groove and located immediately above
the top compression ring. Do not remove this insert.
8–1.4 Piston Rings
Top Compression Ring Width . . . . . . . . . . 0.0771–0.0781 in. (1,958/1,984 mm)
Ring Clearance in Groove . . . . . . . . . . . . . . 0.0024/0.0044 in. (0,051/0,102 mm)
Second and Third Compression Ring Width
0.0615/0 .0625 in. (1,562/1,587 mm)
Ring Clearance in Groove . . . . . . . . . . . . . . . . 0.002/0.004 in. (0,051/0,102 mm)
Fifth Scraper Ring Width . . . . . . . . . . . . . . . 0.1865/0.1875 in. (4,737/4,762 mm)
Ring Clearance in Groove . . . . . . . . . . . . . . 0.0025/0.0045 in. (0,063/0,114 mm)
Ring Gap – (Cast Iron) . . . . . . . . . . . . . . . . . . . . . 0.009/0.020 in. (0,23/0,51 mm)
(Chrome) . . . . . . . . . . . . . . . . . . . . . . 0.012/0.023 in. (0,31/0,59 mm)
The above ring gap is for a bore diameter of 3.125 in. (79,38 mm). Where the bore
diameter is greater than this, the ring gap will be greater and for every 0.001 in.
(0,03 mm) increase to the above bore diameter, 0.003 in. (0,08 mm) should be
added to the quoted ring gap.
8–1.4 Piston Pin Bushing
Length of Bushing . . . . . . . . . . . . . . . . . . . . . 0.935/0.955 in. (23,749/24,257 mm)
Outside Diameter of Bushing . . . . . . . . . . . . 1.221/1.222 in. (31,013/31,039 mm)
Inside Diameter Before Reaming . . . . . 1.0495/1.0545 in. (26,657/26,784 mm)
Inside Diameter After Reaming . . . . . . 1.06315/1.0632 in. (27,004/27,005 mm)
Clearance Between Bushing
Piston Pin . . . . . . . . . . . . . . . . . . . . . . . 0.00045/0,0007 in. (0,0114/0,0178 mm)
8–1.5 Connecting Rod
Big End Bore Diameter . . . . . . . . . . . . . . . 2.146/2.1465 in. (54,508/54,521 mm)
Small End Bore Diameter . . . . . . . . . . 1.21875/1.21975 in. (30,956/30,981 mm)
Connecting Rod Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.375 in. (3/8 in.) U.N.F.
Connecting Rod End Float . . . . . . . . . . . . . . 0.0065/0.0105 in. (0,165/0,267 mm)
825 Loader
145 of Feb.
8–1.6 Connecting Rod Alignment
Large and small end bores must be square and parallel with each other within the
limits of ± 0.010 in. (0,25 mm) measured 5 in. (127 mm) each side of the axis of
the rod on test mandrel as shown in Fig. 1. With the small end bushing installed
the limit of ± 0.010 in. (0,25 mm) is reduced to ± 0.0025 in. (0,06 mm).
Crankshaft
Main Journal Diameter Nos. 1 and 2 . . . . 2.248/2.2485 in (57,099/57,112 mm)
Main Journal Diameter No. 3 . . . . . . . . . . 2.2475/2,248 in. (57,086/57,099 mm)
Main Journal Length No. 1 . . . . . . . . . . . . . . . . . . . . . . . 1.40625 in. (35,719 mm)
Main Journal Length No. 2 . . . . . . . . . . . . . . 1.496/1.504 in. (38,075/38,151 mm)
Main Journal Length No. 3 . . . . . . . . . . . . . . 1.499/1.502 in. (38,075/38,151 mm)
Main Journal Fillet Radii . . . . . . . . . . . . . . . . . . 0.125/0.141 in. (3,175/3,581 mm)
Crankpin Diameter . . . . . . . . . . . . . . . . . . 1.9995/2.000 in. (50,787/50,800 mm)
Crankpin Length . . . . . . . . . . . . . . . . . . . . 1.1875/1,1895 in. (30,969/4,366 mm)
Crankpin Fillet Radii . . . . . . . . . . . . . . . . 0.15625/0.17187 in. (3,969/4,366 mm)
Surface Finish – All Journals . . . . . . . . . . . . . 8––16 micro–in. (0,2––0,4 micron)
Main Journal and Crankpin
Regrind Undersizes . . . . . . . . . . . 0.010,0.020,0.030 in. (0,25,0,51, 0,76 mm)
Oil Seal Helix Diameter . . . . . . . . . . . 2.21075/2.21175 in. (56,153/56,178 mm)
Oil Seal Helix Width . . . . . . . . . . . . . . . . . . . . . 0.050/0.080 in. (1,270/2,032 mm)
Oil Seal Helix Depth . . . . . . . . . . . . . . . . . . . . . 0.004/0.008 in. (0,102/0,203 mm)
Flange Diameter . . . . . . . . . . . . . . . . . . 3.9985/3.995 in. (101,562/101,587 mm)
Flange Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.500 in. (12,700 mm)
Spigot Bearing Recess Depth . . . . . . . . . . . . . . . . . . . . . . . 0.875 in. (22,225 mm)
Spigot Bearing Recess Bore . . . . . . . . . . . . . . . . . . . . . . . . 1.250 in. (31,750 mm)

Crankshaft End Float . . . . . . . . . . . . . . . . . . . 0.002/0.015 in. (0,0508/0,381 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–magnetized, then retreated by
this Tuffride process after which the crankshaft should again be
crack–detected and de–magnetized. 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 correct limits.
8–1.8 Crankshaft Thrust Washers

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel Backed –– Lead Bronze Faced
Position in Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Main Bearing
Thrust Washer Thickness (STD) . . . . . . . . . . . 0.089/0.091 in. (2,261/2,311 mm)
Thrust Washer Thickness (O/S) . . . . . . . . . 0.0965/0.1005 in. (2,451/2,553 mm)
Thrust Washer Outside Diameter . . . . . . . . 3.245/3.255 in. (82,423/82,677 mm)
Thrust Washer Inside Diameter . . . . . . . . . . 2.590/2.600 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 mm)
Inside Diameter of Main Bearing . . . . . . 2.2505/2.2515 in. (57,163/57,188 mm)
Running Clearance – – – Nos. 1 & 2 . . . . . . 0.002/0.0035 in. (0,051/0,089 mm)
Running Clearance – – No. 3 . . . . . . . . . . . . 0.0025/0.004 in. (0,063/0,102 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
2.0015/2.0025 in. (50,838/50,863 mm)
Running Clearance . . . . . . . . . . . . . . . . . . . . . 0.0015/0.003 in. (0,038/0,076 mm)
825 Loader
8–1.11 Camshaft
No. 1 Journal Diameter . . . . . . . . . . . . . . . . . 1.791/1.792 in. (45,491/45,517 mm)
No. 1 Cylinder Block Camshaft
Bore Diameter . . . . . . . . . . . . . . . . . . . . . 1.794/1,7955 in, (45,568/45,606 mm)
No. 1 Journal Running Clearance . . . . . . . . . 0.002/0.0045 in. (0,051/0,114 mm)
No. 2 Cylinder Block Camshaft . . . . . . . . . . 1.784/1.787 in, (45,314/45,390 mm)
No. 2 Journal Running Clearance . . . . . . . . . . 0.002/0.006 in. (0,051/0,152 mm)
No. 3 Cylinder Block Camshaft
Bore Diameter . . . . . . . . . . . . . . . . . . . . . . . 1.776/1.778 in. (45,110/45,161 mm)
No. 3 Journal Running Clearance . . . . . . . . . . 0.002/0.005 in. (0,051/0,127 mm)
Cam Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.266 in. (6,766 mm)
8–1.12 Camshaft Thrust Plates
Thrust Plate Outside Diameter . . . . . . . . . . 2.555/2.557 in. (64,897/64,948 mm)
Thrust Plate Inside Diameter . . . . . . . . . . . . . . . . . . . . . . . . 1.500 in. (38,100 mm)
Thrust Plate Thickness . . . . . . . . . . . . . . . . . . . 0.160/0.162 in. (4,060/4,115 mm)
Thrust Plate Height in Relation to
Cylinder Block Face . . . . . . . . . . . . . . . . 0.004 in. (0,102 mm) Above or Below
Camshaft End Float . . . . . . . . . . . . . . . . . . . . . 0.003/0.013 in. (0,076/0,330 mm)
8–1.13 Cylinder Head
Milling Allowance on
Cylinder Head Face . . . . . . . . . . . . Cylinder Head Face Must Never be Milled
Pressure for Water Leakage Test . . . . . . . . . . . . . . . . . . . . . 20 PSI (1,4 kgf/cm2)

Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Bore in Cylinder Head for Guide . . . . . . 0.4995/0.5005 in. (12,687/12,713 mm)
Bore in Cylinder Head for Combustion
Chamber Inserts . . . . . . . . . . . . . . . . . . . . . 1.250/1.252 in. (31,750/31,801 mm)
Depth of Bore in Cylinder Head for
Combustion Chamber Inserts . . . . . . . . . . . . 0.373/0.376 in. (9,474/9,550 mm)
Compression . . . . . . . . . . . . . . . . . . . . . . . . . . 300–500 PSI (2068,5–3447,5 kPa)
With not more than 50 PSI (344,8 kPa) difference between each cylinder.
8–1.14 Combustion Chamber Inserts
Outside Diameter of Insert . . . . . . . . . . . . . . 1.248/1.249 in. (31,699/31,724 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 mm) Above or Below
Clearance Fit of Insert in Cylinder Head Bore 0.001/0.004 in. (0,025/0,102 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. (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)
Overall Length of Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.130 in. (54,102 mm)
Guide Protection Above
Top Face of Cylinder Head . . . . . . . . . . . . . 0.800/0.815 in. (20,320/20,701 mm)
8–1.16 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 mm)
825 Loader
147 of Feb.
8–1.17 Valves (Inlet)
Valve Stem Diameter . . . . . . . . . . . . . . . . . . . . 0.312/0.313 in. (7,925/7,950 mm)
Clearance Fit of Valve Stem in Guide . . . . 0.0015/0.0035 in. (0,038/0,089 mm)
Valve Head Diameter . . . . . . . . . . . . . . . . . . 1.410/1.414 in. (35,814/35,916 mm)
Valve Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Valve Head Depth Below Cylinder Head Face . 0.028 in. (0,711 mm) Minimum
0.048 in. (1,220 mm) Maximum
Overall Length of Valve . . . . . . . . . . . . . . 4.592/4.608 in. (116,637/117,043 mm)
Sealing Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rubber Oil Seal
8–1.18 Valves (Exhaust)
Valve Stem Diameter . . . . . . . . . . . . . . . . . . 0.3115/0.3125 in. (7,912/7,937 mm)
Clearance Fit of Valve Stem in Guide . . . . . . 0.002/0.004 in. (0,051/0,102 mm)
Valve Head Diameter . . . . . . . . . . . . . . . . . . 1.191/1.195 in. (30,251/30,353 mm)
Valve Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Valve Head Depth Below Cylinder Head Face . . 0.021 in. (0,53 mm) Minimum
0.048 in. (1,22 mm) Maximum
Overall Length of Valve . . . . . . . . . . . . . . 4.600/4.616 in. (116,840/117,246 mm)
Sealing Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . None fitted to exhaust valve
8–1.19 Inner Valve Springs
Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.530 in. (38,862 mm)
Load at Fitted Length . . . . . . . . . . . . . . . . . . 28.6 lbf ± 2 lbf (13,0 kgf ± 9,91 kgf)
Fitted Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Damper Coil to Cylinder Head

8–1.20 Outer Valve Springs
Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.780 in. (45,212 mm)
Load at Fitted . . . . . . . . . . . . . . . . . . . . . . . . 56.0 lbf ± 2.8 lbf (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. (18,301/18,326 mm)
Finished Inside diameter of Rocker
Lever Bushing . . . . . . . . . . . . . . . . . . . 0.6245/0.62575 in. (15,862/15,894 mm)
8–1.22 Valve Clearance
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)
8–1.24 Lifters
Overall Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.250 in. (57,150 mm)
Outside Diameter of Tappet Shank . . . . . . . 0.560/0.561 in. (14,224/14,249 mm)
Cylinder Block Tappet Bore Diameter . 0.562/0.56325 in. (14,275/14,307 mm)
OUtside Diameter of Tappet Foot . . . . . . . . 1.245/1.255 in. (31,623/31,877 mm)
825 Loader
8–2 TIMING GEARS
8–2.1 Injector Pump Gear
Running Clearance of Drive Hub in Bearing
0.0031/0.0051 in. (0,079/0,129 mm)
Drive Hub End Float . . . . . . . . . . . . . . . . . . . . . 0.002/0.010 in. (0,051/0,254 mm)
8–2.2 Crankshaft Gear
Inside Diameter of Gear . . . . . . . . . . . . . . 1.250/1,2512 in. (31,750/31,780 mm)
Crankshaft Diameter for Gear . . . . . . . . . 1.250/1.2506 in. (31,750/31,765 mm)
8–2.3 Timing Gear Backlash
Clearance Between Crankshaft/Idler and
Camshaft/Idler Gears . . . . . . . . . . . . . . . . . . 0.0015/0.003 in. (0,038/0,076 mm)
8–3 LUBRICATION SYSTEM
Lubricating Oil Pressure . . . . . . . . . . . . . . . . . . . . . . 30/60 PSI (2,1/4,2 kgf/cm2)
At maximum engine speed and normal working temperature
8–3.1 Lubricating Oil Pump
Minimum Delivery Rate at 800 Pump RPM
40 PSI (2,81 kgf/cm2) . . . . . . . . . . . . . . . . . . . . . . . . 2.4 U.S. GPM (9,1 liter/min)

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 . . . . . . . 0.500/0.501 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 . . . . . . . . 0.0013/0.0021 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 liter)
Radiator Cap Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 PSI (48,27 kPa)
8–4.1 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
825 Loader
149 of Feb.
8–5.1 Fuel Lift Pump
Method of Drive . . . . . . . . . . . . . . . . . . From Eccentric on Camshaft via Pushrod
Total Stroke of Operating Lever . . . . . . . . . . . . . . . . . . . . . . 0.192 in. (4,877 mm)
Static Pressure – No Delivery . . . . . . . . . . . . . . . . . 4–7 PSI (0,28–0,49 kgf/cm2)
Pump to Spacer Gasket Thickness . . . . . . . . 0.018/0.022 in. (0,457/0,559 mm)
8–5.2 Final Fuel Filter
Element Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper
Overflow Valve Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gravity Ball Check Valve
Valve in Fuel Pump Drain Connection . . Spring Loaded Non–Return Valve set
at 0.75 ––1.25 PSI (0,0525––0,0875 kgf/cm2)
8–5.3 Fuel Injection Pump
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.A.V.
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.P.A.
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
Plunger Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm
Timing Letter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
No. 1 Cylinder Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W
Static Timing Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18° B.T.D.C.
Piston Displacement From T.D.C. at 19° . . . . . . . . . . . . . . . . 0.109 in. (2,75 mm)
8–5.4 Injectors
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roto–Diesel or C.A.V.

Holder Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BKB 40 SD 5147V
Nozzle Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BDN 12 SD 6236
Identification Code Letter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BG
Minimum Working Pressure . . . . . . . . . . . . . . . . . . . . . . . 2000 PSI (140 kgf/cm2)
Setting Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2200 PSI (155 kgf/cm2)
8–5.5 Starting Aid
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.A.V.
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat Type 357
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Volt
Maximum Current Consumption . . . . . . . . . . . . . . . . 12.9 Amperes at 11.5 Volts
8–6 SERVICE WEAR LIMITS

The 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)
Valve Stem 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. (0,13 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)
825 Loader
150 of 176
8–7 DE–RATING FOR ALTITUDE
When engines are operated in high altitude areas, such engine should be
de–rated. The following table is given as a general guide, which may be applied
on a percentage basis, where specific figures for a particular engine rating are not
available.
Maximum Fuel Delivery De–rating

Altitude Measured 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 carrier out
by the C.A.V. dealer for the territory concerned.
8–8 TORQUE SPECIFICATIONS
The following torque figures are with the components lightly oiled before
assembly.
Ft.–Lbs. (Nm)

Cylinder Head Nuts 60 (81)
Connecting Rod Bolts 42 (57)
Main Bearing Bolts 85 (115)
Flywheel Bolts 60 (81)
Idler Gear Hub Bolts 32 (43)
Crankshaft Pulley Bolts 150 (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 inch Fastening Bolts 30 (40,6)
8–8.2 High Pressure Relief Valves:
Hex Plugs 60 (81,4)
8–8.3 Loader Torque Specs
Bolts at Pivot Points 40 (54,2)
Wheel Lub Nuts 90–100 (122–136)
Final Drive Idler: 3/4 Bolt 125–145 (170–197)
1/2 Bolt 45–55 (61–75)
Gearbox–to–Frame Bolts 220–230 (298–312)
Axle Housing to Upright Bolts 240–280 (325–380)
Axle Housing to Frame Bolts 125–140 (170–190)
Bushings Through Frame Walls for
Steering Shaft 100–120 (136–163)
5/8 Nut on the End of Steering Shaft 50–70 (68–95)
Piston Nut for the Lift Cylinder
(1–1/2 inch Rod) 200 (271,2)
(1–1/4 inch Rod) 160 (216,9)
Piston Nut for the Tilt Cylinder 160 (216,9)
Nuts on the end of axles: tighten until there is resistance when turning axle by
hand.
Nuts on steering centering spring: tighten until length of spring if 2.260 inches –
2.340 inches (57,5–59,4 mm)
825 Loader
STANDARD TORQUE SPECIFICATIONS FOR BOLTS
The above illustration shows the most common hex screw marking for each grade. A Grade 2 screw has no markings,
a Grade 5 screw has three radial dashes 120 degrees apart, a Grade 8 screw has six radial dashes 60 degrees apart.
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 1/4–Fine 55–70 45–60 95–120 65–85 135–165 95–120
N (6.21–7.91) (5.08–6.78) (10.73–13.56) (7.34–9.60) (15.25–18.64) (10.73–13.56)
C
H 5/16–Coarse 105–130 75–95 160–200 125–155 240–300 175–215
(11.86–14.69) (8.47–10.73) 18.08–22.60) (14.12–17.51) (27.12–33.90) (19.77–24.29)
L 5/16–Fine 115–145 85–105 180–225 135–165 260–325 190–240

B (12.99–16.38) (9.60–11.86) (20.34–25.4) (15.25–18.64) (29.40–36.72) (21.47–27.12)
S.
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) (24.4–31.2) (47.5–61.0) (33.9–40.7)
(Nm)
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) (27.1–33.9) (61.0–74.6) (47.5–54.2) (88.1–108.5) (67.8–81.4)
L 1/2–Coarse 40–50 30–35 60–75 45–55 90–110 65–80

B (61.0–74.6) (47.5–54.2) (94.9–115.2) (67.8–81.4) (128.8–162.7) (101.7–122.01)
S.
1/2–Fine 45–55 35–40 70–85 50–60 95–120 75–90
(Nm) (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

(81.4–101.7) 61.0–74.60 (128.8–162.7) (101.7–122.0) (183.0–230.5) (142.4–176.3)
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 21–260 160–200 300–380 225–280
(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
(196.6–244.01) (155.9–189.8) (325.4–406.1) (244.0–298.3) (460.1–569) (345.1–433.9)
7/8–Coarse 115–140 90–110 320–400 240–300 500–600 370–460

(155.9–189.8) (122.0–149.1) (433.9–542) (325.4–406.8) (678–814) (502–624)
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) (189.8–237.3) (759–895) (542–664) (1247–1383) (902–1037)
825 Loader
DECIMAL AND MILLIMETER EQUIVALENTS
FRACTIONS DECIMALS MM FRACTIONS DECIMALS MM

1/64 0.015625 — 0.397 33/64 0.515625 — 13.097
1/32 0.03125 — 0.794 17/32 0.53125 — 13.494
3/64 0.046875 — 1.191 35/64 0.546875 — 13.891
1/16 0.0625 — 1.588 9/16 0.5625 — 14.288
5/64 0.078125 — 1.984 37/64 0.578125 — 14.684
3/32 0.09375 — 2.381 19/32 0.59375 — 15.081
7/64 0.109375 — 2.778 39/64 0.609375 — 15.478
1/8 0.1250 — 3.175 5/8 0.6250 — 15.875
9/64 0.140625 — 3.572 41/64 0.640625 — 16.272
5/32 0.15625 — 3.969 21/32 0.65625 — 16.669
11/64 0.171875 — 4.366 43/64 0.671875 — 17.066
3/16 0.1875 — 4.762 11/16 0.6875 — 17.462
13/64 0.203125 — 5.159 45/64 0.703125 — 17.859
7/32 0.21875 — 5.556 23/32 0.71875 — 18.256
15/64 0.234375 — 5.953 47/64 0.734375 — 18.653
1/4 0.2500 — 6.350 3/4 0.7500 — 19.050
17/64 0.265625 — 6.747 49/64 0.765625 — 19.447
9/32 0.28125 — 7.144 25/32 0.78125 — 19.844
19/64 0.296875 — 7.541 51/64 0.796875 — 20.241
5/16 0.3125 — 7.938 13/16 0.8125 — 20.638
21/64 0.328125 — 8.334 53/64 0.828125 — 21.034
11/32 0.34375 — 8.731 27/32 0.84375 — 21.431
23/64 0.359375 — 9.128 55/64 0.859375 — 21.828

3/8 0.3750 — 9.525 7/8 0.8750 — 22.225
25/64 0.390625 — 9.922 57/64 0.890625 — 22.622
13/32 0.40625 — 10.319 29/32 0.90625 — 23.019
27/64 0.421875 — 10.716 59/64 0.921875 — 23.416
7/16 0.4375 — 11.112 15/16 0.9375 — 23.812
29/64 0.453125 — 11.509 61/64 0.953125 — 24.209
15/32 0.46875 — 11.906 31/32 0.96875 — 24.606
31/64 0.484375 — 12.303 63/64 0.984375 — 25.003
1/2 0.5000 — 12.700 1 1.000 — 25.400
1 mm = 0.03937’’ 0.001 = 0.0254 mm
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 Millimeters 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–Meter 1.356
LIQUID VOLUME Quarts Liters 0.9463
Gallons Liters 3.785
LIQUID FLOW Gallons/Minute Liters/Minute 3.785
TEMPERATURE Fahrenheit Celsius 1.Subtract 32°
2. Multiply by 5/9
825 Loader
8–9 SPECIAL TOOLS
PD 1C Valve Guide Remove and Replacer
With this tool, all valve guides can be removed and replaced provided puller bars
are available.
PD 1C–1 Puller Bars
Two bars are supplied for use with PD 1C to suit 0.3125 inch and 0.3750 inch I.D.
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.
PD 150 Cylinder Liner Remover and Replacer
PD 150–5 Adaptors for PD 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 0.3125 inch I.D. bore.

PD 317–22 Valve Seat Cutter Inlet
PD 317–G19 Glaze Breaker Exhaust
PD–317–G22 Glaze Breaker Inlet
Remarks: See PD 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:
PD–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.
825 Loader
825 LOADER SPECIFICATIONS
60
(1524)
155
(3937)
131.5
21.25 38.5° (3340) 76
(540) (1930)
37 94.25 120
(940) (2394) (3048)
46.5
85 (1181)
45° 113
(2159) (2870) 57
65 (1448)
(1651)
44
8.5 (216) (1118)
32° 26°
9.75 (248)
34 51.5
38 (864)
96 (965) (1308)
60.75

(2440) (1543)
126.75
(3219)
PI–01829
SPECIFICATIONS
Weights:
Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5780 lbs. (2624 kg)
Rated Operating Capacity (SAE Rating) . . . . . . . . . . . . . . . 1500 lbs. (681 kg)
Tipping Load (SAE Rating) . . . . . . . . . . . . . . . . . . . . . . . . . 3100 lbs. (1407 kg)
Travel Speed:
Work Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 4.4 MPH (7,1 km/hr.)
Transport Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 7.3 MPH (11,7 km/hr.)
Controls:
Vehicle . . . . . . . . . . . . . . . . . . . . Direction & speed controlled by two steering
levers & hand grip range selector
Loader Function . . . . . . . . . . . . . . . . . . . . . . . . . . Lift, Tilt & Auxiliary functions
controlled by separate foot pedals
Engine . . . . . . . . . . . . . . . . . . . . . hand lever throttle & key type starter switch
Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . mechanical disc, hand operated lever
ENGINE
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Perkins
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.108
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel
Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 HP (28 kW)
Maximum Governed RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2500 RPM
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 ft.–lbs. (108 Nm) @1900 RPM
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.125 (79,4)/3.5 (88,9)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107.4 cu. in. (1759,9 cm3)
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure System W/filter
Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Open
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry replaceable paper element
825 Loader
SPECIFICATIONS (Cont’d)
a
825ServiceManual#6549899–SpecificationsSection
LOADER HYDRAULICS
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine driven, gear type
Pump Capacity . . . . . . . . . . . . . . . . . . . . . . 12.5 GPM (47,3 L/min.) @2500 RPM
System Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2100 PSI (14478 kPa)
Hydraulic/Hydrostatic Fluid (Type) . Use Only Clark Hydraulic/Hydrostatic Fluid
(P/N 6563328) or Rando HDAZ Oil (Texaco Product 1629)
Hydraulic Fluid Filter . . Two 10 Micron replaceable elements on the hydrostatic
inlet, 25 Micron suction replaceable element
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doubleacting
Bore Diameter
Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 (57,1)
Tilt Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 (57,1)
Rod Diameter
Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 (38,1)
Tilt Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25 (31,8)
Stroke
Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.00 (787,4)
Tilt Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.13 (435,1)
Control Valve . . . . 3–spool, open center type lift, tilt & auxiliary with float on lift
Fluid Lines . . . . . . . . . . . . . . . . . . . . SAE standard full flow tube, hoses & fittings
Hydraulic Function Time
Raise Lift Arms to Maximum Height . . . . . . . . . . . . . . . . . . . . . . . 4.8 seconds
Lower Lift Arms from Maximum Height . . . . . . . . . . . . . . . . . . . . . 3.8 seconds

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. @0°F (–17.8°C)
125 minute reserve capacity
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt, gear drive
DRIVE SYSTEM
Transmission . . . . . . . . Two infinitely variable fully reversing hydrostatic pumps
Primary Reduction . . . . . . . . . . . . . . Spur gear operating in sealed oil lubrication
Final Reduction . . . . . . . . . . #100 roller chain, operating in sealed oil lubrication
Total Engine to Wheel Reduction:
Work Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.8:1
Transport Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.1:1
Fluid Type . Clark Bobcat Fluid (P/N 6563328 [5 gal. package]) if fluid is not
available use 10W–30 or 10W–40 Class SE Motor Oil
CAPACITIES
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 qts. (9,5 L)
Fuel (Plastic Tank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 gals. (60,5 L)
(Steel Tank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 gals. (125 L)
Engine Lubrication W/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 qts. (5,7 L)
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 gal. (102 L)
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 gal. (102 L)
TIRES
Standard . . . . . . . . . . . . . . . . . . . . . . . . 8.25 x 15, 6 ply Rating, Nylon W/Bar Lug
Pressure:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45–50 PSI (310 kPa)
Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 PSI (241 kPa)
825 Loader
15682
Revised Aug. of 176 –8–12– Service Manual
ALPHABETICAL INDEX
Paragraph Page
Number Number
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 9–1

ALPHABETICAL
INDEX
825 Loader
825 Loader
9–1 ALPHABETICAL INDEX
Subject Page Subject Page
ADJUSTMENT OF SPEED RANGE LINKAGE . . . . 3–1 LIFT ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
ALTERNATOR OUTPUT . . . . . . . . . . . . . . . . . . . . . . . 6–1 LIFT VALVE SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
ALTERNATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . 6–1 LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 8–1
AXLE BEARING & SEAL REPLACEMENT . . . . . . . 4–1 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
AXLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . 7–1, 8–1
BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
BOB–TACH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 5–1
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1, 2–1
CHECKING HYDROSTATIC SYSTEM . . . . . . . . . . . 3–1
CHECKING RELIEF VALVES . . . . . . . . . . . . . . . . . . . 3–1 PIVOT PIN & BUSHING REPLACEMENT . . . . . . . . . 5–1
CONNECTING RODS AND PISTONS . . . . . . . . . . . 7–1 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . 1–1
CONTROL LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 PROBLEM ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
CONTROL PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 7–1, 8–1 REDUCTION HOUSING ASSEMBLY . . . . . . . . . . . . . 4–1
CRANKSHAFT AND MAIN BEARINGS . . . . . . . . . . 7–1 REDUCTION HOUSING DISASSEMBLY . . . . . . . . . . 4–1
REDUCTION HOUSING REMOVAL . . . . . . . . . . . . . . 4–1
DE–RATING FOR ALTITUDE . . . . . . . . . . . . . . . . . . . 8–1
REGULATOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
DRAINING THE FLUID RESERVOIR . . . . . . . . . . . . 1–1
DRIVE CHAIN INSTALLATION . . . . . . . . . . . . . . . . . . 4–1 REMOVING AIR FROM THE FUEL SYSTEM . . . . . . 1–1
DRIVE CHAIN REMOVAL . . . . . . . . . . . . . . . . . . . . . . 4–1 ROPS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
ELECTRIC MOTOR FOR ROPS . . . . . . . . . . . . . . . . 5–1 SERVICE WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . . . . 8–1

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1

ELECTRICAL CIRCUITRY . . . . . . . . . . . . . . . . . . . . . 6–1
ELECTRICAL SYSTEM MAINTENANCE . . . . . . . . . 1–1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
ENGINE AIR INLET SYSTEM (Air Cleaner) . . . . . . . 1–1 STARTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . 1–1 STARTING ENGINE AFTER RECONDITIONING . . . 7–1
ENGINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . 1–1 STARTING PROCEDURE, AFTER REPAIR . . . . . . . 3–1
ENGINE OIL AND FILTER REPLACEMENT . . . . . . 1–1 STEERING CONTROL LINKAGE . . . . . . . . . . . . . . . . 3–1
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
10 MICRON FINAL FILTER REPLACEMENT . . . . . . 3–1
FAN BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 TEMPERATURE & PRESSURE SWITCHES . . . . . . 3–1
FAN BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 1–1 TILTING THE ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
FINAL DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 TIMING CASE AND DRIVE . . . . . . . . . . . . . . . . . . . . . . 7–1
FINAL DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 4–1 TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
FLUSHING THE COOLING SYSTEM . . . . . . . . . . . . 1–1 TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
FLYWHEEL AND FLYWHEEL HOUSING . . . . . . . . . 7–1 TIRE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
FUEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 1–1 TIRE ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1–1, 7–1, 8–1 TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
FUEL SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . 1–1 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 8–1
FUEL TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 5–1 TUBELINES, HOSES, FITTINGS . . . . . . . . . . . . . . . . 2–1
GEAR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 WHEEL MOUNTING NUTS . . . . . . . . . . . . . . . . . . . . . 1–1

GEAR PUMP DISASSEMBLY . . . . . . . . . . . . . . . . . . 2–1
HYDRAULIC CYLINDERS . . . . . . . . . . . . . . . . . . . . . . 2–1

HYDRAULIC CYLINDER REPAIR . . . . . . . . . . . . . . . 2–1
HYDRAULIC FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
HYDRAULIC FLUID FILTERS . . . . . . . . . . . . . . . . . . . 1–1
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . 1–1, 2–1
HYDRAULIC SYSTEM LEAKS CHECKS . . . . . . . . . 1–1
HYDRAULIC SYSTEM TROUBLESHOOTING . . . . 2–1
HYDROSTATIC DRIVE SYSTEM . . . . . . . . . . . . . . . 3–1
HYDROSTATIC MOTOR INSTALLATION . . . . . . . . 3–1
HYDROSTATIC MOTOR REMOVAL . . . . . . . . . . . . . 3–1
HYDROSTATIC PUMP INSTALLATION . . . . . . . . . . 3–1
HYDROSTATIC PUMP & MOTOR ASSEMBLY . . . . 3–1
HYDROSTATIC PUMP & MOTOR DISASSEMBLY 3–1
HYDROSTATIC PUMP REMOVAL . . . . . . . . . . . . . . 3–1
HYDROSTATIC TRANSMISSION . . . . . . . . . . . . . . . 1–1
HYDROSTATIC TRANSMISSION
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 3–1
INSPECT PARTS FOR WEAR . . . . . . . . . . . . . . 2–1, 3–1

INSTALLING CYLINDER HEAD . . . . . . . . . . . . . . . . . 7–1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1, 7–1
825 Loader
825 Loader
161 of 176
162 of 176
163 of 176
164 of 176
165 of 176
166 of 176
167 of 176
168 of 176
169 of 176
170 of 176
171 of 176
172 of 176
173 of 176
174 of 176
175 of 176
176 of 176

825 6549899 SM 12-83

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

825 6549899 SM 12-83

Hochgeladen von

Copyright:

Verfügbare Formate

8

Dealer Copy -- Not for Resale

CORRECT CORRECT CORRECT

B-10731a B-12365 B-7469

Dealer Copy -- Not for Resale

B-6590 B-6580 B-6589

3. Lubricate the machine.

4. Check battery condition, electrolyte level and cables.

6. Check alternator drive belt for condition and tension.

Dealer Copy -- Not for Resale

11. Make a visual inspection for loose or broken parts or connections.

12. Operate the loader; checking all functions. ENGINE

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1

Dealer Copy -- Not for Resale

Dealer Copy -- Not for Resale

This notice identifies

1–1.2 Serial Number Identification

1–1.3 Loader Serial Number

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

*Fig. 1–3 Pre–Delivery Inspection Form

1–1.6 30 Hour Inspection

Dealer Copy -- Not for Resale

1. For adjustment and inspection after first work period

2. To correct wrong maintenance and operating methods.

3. For demonstration of correct service procedures to customer.

ITEM SERVICE REQUIRED 8–10 50 100 200 500 1000

Dealer Copy -- Not for Resale

The ROPS (Roll Over Protective

1. Remove the retaining nuts at the

Dealer Copy -- Not for Resale

3. Stop the engine, engage the parking brake.

To lower the operator guard, use the

1–5 ENGINE MAINTENANCE

1. Check oil level every eight hours of operation.

Dealer Copy -- Not for Resale

Dealer Copy -- Not for Resale

RECOMMENDED SAE VISCOSITY NUMBER

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE

Dealer Copy -- Not for Resale

1–6 ENGINE OIL AND FILTER REPLACEMENT

1. Empty dust cap daily or as

2. Make replacement of the filter

Dealer Copy -- Not for Resale

3. In the case of leakage, if

NOTE: The seal surface of the filter

Use safety goggles when using air or water

Dealer Copy -- Not for Resale

Adjustment of the fan belt:

1–10 FLUSHING THE COOLING SYSTEM

Stop and cool the engine before

The fuel fill pipe is located at the rear of

1. Use a clean, approved safety

Dealer Copy -- Not for Resale

3. Add fuel only in an area that has a

4. Use only clean fuel of the correct

5. Tighten the cap on the fuel tank

1–12 FUEL SPECIFICATIONS

1–12.1 Water In The Fuel Tank

1. Keep the filler cap in place.

To replace the filter element: Water And

2. Remove the bolt at the top of the

Dealer Copy -- Not for Resale

4. Lubricate and install a new O–ring.