Bobcat 825 11001+ Factory Service & Work Shop Manual

2 5 8 6549899 (12–83) Printed in U.S.A. © Melroe Company 1983 Service Manual

MAINTENANCE SAFETY WARNING Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s 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 service. Untrained operators and failure to follow instructions can cause injury or death. W-2003-0903 Never service the Bobcat Skid- Steer Loader without instructions. Have good ventilation when welding or grinding painted parts. Wear dust mask when grinding painted parts. Toxic dust and gas can be produced. Avoid exhaust fume leaks which can kill without warning. Exhaust system must be tightly sealed. Stop, cool and clean engine of flammable materials before checking fluids. Never service or adjust loader with the engine running unless instructed to do so in the manual. Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes. Never fill fuel tank with engine running, while smoking or when near open flame. Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Do not go under lift arms when raised unless supported by an approved lift arm support device. Replace it if damaged. Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust. Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used. Use eye protection approved for type of welding. Keep rear door closed except for service. Close and latch door before operating the loader. Never work on loader with lift arms up unless lift arms are held by an approved lift arm support device. Replace if damaged. Never modify equipment or add attachments not approved by Bobcat Company. Lead-acid batteries produce flammable and explosive gases. Keep arcs, sparks, flames and lighted tobacco away from batteries. Batteries contain acid which burns eyes or skin on contact. Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention. Use the correct procedure to lift or lower operator cab. Cleaning and maintenance are required daily. 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 WRONG B-6590 WRONG B-16102 B-6580 WRONG B-16102 B-6589 WRONG B-15280 WRONG B-15231 WRONG B-11799 B-10731a CORRECT B-12365 CORRECT B-7469 CORRECT Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

PREVENTIVE MAINTENANCE HYDRAULIC SYSTEM HYDROSTATIC DRIVE SYSTEM MECHANICAL TRANSMISSION MAIN FRAME ELECTRICAL SYSTEM ENGINE SERVICE SPECIFICATIONS ALPHABETICAL INDEX 825 Loader Service Manual ALPHABETICAL INDEX 9–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM 6–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE SERVICE 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC SYSTEM 2–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDROSTATIC SYSTEM 3–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIN FRAME 5–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MECHANICAL TRANSMISSION 4–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREVENTIVE MAINTENANCE 1–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS 8–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTENTS FORWARD This manual provides instruction for proper routine service and adjustment of the Bobcat, and detailed overhaul instructions of the power train, loader hydraulic/hydrostatic system and general mainframe components. Refer to the Owner’s Manual for general operating instructions (Starting Procedure, Daily Checks, Bucket Operation, Minor Maintenance, etc.). A general inspection of the following items should be made whenever the machine has undergone service or repair: 1. Check hydraulic fluid level, engine oil level and fuel supply. 2. Inspect for any sign of fuel, oil or hydraulic fluid leaks. 3. Lubricate the machine. 4. Check battery condition, electrolyte level and cables. 5. Inspect air cleaner system for damage or leaks. Check element and make replacement, if necessary. 6. Check alternator drive belt for condition and tension. 7. Check for loose drive chains by lifting the rear of the machine and turning the rear wheels by hand. 8. Check tires for wear and pressure. 9. Check the Bob–Tach attachment for condition. Inspect the wedges for damage or wear. 10. Inspect safety items for condition (ROPS Guard, Seat Belt, Safety Treads, Lights, etc.). 11. Make a visual inspection for loose or broken parts or connections. 12. Operate the loader; checking all functions. Advise the owner if any of the above items are in need of repair.

825 Loader Service Manual

PREVENTIVE MAINTENANCE 825 Loader Service Manual 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 . . . . . . . . . . . . . . . . . . . . . . . . . . Revised Feb. 82

825 Loader Service Manual

IMPORTANT 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 either by Lot or serial number group) 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 Revised August 79 INTRODUCTION 1–1.1 Symbols 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 service. Failure to follow instructions can cause injury or death [A]. W–2003–0797 This notice identifies procedures which must be followed to avoid damage to the machine. I–2030–0284 B–02144 Fig. 1–2 Engine Serial Number Plate Serial Number B–02969R Fig. 1–1 Loader Serial Number Plate Serial Number Plate 825 Loader Service Manual –1–1–

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. 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: Revised Feb. 82 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 copy is for the dealer. 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. 825 Loader Service Manual –1–2– Fig. 1–4 30 Hour Inspection Form *Fig. 1–3 Pre–Delivery Inspection Form

Bobcat 825 11001+ Factory Service & Work Shop Manual

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