Bobcat 825 Skid Steer Loader Service Repair Manual – PDF Download

8 2 5

Service Manual

6549899 (12–83)

Printed in U.S.A.

© Melroe Company 1983

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 W-2003-0903 instructions can cause injury or death.

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 SkidSteer Loader without instructions.

Use the correct procedure to lift or lower operator cab.

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

B-11799

B-15231

B-15280

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.

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.

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.

WRONG

WRONG

WRONG

B-6590

B-6580 B-16102

B-6589 B-16102

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.

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.

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.

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

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.).

PREVENTIVE MAINTENANCE

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.

2. Inspect for any sign of fuel, oil or hydraulic fluid leaks.

HYDROSTATIC DRIVE SYSTEM

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.

MECHANICAL TRANSMISSION

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.

MAIN FRAME

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.).

ELECTRICAL SYSTEM

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.

ENGINE SERVICE

SPECIFICATIONS

CONTENTS 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

–1––3–

ALPHABETICAL INDEX

825 Loader Service Manual

–1––2–

825 Loader Service Manual

PREVENTIVE MAINTENANCE Paragraph Number

Page Number

BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–30 DRAINING THE FLUID RESERVOIR . . . . . . . . . . . . . . . . . . 1–19 ELECTRICAL SYSTEM MAINTENANCE . . . . . . . . . . . . . . . 1–15 ENGINE AIR INLET SYSTEM (Air Cleaner) . . . . . . . . . . . . . . 1–7 ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8 ENGINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 ENGINE OIL AND FILTER REPLACEMENT . . . . . . . . . . . . . 1–6 FAN BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9 FINAL DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23 FLUSHING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . 1–10 FUEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11 FUEL SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13 HYDRAULIC FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17 HYDRAULIC FLUID FILTERS . . . . . . . . . . . . . . . . . . . . . . . . 1–18 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16 HYDRAULIC SYSTEM LEAK CHECKS . . . . . . . . . . . . . . . . 1–20 HYDROSTATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 1–22 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–28 OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–21 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 1–2 REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 REMOVING AIR FROM THE FUEL SYSTEM . . . . . . . . . . . 1–14 TILTING THE ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–25 TIRE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–27 TIRE ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–26 TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–24 WHEEL MOUNTING NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . 1–29

1–16 1–12 1–10 1–6 1–7 1–4 1–5 1–7 1–14 1–7 1–8 1–8 1–9 1–11 1–11 1–11 1–13 1–13 1–1 1–15 1–13 1–3 1–4 1–9 1–4 1–15 1–15 1–15 1–14 1–15

Revised Feb. 82

–1––1–

PREVENTIVE MAINTENANCE

825 Loader Service Manual

–1–0–

825 Loader Service Manual

INTRODUCTION Serial Number Plate

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].

B–02969R

Fig. 1–1 Loader Serial Number Plate

W–2003–0797

Serial Number

IMPORTANT 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 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.

B–02144

Fig. 1–2 Engine Serial Number Plate

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

–1–1–

825 Loader 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 copy is for the dealer.

Revised Feb. 82

–1–2–

Fig. 1–4

30 Hour Inspection Form

825 Loader Service Manual

SERVICE SCHEDULE Maintenance work must be done at regular intervals. Failure to do so will result in damage to the Bobcat loader or the engine. The SERVICE SCHEDULE is a guide for correct maintenance of the Bobcat loader. DO NOT change this SERVICE SCHEDULE unless you increase the frequency of service when the Bobcat loader is operated in very hot, cold, dusty or corrosive conditions.

Never go under or reach under lift arms or a lift cylinder without an approved lift arm stop installed, or you could be crushed.

W–2060–0887

ITEM Engine Oil Engine Air Cleaner

Engine Cooling System Tires Seat Belt, Operator Guard & Seat Bar Safety Signs (Decals) All Pivot Pins Hydraulic Fluid Water Filter Wheel Nuts Engine Oil and Filter Transmission Fluid Battery Control Pedals and Steering Linkage Bob–Tach Brake Drive Belt (Alternator & Water Pump) Drive Chains Hydraulic Tubes & Hoses Spark Arrestor Muffler Fluid Filter (25 Micron) Fluid Filter (10 Micron [External]) Final Fuel Filter Transmission Fluid Reservoir U–Joint (Hydrostatic & Engine) Seat Bar Transmission Fluid Reservoir Transmission Fluid Filter (10 Micron [Internal])

SERVICE REQUIRED

8–10

50 100 200 500 1000

Check the oil and add oil as needed.

Check the condition indicator. Make inspection of the air cleaner system. Replace the element when the red ring shows in the indicator window.

Make inspection and clean the radiator as necessary.

Check the coolant level and add coolant if level is low.

Check tires for damage and for correct air pressure.

Check the condition of the seat belt. Check the operator guard fastening bolts to make sure they are tight. Check the seat bar for correct operation.

Check for damaged decals. Replace any decals that are not in the correct location.

Add grease to all the fittings.

Check fluid level and add recommended fluid as needed.

Remove the trapped water.

Tighten wheel nuts to 120 ft.–lbs. (163 Nm) torque (Check every 8 hours for the first 20 hours).

Change oil and filter.

Check fluid level and add fluid as needed.

Check the battery cables and the water level.

Check both for correct operation. Make repairs and adjustments as needed.

Check the locking levers and wedges for their condition and correct operation.

Check the brake for correct operation. Make adjustment as needed.

Check condition and tension of the belt.

Raise the loader and check the tension in the chains.

Inspect for damage and leaks and replace as needed.

Empty spark chamber.

Replace the filter element.

Replace the filter element.

Replace the filter element. Remove air from the system.

Remove condensation, check level and add as needed.

Add grease to the fittings (3) Lubricate the detent mechanism.

Drain the reservoir and fill with the correct fluid.

Replace the filter element.

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

825 Loader –1–3– Service Manual Revised Feb. 82

1–3 REAR GRILL

Grill Handle

825ServiceManual#6549899–PreventiveMaintenanceSectionPages1–4

The rear grill is opened by pulling forward 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).

Latch

1–4 TILTING THE OPERATOR GUARD 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 ROPS (Fig. 1–7).

A–02278

Fig. 1–5

ReleasingEngine Cover Fastener

B–01793

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 between the wheels (Fig. 1–8A). Use a rachet and socket (Fig. 1–8a) and tilt the operator guard into the full forward position (Fig. 1–9).

B–01796

Fig. 1–7

NOTE: DO NOT exceed 50 ft–lbs. (68 Nm) torque on the hex bolt used to raise or lower the operator guard.

ROPS Retaining Nuts

Raise

WARNING Tilt Switch

DO NOT raise or lower the 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–03626

B–01781

Fig. 1–8 Revised Feb. 82

Cab Tilt Switch

–1–4–

Fig. 1–8a

Lifting The Operator Guard

825 Loader Service Manual

1–4.1 ROPS Tilt Motor To seal out water from the ROPS tilt motor, clean the area (Fig. 1–9a, Item 1). Seal electric wire opening the R.T.V. (Room Temperature Vulcanizing) type compound.

1

1–5 ENGINE MAINTENANCE 1–5.1 Engine Oil

B–01809

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 of operation.

Fig. 1–9a

ROPS Tilt Motor

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 Marks

1–5.2 Specifications Use good quality detergent motor oil that meets the API service classifications.

(See Chart.)

Max. Min.

A–01528

Fig. 1–10

Dipstick

Dipstick

Fill Pipe

B–01789

Fig. 1–11 Engine Oil Dipstick/Fill Locations Revised Feb. 82

–1–4a–

825 Loader Service Manual

825ServiceManual#6549899–PreventiveMaintenanceSectionPages4a–4b

–1–4b–

825 Loader 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 Revised Feb. 82

–1–5–

Engine Oil Drain Plug

825 Loader Service Manual

1–7 ENGINE AIR INLET SYSTEM (AIR CLEANER) Correct maintenance of air inlet system is necessary for long engine life. A small leak in the system can destroy an engine in a few minutes. Set up a schedule for inspection and follow it regularly. To service the filter, follow these steps:

Dust Cap

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. 1–14).

A–02283

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 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).

Reset Button

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.

2. If the air cleaner has been damaged, check all connections immediately.

Check the internal cartridge seal areas. Make replacement of the air cleaner body if necessary.

Indicator

A–02291

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.

4. Inspect the intake manifold gasket for damage or looseness which can cause dirty air to enter the engine.

Element

B–01791

Fig. 1–15 Removing Air Cleaner Element Revised August 79

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825 Loader Service Manual

1–8 ENGINE COOLING SYSTEM Correct coolant level must be kept to cool the engine or overheating will result.

Check the coolant level in the radiator daily and fill to 2.0 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).

Radiator Cap

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

Fig. 1–17

Cleaning Engine Radiator

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).

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 at the middle point between the pulleys (Item 3).

A–02289

Mounting 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 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 when installing the thermostat housing.

0.375”

Set Screw

A–02287

Fig. 1–18 Adjusting Fan Belt Revised January 77

–1–7–

825 Loader 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).

Fig. 1–19

Fuel Fill Warning

X

B–03756

1. Use a clean, approved safety container to add fuel.

1 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 Revised Feb. 82

–1–8–

Fuel Tank Drain

825 Loader Service Manual

1–13 TO SYSTEM

SERVICE

THE

FUEL

The engine is equipped with two fuel filters; a filter which holds water and a secondary filter (Fig. 1–22). The filter element (Fig. 1–22, Item 1) must be replaced every 250 hours of operation.

Clean the water filter (sediment bowl) (Fig. 1–22, Item 2) at regular intervals (See SERVICE SCHEDULE).

3

1

Secondary Filter

2

Water And Sediment Trap

To replace the filter element:

B–01790

1. Clean the area around the filter housing.

Fig. 1–22

Fuel Filters (Primary And Secondary)

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 Revised Feb. 82

–1–9–

Fuel Filter Bolt

825 Loader Service Manual

4. Operate the lever on the fuel lift pump (Fig. 1–25) pushing the fuel and air through the vent plugs.

NOTE: If the lift pump will not pump fuel, rotate the engine a small amount.

5. When solid flow of fuel flows from the vent plugs (no air bubbles), tighten all the vent plugs in the following order: (a) Final fuel filter bolt (Fig. 1–24, Item 1). (b) Injector pump housing side plug (Fig. 1–23, Item 2). (c) Injector pump housing top plug (Fig. 1–23, Item 1).

6. Loosen the fittings on the high pressure lines of the injectors (Fig. 1–26).

7. Move the throttle to half open position. Turn the engine with the starter until no air bubbles show at the fittings of the injectors. Tighten all the high pressure fittings.

B–03873

Fig. 1–25

Fuel Lift Pump

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 MAINTENANCE

SYSTEM

1–15.1 Electrical System The Bobcat is equipped with a 12 volt generator charging system. Maximum output is 22 Amp. Service Electrical System as follows:

Loosen fittings B–03948

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, 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.

Sender

A–02288

Fig. 1–27 Revised Feb. 82

–1–10–

Wire

Grounding Sender Wire

825 Loader Service Manual

1–16 HYDRAULIC SYSTEM 1–16.1 Hydraulic/Hydrostatic Transmission Fluid Use Clark hydraulic/hydrostatic transmission fluid (P/N 6563328). This fluid is available at Chicago Central Parts. 10W–30 or 10W–40 SAE Motor Oil API Class SE or SF can also be used.

Dipstick

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).

It is important that correct fluid level be maintained at all times. Add fluid at the reservoir fill pipe or fill plug (Fig. 1–29) (See Hydraulic/Hydrostatic Transmission Fluid).

A–02284

Fig. 1–28 Hydraulic Reservoir Dipstick

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 filter (10 Micron) is installed in the return 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.

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

A third final filter (10 Micron) is installed inside the hydraulic reservoir (transmission housing). Replace this filter every 1000 hours. You must remove the transmission cover (floor panel) to replace this filter. (See Final Filter page 3–10).

Revised Feb. 82

Current Models Fig. 1–29

B–02638

Early Models

B–01794

Hydraulic Reservoir Fill

Hydrostatic Transmission (10 Micron)

Suction (25 Micron)

B–01802

Fig. 1–30

Hydraulic And Hydrostatic Filters

–1–11–

825 Loader Service Manual

1–18.1 Replacement Of The Suction (25 Micron) Filter (Fig. 1–31): 1. Tilt the ROPS forward.

2. Clean around the outside of filter base.

3. Use a strap wrench or large size filter wrench to unscrew the 25 micron filter element. (Place a reservoir under the loader to catch fluid spill.) 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 defect. Add lubricant to the seal ring before installing filter.

5. Install the new element and turn it on until it contacts the gasket, then tighten it another 1/2 turn.

25 Micron Filter A–02285

Fig. 1–31

Removing Hydraulic Filter

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): 1. Tilt the ROPS forward.

2. Thoroughly clean the exterior of the filter.

3. Use a filter wrench to remove the 10 micron filter element. Throw away the old element.

Drain

A–02279

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.)

–1–12–

825 Loader Service Manual

Regularly (depending on humidity and/or temperature change) lift the rear of the loader and let stand overnight. Loosen the drain plug to allow water, if any, to run out. A large quantity of water in the sump may cause permanent damage to the hydraulic and transmission system.

1–20 LEAKS Regular inspection must be made to find leaks at tube fittings, hose connections, lift and tilt cylinders, filters, etc. A leak in the hydraulic system must not be permitted. Even a small leak can amount to a large loss of fluid in a short period of time. Most leaks are easily repaired.

Sometimes, tightening a fitting or hose clamp is all that is necessary. Do not over tighten tube fittings, as this can cause a greater leak. A tube fitting that still leaks after it has been properly tightened must be disconnected and checked for foreign particles or damaged joint. If the seat is cracked or has deep scratches, the part must have replacement made.

B–01803

Fig. 1–33

Cleaning The Oil Cooler

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).

Revised January 77

–1–13–

825 Loader Service Manual

1–22.1 Loader Start–Up Follow these procedures when starting the loader, after servicing: 1. Be sure that the system is filled with good grade transmission fluid.

2. Follow correct engine starting procedure (See Owner’s Manual).

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

Revised January 77

–1–14–

825 Loader 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, can result in poor loader performance.

When exchanging a damaged or worn tire, it is important that the replacement tire be of the same size as the tire still on the Bobcat. Two different size tires on the same side of the machine will cause drive chain and tire wear, and loss of power. If two new tires are used for replacement of two worn ones, put both new tires on the same side.

CODE FOR SYMBOLS GREASE

AIR FILTER

ENGINE OIL FILTER

COOLANT

FUEL FILL

HYDRAULIC OIL FILTER

ENGINE OIL

FUEL FILTER

HYDRAULIC OIL RESERVOIR

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 the seat and put grease on the seat rails to keep them working smoothly.

(Early) (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 Revised Feb. 82

Lubrication Chart

–1–15–

825 Loader Service Manual

1–30 BOB–TACH 825ServiceManual#6549899–PreventiveMaintenanceSectionPages5–16

Unlocked

Check the Bob–Tach locking lever and wedges for wear or damage. The lever springs must compress enough to hold the levers in over–centered (lock) position when the levers are pushed down (Fig. 1–37, 1–38).

Spring tension adjustment is 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 & Below) it will be necessary to cut off 0.625 inch from each end of the rod end trunnion (Fig. 1–38a).

Locked

Wedges B–01508

Fig. 1–37

Bob–Tach (Old Style)

Fig. 1–38

Bob–Tach (New 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

Tighten

Lock 0.625”

0.625”

A–02427

Fig.1–38a Revised August 79

Cutting Old Style Cylinder Rod

–1–16–

A–02464

Fig.1–39

Park Brake

825 Loader Service Manual

HYDRAULIC SYSTEM Paragraph Number

Page Number

CONTROL PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9 CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7 GEAR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4 GEAR PUMP DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5 HYDRAULIC CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10 HYDRAULIC CYLINDER REPAIR . . . . . . . . . . . . . . . . . . . . . 2–11 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 HYDRAULIC SYSTEM TROUBLESHOOTING . . . . . . . . . . . 2–3 INSPECT PARTS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . 2–6 LIFT VALVE SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8 OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12 TUBELINES, HOSES, FITTINGS . . . . . . . . . . . . . . . . . . . . . . . 2–2

2–9 2–6 2–4 2–4 2–10 2–10 2–1 2–2 2–5 2–8 2–12 2–1

–2––1–

HYDRAULIC SYSTEM

825 Loader Service Manual

–2–0–

825 Loader Service Manual

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.

Revised Feb. 82

–2–1–

825 Loader Service Manual

Fitting Size

Rotate No. of Hex Flats

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

Mark a Line on Nut and Adapter Before Torquing

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 damage. Make replacement of the part if it is damaged.

A–01897

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 Rough Hydraulic Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B No Lift Hydraulic Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C No Tilt Hydraulic Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C No Auxiliary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C

O–Ring

A–01852

Fig. 2–3 Straight Thread Seal –2–2–

825 Loader Service Manual

CHART A NO OR SLOW HYDRAULICS Check Pump Output Page 2–4

Check Pedal Linkage Page 2–9

Check Fluid Level And Type

Check Suction Side Fittings (Of Pump)

If Not Correct

If Fittings Are Loose

If Output Is Low

Make Repair

Make Replacement of 25 Micron Filter Page 1–12

Check Seals In Cylinder Page 2–11

If Output Is Still Low

If No Defect Is Found

Add Fluid Or Make Replacement

If Good

If Good

If Defect Is Found

Make Repair Or Replacement Of Linkage

If No Defect Is Found

Check Pump Output Page 2–4

Check Release Pressure Page 2–6

If Output Is Still Low

If Pressure Is Correct

Make Repair Or Replacement Of Pump

Check Valve Assembly Page 2–6

If Defect Is Found

Make Repair Or Replacement Of Seals

If Pressure Make Repair Or Adjust Is Not As Needed Correct

If Defect Is Found

Make Repair Or Replacement Of Valve

CHART B

CHART C

ROUGH ACTION OR NO ACTION OF HYDRAULIC CYLINDERS

NO LIFT, NO TILT OR NO AUXILIARY

Check Fluid Level And Type

If Not Correct

Add Or Make Replacement Of Fluid

If Correct

Check Suction Side Of Pump For Air Leaks

Check Cylinder Seals Page 2–11

If No Defect Is Found

Check Linkage Rods Page 2–9

If No Defect Is Found

Check Valve Section Page 2–6

If Defect Is Found

If Defect Is Found

If Defect Is Found

Add Or Make Replacement Of Seals

Make Repair Of Linkage Rods

Make Replacement Of Valve Section

–2–3–

825 Loader Service Manual

2–4 GEAR PUMP 2–4.1 Testing 1. Disconnect the gear box. (See Fig. 3–25, Page 3–15.)

2. Tilt ROPS forward.

3. Remove cover.

transmission

housing

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 the tester fully out (counterclockwise).

B–02242

Fig. 2–4

Testing Gear Pump

7. Start engine and run at low RPM.

WARNING

Loader must not be run with ROPS in 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

1. Tilt the ROPS forward.

2. Remove transmission case cover.

3. Remove hydraulic lines and protect them with poly bags.

4. Remove two fastening bolts and remove pump assembly (See Fig. 2–5). Do not force anything between the two surfaces. Use a soft hammer to loosen the pump, if necessary.

Reverse the above procedure to install.

Tighten the fastening bolts to 33 ft–lbs. torque.

Revised Feb. 81

2

1

6 4 8 11 12 13

9 10

3 14

7 16

5 C–01090

Fig. 2–6 Gear Pump Breakdown –2–4–

825 Loader Service Manual

2–5 DISASSEMBLY OF GEAR PUMP (Fig. 2–6) 1. Clean outside of pump thoroughly.

2. Clamp pump in vise, shaft down.

3. Remove four tie bolts (Item 1).

4. Remove two tie bolts (Item 2).

5. Use a sharp tool to mark across front place, body and back plate. This will aid in correct assembly.

6. Remove the pump from the vise. Hold the pump in both hands and hit the shaft against a wooden block to separate the front plate (Item 3) from the back plate (Item 4). The body (Item 5) will hold to either the front plate or the back plate.

7. To separate the body from the section it is with, put drive gear (Item 6) in the bearing and hit the end with a plastic hammer.

8. Remove the O–ring (Item 7) from the back plate assembly.

9. Remove the diaphragm (Item 8) from the front plate by using a sharp tool.

10. Remove the springs (Item 9), two each, and steel balls (Item 10), two each, from the front plate.

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

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.)

Revised Feb. 81

–2–5–

825 Loader Service Manual

3. Bearings in front plate must be flush with lands in groove pattern.

4. Check for wear on face of back plate – if wear is more than 0.0015 inch, back plate needs replacement.

2–6.3 Body 1. Check inside gear pockets for wear.

2. Body needs replacement if I.D. of gear pocket is more than 1.719 inch.

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 –2–6–

Testing Relief Pressure

825 Loader Service Manual

6. Activate auxiliary pedal so pressure goes over relief setting.

3

4

7. Correct pressure is 2100–2150 PSI. 1

8. If pressure is not correct, make 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 drift after cylinders are found to be good, then check the control valve for the following:

4 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 make pedal adjustment to fit the 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 parts.

5 2

B–01539

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.

2. Tilt ROPS forward.

3. Disconnect control rods from valve bank.

4. Disconnect tubelines at valve bank and protect with poly bags.

5. Remove bolts which hold valve bank assembly (Fig. 2–9).

Valve Bank

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 –2–7–

825 Loader Service Manual

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 careful not to clamp the machine surface in the vise jaws.

B–01511R

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 –2–8–

825 Loader Service Manual

NOTE: Install the rear O–ring seals and seal retainer on the spool before installing spool in the valve section. Push the spool into the rear of the valve section (Fig. 2–12).

Valve Section

Retaining Washer

3. Make lubrication of new O–rings with oil and press them into the seal grooves at each end of the valve section.

O–Ring Seal

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 poppets, springs and hex plugs.

Use new O–rings, lubrication made with oil, on the plugs.

Fig. 2–12

Installing Valve Spool With Seals

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 STEP 3 Adjust Yoke

2–9.1 Adjustment 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).

NOTE: Make adjustment operator.

to

STEP 4

fit STEP 1 Remove Pin

0.250” STEP 2 Loosen Nut D–01170

A–02385

Fig. 2–14 Adjustment Of Control Pedals –2–9–

825 Loader Service Manual

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

Fig. 2–15

1. Lift the lift arms and hold with a support or hoist.

2. Disconnect hydraulic hoses and protect ends with plastic bags.

3. Remove pivot pins.

Pin

2

1

Brake Lever Removal

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 tilt pedal to release hydraulic pressure.

Lift Cylinder

B–02270

Fig. 2–15.2

Foot Pedal Spacer

B–02241

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 can cause damage to cylinder head seals. Carefully remove scratches on a cylinder shaft with a fine carborundum stone (Fig. 2–18).

Revised March 1978

–2–10–

Lift Cylinder Fig. 2–17

B–02239

Tilt Cylinder Removal

825 Loader Service Manual

2. Pin holes at either of the cylinder fittings can cause external leakage.

Pinholes can be welded shut by gas or electric arc welding. When welding the 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.

Stone

3. A bent cylinder case can cause the piston to be worn flat and result in internal leakage.

If a cylinder case has been bent and the piston worn flat, make replacement of the cylinder.

4. Foreign material on the cylinder case can cause damage to the cylinder wall and result in internal leakage. Use caution when opening hydraulic lines or making replacement of the filter element. Do not allow dirt to get into the system, as it will circulate through the system and cause wear to the hydraulic pump, control valve and cylinders.

PI–01221B

Fig. 2–18

Removing Scratches

Cylinder Head

2–11.1 To Disassemble A Hydraulic Lift Or Tilt Cylinder 1. Remove the cylinder from the machine (To remove the lift cylinder, remove both pivot pins first, move the cylinder forward and remove the hydraulic 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 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)

Spanner Wrench Fig. 2–19.1

A–01896

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

2. Install the spacer on the shaft (lift cylinder only).

Rod Seal Inside

File

3. Install the piston seals and put the piston onto the end of the cylinder shaft.

Back–Up Seal Wiper Seal

4. Install the piston locking nut and tighten to 150 – 160 ft.–lbs. (203 – 217 Nm) torque.

PI–01221A

Fig. 2–20 Revised Feb. 81

Beveling The Shoulder

–2–11–

A–01898

Fig. 2–21

Installing Cylinder Head

825 Loader Service Manual

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 By–Pass Valve

1. Remove lines which go to cooler and protect open ends with plastic bags.

2. Remove wire to temperature sending unit.

3. Remove fastening bolts and lift oil cooler out.

B–01794R

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 & 2–23.

Fig. 2–23

Removal Of By–Pass Valve

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.)

Revised Feb. 81

–2–12–

825 Loader Service Manual

HYDROSTATIC SYSTEM Paragraph Number

Page Number

ADJUSTMENT OF SPEED RANGE LINKAGE . . . . . . . . . . . 3–4 CHECKING HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . 3–6 CHECKING RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7 CONTROL LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3 HYDROSTATIC DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 3–1 HYDROSTATIC MOTOR INSTALLATION . . . . . . . . . . . . . . . 3–13 HYDROSTATIC MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . 3–12 HYDROSTATIC PUMP INSTALLATION . . . . . . . . . . . . . . . . 3–11 HYDROSTATIC PUMP & MOTOR ASSEMBLY . . . . . . . . . . 3–16 HYDROSTATIC PUMP & MOTOR DISASSEMBLY . . . . . . 3–14 HYDROSTATIC PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . 3–10 HYDROSTATIC TRANSMISSION TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 INSPECT PARTS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . 3–15 STARTING PROCEDURE, AFTER REPAIR . . . . . . . . . . . . 3–17 STEERING CONTROL LINKAGE . . . . . . . . . . . . . . . . . . . . . . 3–5 TEMPERATURE & PRESSURE SWITCHES . . . . . . . . . . . . . 3–9 10 MICRON FINAL FILTER REPLACEMENT . . . . . . . . . . . . 3–8

3–6 3–8 3–9 3–6 3–1 3–12 3–12 3–11 3–14 3–13 3–11

–3––1–

HYDROSTATIC SYSTEM

3–1 3–14 3–15 3–7 3–10 3–10

825 Loader Service Manual

–3–0–

825 Loader Service Manual

3–1 HYDROSTATIC DRIVE SYSTEM 3–1.1 Description The hydrostatic system is made up of a charge pump (geroter), two hydrostatic pumps and two hydrostatic motors. See the colored Flow Charts PI–02512, PI–02513 and System Operation description for the full operation the Hydrostatic System.

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

–3–1–

825 Loader Service Manual

CHART A– NO DRIVE SYSTEM PRE–CHECK Check Oil Level

If Correct

Turn On Ignition & Check TransFilt Light

If Light

Check TransFilt Light (Max. 5 Sec. For Light To Go Out)

Start Engine & Run At 1/2 Throttle

Is On

If Level Is Low

If Light Is Off

If Light Goes Out

Add Oil

Make Repair On Light System

Go To Chart C

Go To Chart C

If Machine Now Operates Return To Service

Charge Hydraulic System & Repair Air Leaks Page 3–15

If Lift Arms

Operate Lift Arms To Full Height & Over Operate Relief Valve Correctly

If Light Will Not Go Out

Operate Lift Arm Control

If Lift Arms Operate Correctly

If Lift Arms Will Not Operate

If Lift Arms Will Not Operate

Go To Chart B

CHART B – NO DRIVE GEAR PUMP CHECK Check Output Of Implement Pump Page 2–4

If Gal/Min Is Correct

Go To Chart C

If Gal/Min Is Low

Make Replacement Of 25 Micron Filter & Recheck Gal/Min

Revised March 1976

If Gal/Min Is Correct

Check Pump Pressure

If Gal/Min Is Low

If Pressure Is Correct

Make Replacement Of Implement Pump

If System Operates Normally Return To Service

–3–2–

If Pressure Is Low

If System Does Not Operate Correctly

Go To Chart C

825 Loader Service Manual

CHART C NO DRIVE Check Charge Pressure Page 3–8

If Pressure Is Correct

Check Stroked Charge Pressure Page 3–8

If Pressure Is Low

Inspect Components & Case Drain Page 3–14

If Pressure Is Low

If Pressure Is Correct

If No Defect Is Found

Install External 10 Micron Filter

If System Operates Correctly Return To Service

Inspect Charge Relief Spring Page 3–14

If Defect

Install New Component

Is Found

If Defect Is Found

Make Repair Of Spring

If No Defect Is Found

Install Internal 10 Micron Filter

Check Charge Pressure

CHART D DRIVE WITH WARNING LIGHT ON

Check Charge Pump Inlet Pressure Page 3–8

If Pressure Is Low

Check 50–60 PSI Valve Low

If Pressure Is Still Low

Check 20 PSI Valve

If Pressure Is Still Low

Change Internal 10 Micron Filter

If Pressure Is Correct

If Pressure Is Correct

–3–3–

If System Now Operates Correctly Return To Service

If Pressure Is Correct

825 Loader Service Manual

CHART E NO DRIVE ON ONE SIDE

Inspect Control Linkage

If No Defect Is Found

Check Stroked Charge Pressure Page 3–8

If Defect Is Found

If Pressure Is Low

Make Repair Of Linkage

Check Case Drain Of Both Pump And Motor

If Pressure Is Correct

Inspect Drive Chain

If Defect Is Found

If Flow Is Correct

Make Repair Or Install New Drive Chain

If Flow Is Large In Motor Or Pump

Install New Component

CHART F LOADER PULLS TO ONE SIDE

Inspect Linkage (Two–Speed And Control Lever) If Adjustment Is Not Correct

Make Repair Or Adjustment As Necessary

If Adjustment Is Correct

Check Wheel RPM In High And Low Range If Defect Is Found

Make Adjustment Of Lever Stops

–3–4–

If RPM Is Correct

Inspect Tire Pressure And Diameter If Defect Is Found

Make Repair Or Install New Tire

825 Loader Service Manual

CHART G LOADER OPERATES ONLY ONE DIRECTION – ONE SIDE

Inspect Control Linkage

If No Defect Is Found

If Defect Is Found

Inspect High Pressure Relief Valves Page 3–9

Inspect Charge Relief Valves Page 3–9

If Defect Is Found

If Defect Is Found

Install New Valve

Install New Valve

Make Adjustment And/Or Repair

CHART H SYSTEM OVERHEATING Check Oil Level And Type

If Correct

Inspect Oil Cooler

If No Defect Is Found

Inspect Fan Belt

If No Defect Is Found

Check For Suction Air Leak

If Low Or Wrong Type

If Defect Is Found

If Defect Is Found

If Leak Is Found

Add Or Make Replacement Of Oil

Make Repair Or Clean

Make Repair Of Belt

Make Repair

Install New Transmission Assembly

If In Low Range

–3–5–

Check For Loader Being Operated In High Range

If No Defect Is Found

If No Leak Is Found

Inspect Cooler By–Pass Valve Page 2–12

If In High Range

If Defect Is Found

Operate In Low Range

Make Repair Or Install New Valve

825 Loader Service Manual

3–3 CONTROL LINKAGE 3–3.1 Adjustment Of Steering Linkage 1. Lift and block loader so all wheels are off floor, or pull out transmission gear box levers (Fig. 3–10).

2. Tilt ROPS and transmission cover.

Lever

remove

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.

Gasket

6. Put steering levers in neutral position.

7. Loosen lock nut and turn swivel linkage rod until eye of swivel is in alignment with bolt in pump arm.

8. When alignment is correct, fasten swivel with bolt and tighten lock nut on swivel.

Tighten nut for swivel bolt to 10 ft.–lbs. (14 Nm) torque.

Steering Linkage C–01829

Fig. 3–2

Removing Drive Linkage

9. Install a new gasket before putting transmission cover on.

3

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 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 bar and motor control arms. Check for hose or tubelines in wrong position and stopping movement of linkage.

6 4

2

5

C–01754

Fig. 3–3 Adjustment Of Linkage Rod Revised April 80

–3–6–

825 Loader 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 Motor

2. Remove the bolts holding the linkage to the arm of the front motor and bellcrank (Fig. 3–5).

3. Remove the bolts holding the bellcrank and linkage rod (Fig. 3–3, Item 3).

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

Linkage Linkage

B–01905

Fig. 3–4 Removing Rear Motor Linkage

C–01826

3–5 STEERING LINKAGE

Fig. 3–5 Removing Front Motor Linkage

CONTROL

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.

Support Nut

4. Remove the brake if equipped.

5. Remove the steering levers (Fig. 3–6).

6. Disconnect linkage.

Steering Lever

7. Loosen the support nuts (Fig. 3–7).

8. Slide left hand shaft over to welded bracket.

B–02209

Fig. 3–6 Removing Steering Lever

B–02207

Fig. 3–7 Steering Lever Support Nuts

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 Revised Feb. 81

Removing Control Lever Assembly

–3–7–

825 Loader Service Manual

100 – 120 ft.–lbs.

(136 – 162 Nm) 50 – 70 ft.–lbs.

(68 – 94 Nm)

25 – 28 ft.–lbs.

(34 – 38 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) Fig. 3–8.1

D–01357

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

Revised Feb. 82

–3–7a–

825 Loader Service Manual

825ServiceManual#6549899–HydrostaticSystemSectionPage7a–7b

–3–7b–

825 Loader Service Manual

3–6.2 Charge Pressure Check Steering Levers In Neutral Position: 1. Remove the sending unit from the right rear of the tank and install 0–300 PSI pressure gauge (Fig. 3–9).

Pressure Gauge

1

The transmission must not be disengaged with the loader parked on a slope.

W–2305–0298

B–02267

Fig. 3–8.2

Steering Lever Spacer

C–01821

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): Pull Out

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

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 1

2. Pull out the transmission gear box levers (Fig. 3–10).

3. Start the engine and run at full RPM. 4. Normal charge inlet pressure is 15–20 PSI (103–138 kPa).

Minimum charge inlet pressure is 4 PSI (28 kPa).

B–02167

Fig. 3–11 Checking Inlet Pressure To Charge Pump Revised Feb. 82

–3–8–

825 Loader Service Manual

3–7 CHECKING RELIEF VALVES

Cup

3–7.1 Charge Relief Valve NOTE: See Bobcat Technical Information Bulletin #162 for more information on the Charge Relief Valve.

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

Hydrostatic Transmission (10 Micron)

2. Connect compressed air line to each end of valve to see if air goes through.

3. Air must go only one way.

Charge Inlet Relief Valve

Filter Relief Valve

3–7.3 Charge Inlet Relief Valve (Fig. 3–13).

Suction (25 Micron)

1. Disconnect tubelines and remove valve from unit.

2. Connect air hose to each end to see if air goes through.

3. Air must go only one way.

B–01802

Fig. 3–13

Hydraulic And Hydrostatic Filters

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

2. Tilt ROPS forward.

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 valve with defect.

Spring Hex Plug C–01961

Fig. 3–14 Revised Feb. 82

Lift Arm Cylinder Stop

–3–9–

B–02175

Fig. 3–15

Removing Relief Valve

825 Loader Service Manual

3–8 10 MICRON FINAL FILTER ELEMENT REPLACEMENT (Fig. 3–16) 1. Lift the lift arms and install cylinder stop on lift cylinder (Fig. 3–14).

2. Remove steering levers by removing bolts and hitting with hammer to force lever off.

3. Activate tilt switch and tilt cab all the way forward.

4. Attach overhead hoist to ROPS and take up all loose play.

5. Remove bolt which fastens tilt assembly to ROPS. 6. Tilt ROPS fully forward and hold in position with a support.

10 Micron Filter

7. Disconnect linkage rods and remove pedal assembly.

NOTE: CLEAN LOADER FLOOR AREA THOROUGHLY (Transmission Housing).

C–01878

Fig. 3–16

10 Micron Final Filter Location

Fig. 3–17

Removing Pump Suction Hose

8. Remove floor plate.

9. Remove the final filter element.

10. Install new 10 micron element.

Tighten it hand tight.

3–9 TEMPERATURE PRESSURE SWITCHES

AND

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

–3–10–

825 Loader Service Manual

The charge pump inlet switch (2) is set to activate when pressure goes below 4 PSI. The temperature inlet switch is set to activate when temperature goes above 210°F (99°C).

3–10 REMOVAL OF HYDROSTATIC PUMP ASSEMBLY 1. Tilt or remove ROPS (See Section 5–2).

2. Lift the lift arms and install cylinder stops (Fig. 3–14).

3. Steam clean thoroughly.

the

loader

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 from pump assembly (Fig. 3–19).

Fig. 3–18

Removing Pressure Hose

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 Revised January 77

–3–11–

825 Loader Service Manual

3. Connect steering linkage to pump control arms.

825ServiceManual#6549899–HydrostaticSystemSectionPages8–12

4. Connect hoses.

5. Install new cover and gasket.

3–12 REMOVAL HYDROSTATIC MOTOR

OF

1. Tilt or remove ROPS (See Section 5–2).

B–02022

Fig. 3–20

Removing Front Pump Support

2. Lift the lift arms and install cylinder stops (Fig. 3–14).

3. Steam clean thoroughly.

the

loader

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.

B–01901

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

Fig. 3–21 Removing Pump Fastening Bolts

9. Remove the motor. Weight is 22 pounds.

Remove Bolts

Rear Motor

B–01905

Fig. 3–22 Removing Speed–Range Linkage

Revised August 79

–3–12–

C–01819

Fig. 3–23 Hydrostatic Motor 825 Loader Service Manual

3–13 INSTALLING MOTOR

HYDROSTATIC

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 & Motor

C–01752

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 Pump

ID. No.

ID. No.

B–02670

Fig. 3–23b Checking Hydrostatic Units Revised Feb. 82

–3–12a–

825 Loader Service Manual

825ServiceManual#6549899–HydrostaticSystemSectionPages12a–12b

–3–12b–

825 Loader Service Manual

3–14 HYDROSTATIC PUMP OR MOTOR DISASSEMBLY (Fig. 3–24) The inner parts of hydrostatic pumps and motors are similar. The following procedure for pump disassembly can be used for disassembly and assembly of motor. (Do not do the steps which belong to pump disassembly.)

23 22 21 18 14

To disassemble the pump, begin by: 1. Remove pump assembly from the transmission housing. Put plugs in all fluid openings to keep out dirt.

2. Separate assembly.

pump

from

13

the

To disassemble motor, begin by:

7 1

19 20 24 25

10

11

10

39

5

3

12

8

9

11 15

12

38

14 44

35 33

1. Remove the motor transmission housing.

from

the

2. Remove the back plate from the motor.

2

4

6

48 45

50 49

41 40

4

50

34

33

43

34

Continue to disassemble the pump or motor by: 3. Clamp the end of the drive shaft in a protected jaw vise with the body of the pump up and remove the four bolts (Fig. 3–24, Items 48 and 50) from the gerotor plate of the pump.

22A*

32 30 * In Motor Only * See The Parts Microfiche For The Correct Kit P/N ** Some Pumps Do Not Use This Bearing (See BTIB #162) Fig. 3–24 Hydrostatic Pump Breakdown

C–01958

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

–3–13–

825 Loader Service Manual

3–15 INSPECT PARTS FOR WEAR 1. Inspect the charge pump (gerotor) relief valve seat inside the charge pump adaptor. It must be smooth and free of defects.

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

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

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).

Revised Feb. 82

–3–14–

825 Loader Service Manual

7. Install shaft in housing and install washer (3), shaft seal (2) and hold with snap ring (1).

8. Clamp this assembly in a vise with the open end of the housing up.

9. Compress the pin keep (24) and install the spline. Install the three pins (25) with the head to the inside of the block. Install the wave washer (Fig. 3–24.1).

Install pins in the special grooves of the piston block spline.

10. Install the pivot (22), spider (21) and the piston assemblies (20) in the piston block. Install this assembly in the housing assembly, the piston shoes must be in contact with the camplate. Be sure all the parts are in their correct position.

B–02648

11. Install and tighten the back plate to give a preload to the wave washer.

Remove the back plate (motor only).

Fig. 3–24.1

Install Wave Washer (Motor)

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.

NOTE: On the new adaptor plate (Item 43) the bearing has been removed.

When installing this type of adaptor plate (Item 43) use the following procedure for correct alignment.

B–02949R

Fig. 3–25

Gearbox Lever

(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.

Revised Feb. 82

–3–15–

825 Loader Service Manual

3. Connect the pressure line to the implement pump.

825ServiceManual#6549899–HydrostaticSystemSectionPages13–16

To clean and charge the system, use the following procedure:

Temperature Sender

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.

W–2305–0298

B–01794

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

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 4

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

10. After running the machine, remove the outside filter and install new 10 and 25 micron filters in their correct locations. Install a new 10 micron filter in the reservoir if the hydrostatic motors or pumps are removed from service.

3 2 B–02107

Fig. 3–27 Cleaning And Charging System Revised Feb. 82

–3–16–

825 Loader Service Manual

FINAL DRIVE SYSTEM Paragraph Number AXLE BEARING & SEAL REPLACEMENT . . . . . . . . . . . . . .

AXLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE CHAIN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE CHAIN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FINAL DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REDUCTION HOUSING ASSEMBLY . . . . . . . . . . . . . . . . . . .

REDUCTION HOUSING DISASSEMBLY . . . . . . . . . . . . . . . .

REDUCTION HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . .

4–8 4–7 4–6 4–5 4–1 4–4 4–3 4–2

Page Number 4–6 4–5 4–4 4–4 4–1 4–2 4–1 4–1

MECHANICAL TRANSMISSION

–4––1–

825 Loader Service Manual

–4–0–

825 Loader Service Manual

4–1 FINAL DRIVE SYSTEM 4–1.1 Description (Fig. 4–1) The final drive system is made up of a 3–step reduction gearcase, a 100 H.E. final drive chain, axles and idler assemblies.

Final Drive Chain Reduction Gearcase

Front Of Loader Axle (Front)

4–2 REMOVAL OF REDUCTION HOUSING 1. Tilt or remove the ROPS enclosure (See Section 5).

Clean the transmission area thoroughly.

Idler Assembly Axle (Rear)

2. Lift the lift arms and install the cylinder stops (Fig. 4–2).

3. Remove the fluid from the reservoir.

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).

5. Connect the hoist to the reduction housing. Remove three bolts holding the reduction housing to the transmission housing (Fig. 4–4).

C–01842

Fig. 4–1 Final Drive Chain System

Lift Arm Stop The transmission must not be disengaged with the loader parked on a slope.

W–2305–0298

NOTE: The bolts on the reduction housing must be tightened to 220–230 ft.–lbs.

(298–312 Nm) torque when installing the housing (Fig. 4–4).

6. Use the hoist to remove the reduction housing from the transmission housing (Fig. 4–5). Weight of reduction housing is 120 lbs.

Gear Lever

C–01961

Fig. 4–2 Lift Arm Cylinder Stop

4–3 DISASSEMBLY OF REDUCTION HOUSING (Fig. 4–6)

B–02949R

Fig. 4–3

4–3.1 Removal Of The Intermediate Gear (6) 1. Remove the bolts which hold the detent part (1) to the reduction housing.

Drive Gear Lever

Reduction Housing

2. Remove the snap ring on the intermediate shaft (Fig. 4–7).

3. Slide the shaft a short way out of the housing. Do not remove the shaft at this time.

4. Remove the thrust washer and small steel ball (2).

Reduction Housing Bolts

C–01820

Fig. 4–4 Revised Feb. 82

Removing Gearcase Bolts

–4–1–

B–02143

Fig. 4–5 Removing Reduction Housing 825 Loader Service Manual

5. Remove the shaft from the housing.

6. Remove the gear (6).

20

15

14

19 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 holding ball bearing (13).

17

18

1

2. Remove the gear and shaft (7) with bearing (13).

2

3

3. Remove the snap ring (10) holding needle bearing (11) and remove the needle bearing.

4

12 8

13

7 11

4–3.3 Removal Of Output Gear (14) Fig. 4–6

6

10 C–01640

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 fully into the housing.

Spring

Ball

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).

Revised January 77

Fig. 4–8 Detent, Ball And Spring –4–2–

825 Loader Service Manual

3. Tilt or remove ROPS enclosure (See Section 5–2).

4. Clean area thoroughly.

5. Remove foot pedal assembly (See Section 2).

Idler Fastening 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 tightening (Fig. 4–10). Tighten the drive chain when freeplay at the wheel reaches 0.500 inch maximum.

9. Tighten the bolts.

idler

Adjustment Bolt

fastening

10. Install a new gasket under the floor plate.

11. Reverse Steps 1–7.

4–4.5 Drive Chain Adjustment (External Adjustment Type)

B–01773

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 reaches 0.500 inch maximum.

B–02650 B–02653

Fig. 4–10 Loosening Bolts

Fig. 4–10a Adjusting Chain Tension (External)

4. Tighten idler fastening bolts to 230 ft.–lbs. (312 Nm) torque.

4–4.6 Drive Chain Idler Removal (Internal Adjustment Type) 1. Lift the lift arms and install cylinder stops (Fig. 4–2).

2. Remove the ROPS enclosure.

3. Clean area thoroughly.

4. Remove cover.

the

transmission

5. Remove the pedal assembly and floor cover.

C–01817

Fig. 4–10b Revised Feb. 82

Checking Chain Tension

–4–3–

825 Loader Service Manual

6. Remove the 10 micron (internal) filter assembly.

7. Separate the chain and remove links until end clears idler assembly.

8. Loosen the reduction gear housing fastening bolts and move the gear housing away from the side wall of the transmission housing.

9. Remove the two fastening nuts on the idler assembly (Fig. 4–11).

Fastening Nuts

10. Remove the idler assembly.

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) Revised Feb. 81

–4–4–

825 Loader Service Manual

4–5 REMOVAL OF DRIVE CHAIN 1. Lift the loader and put on safe blocks.

2. Remove ROPS (cab).

3. Lift loader lift arms and install cylinder stops.

4. Steam clean thoroughly.

the

loader

5. Remove the front transmission cover.

6. Remove pedal assembly and floor plate.

7. Loosen the chain idler bracket (Fig. 4–9).

8. Remove from sprocket lock bolt and nut.

9. Put reduction housing gears in neutral. (Lever on outside of transmission housing (Fig. 4–14).

B–02949R

Fig. 4–14 Drive Gear Lever

10. Rotate drive chain until master connector link (white) is in location for removal with chain breaking tool. (If no white link is found, break at any link).

11. Remove connector link and separate the chain.

12. Remove from sprocket, from the axle (Fig. 4–15).

13. Connect a long wire to the chain to aid when installing chain (Fig. 4–16). (If chain replacement only.)

14. Gather up chain while pulling it out of transmission. Disconnect wire from chain and leave wire in loader.

B–01908

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 (Fig. 4–17).

Wire

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 until there is 0.250 inch maximum wheel movement.

Rotate wheel several revolutions to prevent over tightening as a result of high spots on sprockets.

Revised Feb. 82

Wire

C–01834

Fig. 4–16 Removing Drive Chain –4–5–

C–01835

Fig. 4–17 Installing Drive Chain 825 Loader Service Manual

6. When chain tension is correct, tighten the fastening nuts on tighter.

7. Install chain guide (Fig. 4–18).

Axle Nut 4–7 REMOVAL OF AXLE 4–7.1 Removal Of Rear Axle 1. Steam clean the loader thoroughly.

2. Remove the ROPS enclosure (See Section 5–2).

B–01902

Fig. 4–19

3. Lift the lift arms and install cylinder stops (Fig. 4–2).

4. Remove drain plug and let out the hydraulic fluid. (If fluid is to be used again, store it in a clean, covered reservoir.)

Removing Axle Nut

B–02208

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 turning axle.

1.0” to 2.0” Welds

16. When chain is out, disconnect wire and leave wire in loader to aid in installation.

17. Remove the sprocket from axle (Fig. 4–15).

3/4” Bolts (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 Use the same steps as rear axle except omit Step 7, 8, 12, 14, 15 & 16.

Revised August 79

1.0” to 2.0” Welds C–02186

Fig. 4–20a

Axle Housing Mounting Repair

–4–6–

825 Loader Service Manual

4–7.3 Installation Of The Axle Bearing Puller

Reverse the above steps to install axles.

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 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.

Axle

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 will cause axle housing distortion and removal will not be possible.

B–01909

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 axle (Fig. 4–22).

Bearing

Seal

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 (79,17–79,27 mm).

B–01941

Fig. 4–23 Installing The Axle Bearings

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.

B–01944

Fig. 4–24 Installing Axle Seal

Axle Housing

5. Install new races, outer bearing and seal in housing (Fig. 4–23, 4–24 & 4–25).

Press 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 Revised Feb. 81

–4–7–

Fig. 4–26 Installing Axle In Housing 825 Loader Service Manual

4–9 INSTALLATION SPROCKET

OF

AXLE

825ServiceManual#6549899–FinalDriveSystemSection

3

Install the axle sprockets after the axle is installed in the loader.

125 – 140 ft.–lbs.

(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).

4

3. Hit the end of the axle and check for end play.

4. Tighten the axle nut to the nearest hole on the axle nut that will align with the hole in the axle and remove end play from the axle.

5

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).

4–10 PARK BRAKE REMOVAL

C–01638

Fig. 4–27 Installation Of Axle Sprocket

1. Lift the lift arms and install cylinder stops (Fig. 4–2).

2. Tilt the ROPS enclosure.

3. Clean area thoroughly.

4. Remove transmission cover.

5. Before removal of the left brake, remove the steering linkage. Brake linkage rod and hydraulic oil pickup tube.

Before removal of the right brake, remove steering linkage and steering arm from the pump. Remove the brake linkage rod.

6. Remove shoulder screws from the case and lift out brake assembly. Use caution not to drop the actuator lever from the bottom of the brake assembly (Fig. 4–28).

B–02651

Fig. 4–28

Removing Brake Assembly

Reverse the above steps to install the brake.

Revised Feb. 81

–4–8–

825 Loader Service Manual

MAIN FRAME Paragraph Number BOB–TACH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRIC MOTOR FOR ROPS . . . . . . . . . . . . . . . . . . . . . . .

FUEL TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIFT ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PIVOT PIN & BUSHING REPLACEMENT . . . . . . . . . . . . . . .

ROPS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5–4 5–7 5–6 5–5 5–1 5–3 5–2

Page Number 5–1 5–2 5–2 5–2 5–1 5–1 5–1

MAIN FRAME

–5––1–

825 Loader Service Manual

–5–0–

825 Loader Service Manual

5 MAIN FRAME ROPS

5–1.1 Description (Fig. 5–1) The loader main frame is separate from the upright frame assembly. The main frame is the housing for the drive system and is part of the support for the engine.

Lift Arms

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

Grill

4. Attach a chain to the ROPS, connect to an overhead hoist and take up all loose play.

5. Remove the two front pivot bolts.

6. Remove the bolt which fastens the tilt assembly to the cab (Fig. 5–2 for electric tilt and Fig. 5–6 for mechanical tilt).

Upright Frame 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 tool.

Fig. 5–1

Main Frame

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.

Revised Feb. 81

–5–1–

825 Loader Service Manual

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 Assembly

5. Remove the rear thru bolts and 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 Bushing

1. Remove the engine.

2. Remove or loosen the hoses and electrical wires.

3. Loosen the upright frame to axle housing bolts and move the frame about 1.0 inch toward the rear.

Bushings

4. Remove the fuel tank fastening bolts.

5. Move the fuel tank toward the rear and remove from under the loader.

Pivot Pins

5–6.2 Removing Fuel Tank On Loader S/N 17001 & Above (Fig. 5–4) 1. Remove the filler hose.

D–01169

Fig. 5–3

Lift Arm And Bob–Tach Assemblies

Fig. 5–4

Fuel Tank Removal (S/N 17001 & Above)

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.

Revised Feb. 82

E–01086R

–5–2–

825 Loader Service Manual

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) 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).

D–01534

Fig. 5–6 ROPS Tilt (Mechanical)

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 Revised Feb. 82

–5–3–

Raising & Lowering the ROPS

825 Loader Service Manual

825ServiceManual#6549899–MainFrameSection

–5–4–

825 Loader Service Manual

ELECTRICAL SYSTEM Paragraph Number ALTERNATOR OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ALTERNATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL CIRCUITRY . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAN BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROBLEM ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REGULATOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6–4 6–6 6–1 6–3 6–2 6–5 6–7

Page Number 6–3 6–4 6–1 6–3 6–1 6–3 6–6

ELECTRICAL SYSTEM

Revised Feb. 82

–6––1–

825 Loader Service Manual

–6–0–

825 Loader Service Manual

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 needed to turn the engine.

Battery

NOTE: When using an extra battery (jump start) to start the engine the ground wire (Fig. 6–1, Item 1) can burn through the insulation. Replace the ground wire (Fig. 6–1, Item 1) with a 4 gauge wire. Do not put the ground wire through the harness clip.

See Figure 6–1 for wiring diagram.

The two most common problems with the electrical system are:

1

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

Fig.6–1

Electrical System

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.

Revised Feb. 82

–6–1–

825 Loader Service Manual

CHART A BATTERY LOSES CHARGE Check Generator Drive Belt

If Good

If Loose Or Defect Is Found

Make Repair As Needed (Page 6–3)

Check Condition Of Battery & Cable

If Good

Check Wiring (Page 6–3)

If Good

Check If Output Output (Page 6–3) Is Correct

If Defect Is Found

If Defect Is Found

If Output Is Not Correct

Make Repair As Needed

Make Repair As Needed

Check Regulator (Page 6–4)

If No Defect Is Found

Charging System Works Correctly

Remove And Inspect Generator (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 For Engine Seizure

If Engine Is Good

Check Condition Of Battery & Cables

If Good

Check Starter (Page 6–6)

If Engine Has Defect

If Defect Is Found

Correct Engine Problem

Remove And Make Repair As Needed (Page 6–6)

Revised January 77

–6–2–

If Good

Check Wiring, Ignition Switch & Circuit Breaker

825 Loader Service Manual

6–3 FAN BELT Mounting Bolt

Check the drive belt for correct tension. A loose belt can cause charging problems.

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.

Set Screw

4. There is no more adjustment.

A–02287

Fig. 6–2

To check wiring:

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 OUTPUT

CHECK

ALTERNATOR

1. Put the machine on safe blocks.

2. Disconnect negative battery cable. Connect an ammeter in line with the Bat terminal of the generator. Connect the battery cable.

No. 1 Terminal

No. 2 Terminal

Bat 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 Revised Feb. 82

Alternator

–6–3–

825 Loader Service Manual

2. Lower the electric charge in battery. (Turn engine with starter, connect lights, etc.)

Test Hole

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.

B–02113 A–02211

6–6 ALTERNATOR SERVICE

Fig. 6–4 To Check The Regulator

6–6.1 Removal (ROPS Must Be Tilted) 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

Fig. 6–5

2. Remove the pulley from the shaft.

3. Remove the four bolts which hold the housing together.

4. Use a screwdriver to separate each half of housing (Fig. 6–5). Slide the rotor out of the housing.

Separating Alternator Housing

(Check for Ohmmeter Shorts and Opens)

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) 1. Connect an ohmmeter from one slip ring to the shaft. There must be maximum resistance.

Check For Grounds Fig. 6–6

A–01857

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) Fig. 6–6

Revised Feb. 82

–6–4–

B–02108

Checking Stator Coil Wires

825 Loader Service Manual

a 6–6.5 To Check Diode Trio (Fig. 6–8) Insulated Half

1. Connect a D.C. test light from one 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 check diode trio or rectifier.

Fig. 6–8 Checking Diode Trio

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 –6–5–

825 Loader Service Manual

a 6–7 STARTER SERVICE

Jumper Wire

825ServiceManual#6549899–ElectricalSystemSection

Solenoid

6–7.1 To Check The Starter

Bat S M

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

2. Connect a jumper wire from the 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 turn, do this: 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 solenoid. If starter does not turn, the defect is in the starter.

Cranking Motor

A–01991

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 nuts which hold the starter in place, and lift it out.

Cranking 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

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 inside connections (Fig. 6–16). If the light doesn’t come on, the field coils have a defect.

Fig. 6–14

Armature Testing (Grounds)

Armature Tester Coil Armature

6–7.4 Assembly Assembly is disassembly.

the

reverse

of

A–01994

Fig. 6–15 Armature Testing (Shorts) –6–6–

B–02122

Fig. 6–16 Checking Field Coil Wires 825 Loader Service Manual

ENGINE SERVICE Paragraph Number

Page Number

CONNECTING RODS AND PISTONS . . . . . . . . . . . . . . . . . . 7–5 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–10 CRANKSHAFT AND MAIN BEARINGS . . . . . . . . . . . . . . . . . 7–6 ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3 FLYWHEEL AND FLYWHEEL HOUSING . . . . . . . . . . . . . . . . 7–7 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–11 INSTALLING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 7–4 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9 STARTING ENGINE AFTER RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2 TIMING CASE AND DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8

7–9 7–28 7–13 7–1 7–17 7–31 7–8 7–1 7–25 7–1 7–18

ENGINE SERVICE

–7––1–

825 Loader Service Manual

–7–0–

825 Loader Service Manual

7–1 INTRODUCTION 7–1.1 Engine Parts Whenever engine parts are ordered, be sure that all information is given. Always quote the engine serial number, engine part number and description.

7–1.2 Engine Number Location The engine number is stamped on the fuel pump mounting flange as shown in Figure 1–2.

7–2 STARTING A NEW OR RECONDITIONED ENGINE 1. Remove the plug on the thermostat housing so that all the air will be removed from the system when the radiator is filled.

2. Fill the cooling system with a 50 – 50 mixture of antifreeze and water.

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

NOTE: The oil passages and the rocker arm shaft will need a little time to fill with oil. Once the oil flow to the rocker arms is satisfactory, the rocker arm cover and the air cleaner can be installed.

4. Run the engine at idle (1200 – 1500 RPM) for 10 – 15 minutes to let 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.

Revised Feb. 82

–7–1–

825 Loader 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 terminals.

the

battery

3. Remove the fastening nuts and remove the muffler from the exhaust manifold.

4. Disconnect the water outlet connection on the front of the cylinder head.

5. Remove the air cleaner.

6. Disconnect the fuel pipe and electrical connection to the starting aid located in the intake manifold.

C–01832

Fig. 7–1 Removing Engine

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 fuel filter.

Revised Jan. 77

C–01813

Fig. 7–2

Rocker Shaft Removal

–7–2–

825 Loader Service Manual

12. Remove the low pressure fuel pipes between the fuel filter and the fuel pump, remove the fuel filter after disconnecting the feed pipe from the lift pump, plug all pipes and openings to prevent entry of foreign particles.

13. Remove the four high pressure fuel pipes from the fuel pump to the injectors. Plug fuel pump outlet ports.

14. Remove the injector fastening nuts and carefully remove the injectors. Plug the exposed openings on the injectors.

15. Remove the alternator adjusting arm.

16. Remove the cylinder head fastening nuts and lift off the Fig. 7–3 Lifting Cylinder Head cylinder head completely with 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.

C–01810

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 a deeper center portion to fit this seal.

During re–assembly, be sure that the correct spring caps are fitted to the inlet valves and the seals are fitted in the sequence detailed on page 7–7.

B–01862

Fig. 7–4 Valve Numbering

Fig. 7–5 Valve Spring Compression

Expansion Washer

7–3.4 Combustion Chamber Inserts When it is necessary to remove combustion chamber inserts from their seats in the cylinder head, they can be pushed out of their locations by a short curved bar through the injector bore.

When installing inserts they must be held by expansion washers in the seats to prevent them from turning. The expansion washers are fitted as shown in Figures 7–6 and 7–7.

B–01856

Fig. 7–6

Fitting Expansion Washers

–7–3–

B–01857

Fig. 7–7 Seating Expansion Washers 825 Loader Service Manual

7–3.4a Reconditioning Cylinder Heads When reconditioning cylinder heads, it is not always necessary to replace cracked pre–combustion chamber inserts. As a general rule, inserts having a single straight crack less than 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 water leakage after this cleaning.

A

B

A

Clean all the studs on top of the cylinder head and those in the top face of the cylinder block. Examine for thread damage or stretching and replace with new ones where necessary.

Any loose studs must be tightened and any cylinder head nuts found with damaged threads replaced.

A–02681

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 inspected, paying special attention to squareness of ends and pressures at specific lengths. The details can be found on page 8–4.

B–01887

Fig. 7–8 Valve Guide Removal

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.

Revised August 79

–7–4–

825 Loader Service Manual

3. Valves and Valve Seats The valves should be checked in their guides for wear and replacement made if worn. Be sure that the wear is on the valve stem and not in the guide bore before making a replacement.

7–3.7 Reconditioning Of Valves And Valve Seats The valve and valve seat faces using specialized equipment or with grinding compound, according to their condition.

A valve seat (hand operated) cutting tool is shown in Figure 7–10. Valves should always be fitted to their original seats and 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 described on page 7–4.

as

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

Fig. 7–10 Refacing Valve Seats –7–5–

A–01653

Fig. 7–11 Checking Valve Head Depth 825 Loader Service Manual

4. Using the valve guide bore as a pilot once again press the insert in with the insert driver, this tool is shown fully dimensioned in Figure 7–13. Steady pressure should be given with either a hand or a hydraulic press. The purpose of the insert driver is to get squareness when the insert is being pressed in.

NOTE: The insert must not be driven by hammer and lubrication must not be used.

5. Visually inspect to be sure that the insert has been pressed fully in (flush with the bottom of the recess).

6. Cut the valve seat at an included angle of 90° (which will give the 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.

Valve Inlet

B

C

Valve Exhaust

A

Inlet A – 1.530” to 1.531” B – 0.3125” to 0.3175” C – 0.015” Chamfer at 45° (Max.)

Exhaust A – 1.296” to 1.297” B – 0.3125” to 0.3175” C – 0.015” Chamfer at 45° (Max.) A–02350

Fig. 7–12 Valve Insert Detail

INSERT DRIVER (Fig. 7–13) Inlet Dimensions A. – 2.750 inch B. – 2.0 inch C. – 0.750 inch

Exhaust Dimensions A. – 2.750 inch B. – 2.0 inch C. – 0.750 inch

D. – 0.309 to 0.310 inch E. – 0.0625 inch at 45° F. – 0.0625 inch at 45° G. – 0.0312 inch Radius

D. – 0.309 – 0.310 inch E. – 0.0625 inch at 45° F. – 0.0625 inch at 45° G. – 0.03125 inch Radius

H. – 1.238 to 1.239 inch J. – 0.222 to 0.225 inch K. – 1.523 to 1.533 inch

H. – 1.018 to 0.019 inch J. – 0.222 to 0.225 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 shaft.

E

3. Unscrew the oil feed pipe from the connector and remove the connector.

(When refitting this feed pipe, it should be noted that the end of the pipe locates the connector position on the shaft.)

After disassembly, thoroughly wash all parts in clean solvent. Inspect the rocker bushings and shaft for wear. The rocker levers should be an easy fit on the rocker shaft without loose side play.

H

C J

G Rad.

A B

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.

F

New rocker levers are supplied complete with bushing fitted and reamed to size.

D

B–02016

Fig. 7–13 Insert Driver –7–6–

825 Loader Service Manual

NOTE: When fitting new bushings, see that the oil feed holes are in alignment before pressing in, and when pressed fully in see that the holes are in alignment (Fig. 7–14).

Align Oil Feed Holes

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 clearance.

of

B–01892

valve 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 coil is nearest the cylinder head top face. See note on spring caps on page 8–4.

5 3 Inner Valve Spring

2

5. Use a valve spring compressor, as shown in Figure 7–16, to compress the valve springs and locate the retaining semi–conical collets.

Outer Valve Spring

1

NOTE: Inlet valve stems are fitted with rubber O–ring seals.

They fit inside the valve spring cap bore and must align with groove on the valve stem. Assembly of the inlet valve assemblies should be carried out as follows: (Fig. 7–17).

4 A–02340

B–01862

Fig. 7–16 Valve Spring Compression –7–7–

Fig. 7–17

Valve Assembly

825 Loader Service Manual

6. Put spring seating washer in position (Item 1).

7. Position the valve springs correctly on the seating washer (Item 2).

8. Put the valve spring cap in position (Item 3).

9. Compress with the valve spring compressor until the valve stem is through the cap enough to install the O–ring seal.

10. Install the O–ring over the valve stem and slide it down until it locates in the groove (Item 4).

11. Install the collets (Item 5).

Top Front

7–4 INSTALLING CYLINDER HEAD 7–4.1 Cylinder Head Gasket

Fig.7–18

B–01990

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 of a black composite material and is known as a Klinger type. It MUST be fitted DRY, and gasket cement must not be used.

18

8

12

3 1

4

7

11

17

The copper asbestos type of cylinder head gasket is not suitable and must not be used.

Since the cylinder liners on this engine, when correctly installed, are above the cylinder block face, it is very important that the gasket is placed correctly, otherwise the steel beading may be pinched between the cylinder head face and the top of the liner when installing the head.

NOTE: Before installing the cylinder head, be sure that the faces are clean. Check that the rocker assembly oil passage in the cylinder head is not restricted.

16 15

14

9

5

2

6

10

13 B–01886

Fig. 7–19

Tightening Order

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.

Revised Feb. 81

–7–8–

825 Loader Service Manual

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.

B–01861

8. Install the injectors (refer to page 7–34) but do not tighten the holding nuts.

9. Install the leak off pipe assembly and four high pressure fuel pipes to the injectors. Tighten the holding nuts.

Fig. 7–20 Rocker Oil Line

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).

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.

B–01989

Fig. 7–22

Removing Pistons

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.

–7–9–

825 Loader Service Manual

7–5.2 To Remove Pistons And Rings From The Connecting Rods 1. Remove the piston rings from each piston, using a piston ring tool, as shown in figure 7–23.

NOTE: The laminated pieces fitted in the fourth ring groove should be removed by hand.

IMPORTANT

There is a steel insert rolled into the top ring groove during piston manufacture, it is part of the piston and must not be removed from its location.

B–01868

I–2162–0298

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 8–2).

B–01987

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 100 – 120°F (40–50°C) until the piston pin can be easily pushed into the piston bore when the piston and rod have correct alignment.

Revised Feb. 82

Fan B–01891

Fig. 7–25

Location Of Piston Numbering

–7–10–

825 Loader Service Manual

2. Position No. 1 piston on its head, noting the position of the F mark indicating Front. (When there is no mark, pistons can be installed either way.)

3. Hold No. 1 connecting rod with the small end between the piston pin bores so that the word Front on the rod is towards the same side.

4. Push the piston pin into the piston to hold the connecting rod in position.

5. Install the two retaining snap rings making sure that they fit correctly in their recesses (Fig. 7–26).

NOTE: If the engine has been in use for a long time, install new snap rings, even if the old ones are not damaged.

6. Repeat this procedure for the other three pistons and connecting rods.

B–01878

Fig. 7–26 Piston Pin Retainer

7–5.5 Installing The Piston Rings The piston rings should be fitted to the piston in the following order: (Fig. 7–27).

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

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

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

Fig. 7–27 Piston Rings

1. Hold the connecting rod, with 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 groove above piston pin. (Either side up.)

2nd & 3rd Ring (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

–7–11–

825 Loader Service Manual

When all the rings have been fitted, they must be as shown in Figure 7–28.

7–5.7 To Install Piston And Connecting Rod Assemblies Before installing the piston and connecting rod assemblies in their respective cylinder bores, thoroughly clean and wash each bore with clean engine oil.

1. Turn the engine until the crankpins of numbers 1 and 4 cylinders are at bottom dead center.

2. Use a ring clamp of the type shown in Figure 7–29 carefully compress the rings on No. 1 piston and hold in this position.

3. With the word Front on the connecting rod facing the front of the engine, insert the rod carefully into No. 1 cylinder bore.

NOTE: The cylinders are numbered 1, 2, 3 & 4 starting from the (water pump) end of the engine. It is important that these components (marked as shown in figures 7–24 and 7–25) are installed in their original locations.

4. The piston head may be hit lightly with the shaft of a hammer as shown in figure 7–29 until all the rings have entered the cylinder bore.

5. Pull the rod towards the crankshaft, put the top half bearing shell in position with the tag in the machined slot and add oil lubricant. Pull the rod fully onto the crank pin.

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 –7–12–

Piston Installation

825 Loader Service Manual

7–5.9 Cylinder Liners The cylinder liners are made of cast alloy iron, they are an interference fit in the cylinder block and are of the thinwall dry type.

Boring of these liners to a larger size is not possible and new liners must be fitted when liners have become worn.

Dimensional checks of the cylinder bore is best done with an inside micrometer.

When checking liners each one should be measured in three positions – top, center and bottom; the readings being taken parallel and at right angles to the center line of the cylinder block, giving six readings for each cylinder bore.

When checking the internal bore of a new installed liner, first let the liner settle for a period of time.

7–5.10 To Install New Cylinder Liners 1. Remove all the components from the cylinder block. (Refer to the specific sections for details of their removal.)

2. Remove the cylinder head studs from the cylinder block top face.

3. Use a liner removal tool to pull the liners carefully out through the top of the cylinder block (Fig. 7–30).

4. Clean the bore thoroughly and remove any burrs which may be present.

5. Thoroughly clean and dry the liner after the removal of any grease or preservative.

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.

11. Bore and hone the liners to the dimensions quoted on page 8–1.

Fig. 7–30 Liner Removal

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 –7–13–

Liner Protrusion Check

825 Loader Service Manual

The main bearing caps are not interchangeable and must always be kept as a set and regarded as an integral part of the block. The main bearing shells are located in position in the same manner as the connecting rod bearing shells by means of tabs, which locate in machined slots in the bearing housings.

NOTE: Before renewal of the main bearings is attempted, make sure that the correct replacement parts are available.

7–6.2 To Install Main Bearings And Thrust Washers When installing new main bearings, also check the crankshaft for wear. Removal of the main bearings and thrust washers can be done without removing the crankshaft by the following procedure: 1. Remove the oil pan and suction pipe assembly.

2. Loosen the six capscrews which hold the main bearing caps.

3. Remove completely one of the main bearing caps and remove the bearing shell from the cap.

4. Remove the top half of the bearing shell by pushing it, on the side opposite to the one having the locating tab, using a strip of wood and rotating it on the crankshaft as shown in Figure 7–32.

5. Inspect the bearing shells and if replacements are necessary, add light lubricant and insert the new top half bearing shell, plain end first, into the side having the tab location.

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

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

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

9. Follow items 3–8 for the other two bearings.

NOTE: To remove the rear main bearing cap, first remove the two oil seal housing bolts as shown in Figure 7–33.

10. Finally, tighten the main bearings to 85 ft.–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 –7–14–

Removing Bearing Insert

825 Loader Service Manual

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

Fig. 7–33 Rear Main Seal Removal

B–01870

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 locations when they are later installed.

Thrust 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 pump drive hub. (Refer to page 7–19.)

B–01869

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.

NOTE: The rear seal half housing fastening bolts must be removed before the rear main bearing cap can be removed (Fig. 7–33).

Upper Thrust Washer Half

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

Fig. 7–36 Thrust Bearing Installation –7–15–

B–01866

Fig. 7–37 Crankshaft End Float 825 Loader Service Manual

7–6.5 To Reinstall The Crankshaft 1. First clean the crankshaft and check that all the oilways are clear.

2. Clean the bearing housings, put the three top bearing shells in position then give them lubrication with clean engine oil.

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 position as shown in Figure 7–36.

B–01993

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.

–7–16–

825 Loader Service Manual

7–6.6 Crankshaft Rear End Oil Seal The seal assembly location is in two half housings bolted around the rear of the crankshaft.

NOTE: When traces of oil is noticed from behind the flywheel and a faulty rear oil seal is expected, first make sure that the crankcase is vented correctly. Any build up in crankcase pressure could cause oil to be forced past the rear sealing assembly. If crackcase pressure is normal and new seals need to be installed, the following procedure should be followed with the crankshaft in position.

B–01986

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 then tighten the bolts to block.

B–01864

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.

–7–17–

825 Loader Service Manual

2. The outer face of the flywheel should be thoroughly cleaned to give a smooth fit when the new ring gear is installed.

3. Clean, then heat the new ring gear to a temperature not more than 480°F (250°C).

4. Fit the ring gear over the flywheel with the lead on the teeth facing uppermost (facing away from the engine when the flywheel is installed). Rotate the gear quickly on its location as soon as it is fitted to make sure that it is laying flat, then let cool.

7–7.3 To Reinstall The Flywheel It is important that the crankshaft flange face is clean and free from burrs, also the mating face of the flywheel before installing the flywheel.

B–01991

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.

–7–18–

825 Loader Service Manual

7–8.2 Replacement Of The Crankshaft Front Oil Seal 1. Use a press to remove the oil seal from the timing case cover by pushing out through the front.

2. Put the new seal in position so that the lip faces inwards.

3. Press in the new seal from the front until it is lightly against the seal holding lip.

7–8.3 To Install The Timing Case Cover 1. Thoroughly clean the faces of the timing case front cover and the timing case back plate.

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 Marks

6. Install the fan belt and make adjustment for 0.375 inch deflection.

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.

2. Install the hub as shown in Figure 7–42 so that the holes in the hub and the cylinder block are in alignment.

B–01881

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 –7–19–

825 Loader Service Manual

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, etc., as described earlier in this section.

Timing Marks

7–8.5 To Remove The Camshaft Gear 1. Remove the timing case front cover as described earlier in this section.

Timing 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 described earlier in this section.

C–01811

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 camshaft hub are in alignment as shown in Figure 7–47.

D Marks

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 kgf/m)*.

–7–20–

B–01883

Fig. 7–48 Fuel Pump Gear 825 Loader Service Manual

3. Install the idler gear and hub, timing case front cover, etc., as previously detailed in this section. *Tightening these bolts to the correct torque is more easily done after the idler gear and hub have been installed.

7–8.9 to Remove The Fuel Pump Drive Hub 1. Remove the timing case front cover as described earlier in this section.

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 in Figure 7–50.

Snap Ring

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

–7–21–

825 Loader Service Manual

7–8.12 To Install The Timing Case Back Plate

Thrust Plate

1. Make sure that both the cylinder block and timing case back plate faces are clean. Install the timing case back plate to the cylinder block using a new gasket and sealing material.

2. Install the bolts.

3. Install the fuel pump drive hub and fuel pump as previously detailed.

Camshaft

4. Install the timing gears, timing case front cover, etc., as previously detailed.

Fig. 7–52 Removing Camshaft

7–8.13 To Remove The Camshaft And Tappets

A–02343

Camshaft B–01876

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.

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

Tappet A–02345

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.

–7–22–

825 Loader Service Manual

3. Before the camshaft is pushed fully in, locate the two thrust plates (Fig. 7–54) (one of which locates on the dowel in the recess) in position, either side of the camshaft hub, when correctly located the camshaft can be pushed fully in and will appear as in Figure 7–51.

Thrust Plate

4. Install the timing case back plate as described earlier.

5. Install the lubricating oil pump assembly and sump as described on page 7–27.

Push Rod B–01875

Fig. 7–54 Cam Thrust Plate Position

B–01874

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), tappet inspection cover and fuel lift pump.

Timing Marks

9. Assemble the remainder of the engine components as described in the instructions given for each specific part of this section.

Timing Marks

7–8.15 Timing Marks When the engine is originally timed at the factory, certain marks are stamped on the gears, so that if for any reason the engine timing has to be changed, then setting to the original timing is easily done.

Keyway Timing Marks

To Reset The Engine To The Original Timing If the cylinder head assembly is still in position, it is best to remove the injectors and rocker shaft to make timing easier.

C–01811

Fig. 7–56

Alignment Of Timing Marks

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 –7–23–

825 Loader Service Manual

3. Install the fuel pump gear on to the fuel pump drive hub, making sure that the stamped timing marks align as shown in figure 5–58. Fasten with the three bolts.

Timing Marks

4. Install the idler gear so that the double dots on the idler gear are in alignment to the single dot on the crankshaft gear and single line (or dot) on the camshaft gear, with the single dot on the idler gear in alignment with the double dots on the fuel pump gear. These timing marks when correctly positioned will appear as shown in Figure 7–56.

5. Put the idler gear with the hub and install the two retaining screws using a new washer.

6. Gear play adjustment should be done as described on page 7–19.

B–01883

Fig. 7–58

Fuel Pump Gear

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).

3. Turn the engine slowly in the normal direction of rotation until the clearance of No. 1 inlet valve is just taken up. (In this condition it will be possible to rotate No. 1 inlet valve push rod between the thumb and the forefinger.)

Timing Pin B–01872

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.

–7–24–

825 Loader Service Manual

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 adjustment is necessary, loosen the locknut and turn the adjustment screw clockwise to decrease or counterclockwise to increase the clearance as shown in Figure 7–60.

When a sliding fit between the surfaces is obtained with the feeler gauge, lock the adjustment screw and check the clearance again. When satisfactory, proceed to the next valve in the adjustment sequence.

Feeler Gauge

Adjustment Screw

A–01770

7–8.19 Valve Adjustment Sequence 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.

–7–25–

825 Loader Service Manual

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 1. Remove the suction pipes.

delivery

and

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.

B–01885

Fig. 7–61

Oil Suction Strainer

Remove

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

–7–26–

825 Loader Service Manual

2. Install the drive shaft complete with inner rotor, then the outer (driven) rotor making sure that the face which holds the tapered edge enters the pump body first (Fig. 7–63). Now make the three following dimensional checks: (a) Check the clearance between the inner and outer rotor (Fig. 7–64).

Outer Rotor

(b) Check the clearance between the outer rotor and the pump body (Fig. 7–65). (c) Check the clearance between the rotors and the end cover assembly using a straight edge and feeler gauge (Fig. 7–66).

7–9.7 To Assemble The Oil Pump 1. Install the outer rotor making sure that the face which holds the tapered edge enters the pump body first (Fig. 7–63).

Inner 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

Fig. 7–65 CheckingOuter Rotor Clearance –7–27–

B–01879

Fig. 7–66 Oil Pump Rotor Clearance 825 Loader Service Manual

7–9.10 To Dismantle The Oil Pressure Relief Valve

Housing

1. Empty the engine oil from the oil pan.

Plunger

2. Remove the oil pan fastening bolts and carefully remove the oil pan.

3. Continue by removing the oil pump as described earlier.

4. Remove pipes.

suction

Spring Cap Split Pin

and delivery

5. Remove the four bolts and remove the end cover assembly.

Spring B–01877

Fig. 7–67 Oil Pressure Relief Valve

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.

–7–28–

825 Loader Service Manual

NOTE: When a new belt has been installed, check the adjustment again after a short running period.

7–10.3 Water Pump The water pump shaft rotates within two bearings. The impeller aids the circulation of the water through the system. Water is held within the impeller chamber by a carbon–faced seal which is spring pressed against the face of a phosphor bronze bearing in the pump body. Figure 7–68 shows the positions of the assembled parts.

1 12 2 11

4 5

1.

2.

3.

4.

5.

6.

7.

8.

9.

10 8

9

7–10.4 Remove The Water Pump 1. Straighten the washer locks, remove the fan bolts and remove the fan.

3

3

7

6

10.

11.

12.

Pump Body Seal Shaft Bearings Retaining Circlip PUmp Shaft Distance Piece Flange–Oil–Seal Retaining Retainer–Oil Seal Flange–Water Pump Thrower Impeller Seal Insert

A–02351

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.

A–02309

6. Remove the felt seal and holding flanges.

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.

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825 Loader Service Manual

7–10.7 To Assemble The Water Pump 1. Install the oil seal holder and oil seal, followed by the oil seal holding flange.

2. Fit the two bearings and spacer onto the shaft and pack the space between the two bearings about 3/4 full of high temperature grease.

3. Press the bearing and shaft assembly into the pump body, impeller end first and locate with the snap ring.

4. Press the water thrower flange into position on the drive shaft.

5. Thoroughly clean the insert recess and drain hole in the pump body.

A–02313

6. Lightly coat the inner diameter of the insert area and outside diameter of the insert with sealing material.

Fig. 7–70

Pump Impeller Clearance

7. After removing any traces of oil or grease from the insert, press it fully in.

Remove all extra sealing material.

NOTE: Special care must be taken during this operation not to mark the face upon which the seal contacts.

8. Place the carbon–faced seal on the drive shaft so that this face contacts with the insert face.

9. Press the impeller onto the shaft over this seal until the clearance of 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.

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825 Loader Service Manual

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.

2. Note the temperature at which the valve in the unit begins to open. This temperature should be as marked on the unit.

3. If the unit does not function properly, then a replacement thermostat will be necessary. No adjustment of these units is possible.

Thermostat B–01984

Fig. 7–71

Removing Thermostat

7–10.12 Replacement Of The Thermostat Replacement of the thermostat is in reverse of the removal procedure. A new gasket must be installed between the thermostat housing and the water outlet connection. When the radiator has been filled with coolant, check that there are no leaks.

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 every two revolutions.

B–01772

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) Lift Pump

Spacer

7–11.2 To Remove The Lift Pump 1. Disconnect the pipes from the inlet and outlet connections. Seal the ends of the pipes to keep out dirt.

2. Remove the two nuts and washers holding the pump to the tappet inspection cover.

3. Remove the pump, spacer and gasket (Fig. 7–73).

4. To install the pump, reverse the above procedure. Be sure to install two gaskets, one on each side of spacer.

Gasket A–02342

Fig. 7–73 Revised August 79

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Removing Fuel Lift Pump

825 Loader Service Manual

7–11.3 Fuel Injection Pump 7–11.4 To Remove The Fuel Injection Pump 1. Remove the four high pressure pipes between the pump and the injectors and cover all openings to keep out dirt.

2. Remove the low pressure fuel pipes from the inlet and outlet connections and cover the openings.

3. Disconnect the stop and throttle controls and return springs.

4. Remove the two nuts and the socket headed bolt which hold the fuel pump to the fastening flange together with the spring and flat washers.

Fuel Pump

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 pushed in until the fastening flanges contact each other.

Timing Marks

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.

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825 Loader Service Manual

3. Remove the valve springs from No. 1 exhaust valve and let the valve head rest on the piston crown.

825ServiceManual#6549899–EngineServiceSectionPart2of4

4. Mount a dial indicator on top of the valve stem as shown in Figure 7–76 and zero the gauge at the point of maximum cylinder height (determined by turning the engine just over T.D.C.).

5. When the gauge has been set at zero, turn the engine AGAINST normal direction of rotation until the piston (and valve) have moved a distance of 0.120 inch (3,05 mm) down the cylinder bore.

NOTE: This is equal to 19° angle movement of the flywheel B.T.D.C. and is the static timing point.

A–02347

6. When this static timing point has been accurately determined, the C line on the fuel pump rotor must be in alignment with the straight edge of the timing snap ring (Fig. 7–77).

Fig. 7–76 Fuel Pump Timing

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 direction of rotation once again to a piston displacement of 0.120 inch (3,05 mm) to check that the squared end of the snap ring is now aligned with the C line on the rotor.

Timing Mark B–01982

Fig. 7–77

Fuel Pump Timing Marks (Internal)

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

Fig. 7–78 Fuel Pump Gear Revised October 79

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825 Loader Service Manual

3. Loosen the adjusting bolt of the rocker arm on the No. 1 cylinder exhaust valve, so that the rocker arm can be moved to the one side and the pushrod removed. Move the rocker arm so that a valve spring compressor can be used to remove the valve springs (Fig. 7–78a).

4. Remove the valve springs from the No. 1 cylinder exhaust valve and put the valve head on the top of the piston crown.

5. Install a dial indicator on the top of the valve stem (Fig. 7–76). Turn the engine backward and forward to find T.D.C. (maximum piston height) and zero the dial indicator.

NOTE: Do not turn the engine crankshaft too far because the valve can fall into the combustion chamber.

B–03303

Fig. 7–78a Removing Valve Springs 6. Remove the fuel injection pump (See Paragraph 7–11.4).

7. Loosen the screw (Fig. 7–78b, Item 1) on the timing tool and set the gauge as shown in the chart below.

Engine Fuel Pump Setting Type Code 4.108

EH34E EH39 LH30 PH23E PH25E (exceptions below) PH25E500/5/2450 PH25E500/9/1990 PH25E500/9/2090 PH27 PH30 (exceptions below) PH30/30/5/2450 PH30/500/6/1570 PH30/500/9/1990 PH30/500/9/2090 RH30E SH33E

Engine Checking Angle (Degrees)

Fuel Pump Marking Angle (Degrees)

281 281 281 281 281 279–1/2 279–1/2 279–1/2 281 281 279–1/2 279–1/2 279–1/2 279–1/2 279–1/2 279–1/2

290 290 292 290 290 290 290 290 290 290 290 290 290 290 290 290

3

1 2

B–03361

Fig. 7–78b

Timing Tool

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 10. Loosen the screw (Fig. 7–78d, Item 1) and move the plate with the mark close to the flange on the engine (Fig. 7–78d). Tighten the screw.

Installing Tool On Engine

Flange

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 Be In Alignment

1 B–03354

Fig. 7–78d Alignment Of Mark To Engine Revised Feb. 82

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825 Loader 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 The Timing Case).

825ServiceManual#6549899–EngineServiceSectionPages33a–33b

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.

Install the plate again the opposite way. Tighten the screw.

3. Loosen the screw (Fig. 7–78b, Item 1) and set the gauge as shown in the chart.

1 B–03353

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.

Revised Feb. 82

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825 Loader 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 7–11.10 Testing For Faulty Injector

Fig. 7–79

B–01860 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.

–7–34–

825 Loader Service Manual

The pipes must be clean (wash in clean fuel oil and blow through the fine bore with compressed air), the fittings at each end should not be split or compressed, or leakage will result and a new pipe will be needed.

Be sure when installing, that the pipe fits squarely at both ends and that the nuts are tight but not over tight.

When changing an injector, always loosen both the nuts or remove the pipe completely, do not leave one end tight and the pipe under tension. The correct size wrench for the job is a 5/8 inch open end.

7–11.13a Using C.A.V. Thermostart Units

IMPORTANT

Be sure there is fuel getting to the thermostart unit. If you operate the 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 the thermostart unit to see if the heating element gets red.

If it does not get red, the unit has a defect and must be replaced. If fuel is not getting to the inlet of the thermostart, you will need to charge the fuel line (See Charging The Fuel Line below). Troubleshoot the electrical system if there is not 12 volts at the thermostart unit.

1

2

Injection Pump A–02290

Fig. 7–80 Revised August 79

Venting Injection Pump

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825 Loader Service Manual

825ServiceManual#6549899–EngineServiceSectionPart4of4

WARNING

If you use ether as a starting aid, wait until the thermostart unit is cold before putting ether into the manifold.

Never activate the thermostart when using ether.

Secondary Filter

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.

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.

B–01798

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.

8. Tighten all the injector line fittings and start the engine.

B–03873

Fig. 7–82

Fuel Lift Pump

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 Revised Feb. 82

Injectors Fittings

–7–36–

825 Loader Service Manual

SPECIFICATIONS Paragraph Number

Page Number

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4 DE–RATING FOR ALTITUDE . . . . . . . . . . . . . . . . . . . . . . . . . . 8–7 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5 LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 8–10 LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 SERVICE WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 8–8

8–5 8–7 8–5 8–11 8–5 8–6 8–10 8–1 8–5 8–7

SPECIFICATIONS

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825 Loader Service Manual

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825 Loader Service Manual

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

Revised Feb. 82

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825 Loader Service Manual

8–1.6 Connecting Rod Alignment Large and small end bores must be square and parallel with each other within the limits of ± 0.010 in. (0,25 mm) measured 5 in. (127 mm) each side of the axis of the rod on test mandrel as shown in Fig. 1. With the small end bushing installed the limit of ± 0.010 in. (0,25 mm) is reduced to ± 0.0025 in. (0,06 mm).

Crankshaft Main Journal Diameter Nos. 1 and 2 . . . . 2.248/2.2485 in (57,099/57,112 mm) Main Journal Diameter No. 3 . . . . . . . . . . 2.2475/2,248 in. (57,086/57,099 mm) Main Journal Length No. 1 . . . . . . . . . . . . . . . . . . . . . . . 1.40625 in. (35,719 mm) Main Journal Length No. 2 . . . . . . . . . . . . . . 1.496/1.504 in. (38,075/38,151 mm) Main Journal Length No. 3 . . . . . . . . . . . . . . 1.499/1.502 in. (38,075/38,151 mm) Main Journal Fillet Radii . . . . . . . . . . . . . . . . . . 0.125/0.141 in. (3,175/3,581 mm) Crankpin Diameter . . . . . . . . . . . . . . . . . . 1.9995/2.000 in. (50,787/50,800 mm) Crankpin Length . . . . . . . . . . . . . . . . . . . . 1.1875/1,1895 in. (30,969/4,366 mm) Crankpin Fillet Radii . . . . . . . . . . . . . . . . 0.15625/0.17187 in. (3,969/4,366 mm) Surface Finish – All Journals . . . . . . . . . . . . . 8––16 micro–in. (0,2––0,4 micron) Main Journal and Crankpin Regrind Undersizes . . . . . . . . . . . 0.010,0.020,0.030 in. (0,25,0,51, 0,76 mm) Oil Seal Helix Diameter . . . . . . . . . . . 2.21075/2.21175 in. (56,153/56,178 mm) Oil Seal Helix Width . . . . . . . . . . . . . . . . . . . . . 0.050/0.080 in. (1,270/2,032 mm) Oil Seal Helix Depth . . . . . . . . . . . . . . . . . . . . . 0.004/0.008 in. (0,102/0,203 mm) Flange Diameter . . . . . . . . . . . . . . . . . . 3.9985/3.995 in. (101,562/101,587 mm) Flange Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.500 in. (12,700 mm) Spigot Bearing Recess Depth . . . . . . . . . . . . . . . . . . . . . . . 0.875 in. (22,225 mm) Spigot Bearing Recess Bore . . . . . . . . . . . . . . . . . . . . . . . . 1.250 in. (31,750 mm) 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)

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8–1.11 Camshaft No. 1 Journal Diameter . . . . . . . . . . . . . . . . . 1.791/1.792 in. (45,491/45,517 mm) No. 1 Cylinder Block Camshaft Bore Diameter . . . . . . . . . . . . . . . . . . . . . 1.794/1,7955 in, (45,568/45,606 mm) No. 1 Journal Running Clearance . . . . . . . . . 0.002/0.0045 in. (0,051/0,114 mm) No. 2 Journal Diameter . . . . . . . . . . . . . . . . . 1.781/1.782 in. (45,237/45,263 mm) No. 2 Cylinder Block Camshaft . . . . . . . . . . 1.784/1.787 in, (45,314/45,390 mm) No. 2 Journal Running Clearance . . . . . . . . . . 0.002/0.006 in. (0,051/0,152 mm) No. 3 Journal Diameter . . . . . . . . . . . . . . . . . 1.773/1.774 in. (45,034/45,060 mm) No. 3 Cylinder Block Camshaft Bore Diameter . . . . . . . . . . . . . . . . . . . . . . . 1.776/1.778 in. (45,110/45,161 mm) No. 3 Journal Running Clearance . . . . . . . . . . 0.002/0.005 in. (0,051/0,127 mm) Cam Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.266 in. (6,766 mm) 8–1.12 Camshaft Thrust Plates Thrust Plate Outside Diameter . . . . . . . . . . 2.555/2.557 in. (64,897/64,948 mm) Thrust Plate Inside Diameter . . . . . . . . . . . . . . . . . . . . . . . . 1.500 in. (38,100 mm) Thrust Plate Thickness . . . . . . . . . . . . . . . . . . . 0.160/0.162 in. (4,060/4,115 mm) Thrust Plate Height in Relation to Cylinder Block Face . . . . . . . . . . . . . . . . 0.004 in. (0,102 mm) Above or Below Camshaft End Float . . . . . . . . . . . . . . . . . . . . . 0.003/0.013 in. (0,076/0,330 mm) 8–1.13 Cylinder Head Milling Allowance on Cylinder Head Face . . . . . . . . . . . . Cylinder Head Face Must Never be Milled Pressure for Water Leakage Test . . . . . . . . . . . . . . . . . . . . . 20 PSI (1,4 kgf/cm2) 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)

Revised Feb. 81

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825 Loader Service Manual

8–1.17 Valves (Inlet) Valve Stem Diameter . . . . . . . . . . . . . . . . . . . . 0.312/0.313 in. (7,925/7,950 mm) Clearance Fit of Valve Stem in Guide . . . . 0.0015/0.0035 in. (0,038/0,089 mm) Valve Head Diameter . . . . . . . . . . . . . . . . . . 1.410/1.414 in. (35,814/35,916 mm) Valve Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Valve Head Depth Below Cylinder Head Face . 0.028 in. (0,711 mm) Minimum 0.048 in. (1,220 mm) Maximum Overall Length of Valve . . . . . . . . . . . . . . 4.592/4.608 in. (116,637/117,043 mm) Sealing Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rubber Oil Seal 8–1.18 Valves (Exhaust) Valve Stem Diameter . . . . . . . . . . . . . . . . . . 0.3115/0.3125 in. (7,912/7,937 mm) Clearance Fit of Valve Stem in Guide . . . . . . 0.002/0.004 in. (0,051/0,102 mm) Valve Head Diameter . . . . . . . . . . . . . . . . . . 1.191/1.195 in. (30,251/30,353 mm) Valve Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Valve Head Depth Below Cylinder Head Face . . 0.021 in. (0,53 mm) Minimum 0.048 in. (1,22 mm) Maximum Overall Length of Valve . . . . . . . . . . . . . . 4.600/4.616 in. (116,840/117,246 mm) Sealing Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . None fitted to exhaust valve 8–1.19 Inner Valve Springs Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.530 in. (38,862 mm) Load at Fitted Length . . . . . . . . . . . . . . . . . . 28.6 lbf ± 2 lbf (13,0 kgf ± 9,91 kgf) Fitted Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Damper Coil to Cylinder Head 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)

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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 Revised Feb. 82

–8–5–

825 Loader Service Manual

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

Revised January 77

–8–6–

825 Loader Service Manual

8–7 DE–RATING FOR ALTITUDE When engines are operated in high altitude areas, such engine should be de–rated. The following table is given as a general guide, which may be applied on a percentage basis, where specific figures for a particular engine rating are not available.

Altitude

Maximum Fuel Delivery De–rating Measured at 800 RPM Pump Speed

0–2,000 feet (600 meters) 2,000–4,000 feet (1,200 meters) 4,000–6,000 feet (1,800 meters) 6,000–8,000 feet (2,400 meters)

No Change 6% 12% 18%

8,000–10,000 feet (3,000 meters) 10,000–12,000 feet (3,600 meters)

24% 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 Connecting Rod Bolts Main Bearing Bolts Flywheel Bolts Idler Gear Hub Bolts Crankshaft Pulley Bolts Injector Fastening Nuts Generator Pulley Nut

60 42 85 60 32 150 12 20

(81) (57) (115) (81) (43) (203) (16) (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)

30

(40,6)

60

(81,4)

8–8.1 Hydrostatic Pump and Motor: 3/8 inch Fastening Bolts 8–8.2 High Pressure Relief Valves: Hex Plugs 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) –8–7–

825 Loader Service Manual

STANDARD TORQUE SPECIFICATIONS FOR BOLTS

The above illustration shows the most common hex screw marking for each grade. A Grade 2 screw has no markings, a Grade 5 screw has three radial dashes 120 degrees apart, a Grade 8 screw has six radial dashes 60 degrees apart.

THREAD SIZE

I N C H L B S.

DRY

GRADE–2 LUBE

DRY

GRADE–5 LUBE

DRY

GRADE–8 LUBE

1/4–Coarse

45–60 (5.08–6.78)

35–45 (3.95–5.08)

75–95 (8.47–10.73)

55–70 (6.21–7.91)

115–145 (12.99–16.38)

85–105 (9.6–11.86)

1/4–Fine

55–70 (6.21–7.91)

45–60 (5.08–6.78)

95–120 (10.73–13.56)

65–85 (7.34–9.60)

135–165 95–120 (15.25–18.64) (10.73–13.56)

5/16–Coarse

105–130 (11.86–14.69)

75–95 (8.47–10.73)

160–200 18.08–22.60)

125–155 (14.12–17.51)

240–300 175–215 (27.12–33.90) (19.77–24.29)

5/16–Fine

115–145 (12.99–16.38)

85–105 (9.60–11.86)

180–225 (20.34–25.4)

135–165 (15.25–18.64)

260–325 190–240 (29.40–36.72) (21.47–27.12)

3/8 Coarse

190–250 (21.47–28.25)

145–180 (16.38–20.34)

25–30 (33.9–40.7)

18–23 (24.4–31.2)

35–45 (47.5–61.0)

25–30 (33.9–40.7)

3/8–Fine

220–275 (24.86–31.07)

160–200 (18.08–22.60)

30–35 (40.7–47.5)

20–25 (27.1–33.9)

40–50 (54.2–67.8)

30–35 (40.7–47.5)

7/16–Coarse

25–30 (33.9–40.7)

15–20 (20.3–27.1)

40–50 (54.2–67.8)

30–35 (40.7–47.5)

55–70 (74.6–94.9)

45–55 (61.0–74.6)

7/16–Fine

30–35 (40.7–47.5)

20–25 (27.1–33.9)

45–55 (61.0–74.6)

35–40 (47.5–54.2)

65–80 (88.1–108.5)

50–60 (67.8–81.4)

1/2–Coarse

40–50 (61.0–74.6)

30–35 (47.5–54.2)

60–75 (94.9–115.2)

45–55 (67.8–81.4)

90–110 65–80 (128.8–162.7) (101.7–122.01)

1/2–Fine

45–55 (61.0–74.6)

35–40 (47.5–54.2)

70–85 (94.9–115.2)

50–60 (67.8–81.4)

95–120 75–90 (128.8–162.7) (101.7–122.0)

9/16–Coarse

55–65 (74.6–88.1)

40–50 (54.2–67.8)

90–110 (122.0–149.1)

65–80 (88.1–108.5)

120–150 90–110 (162.7–203.3) (122.0–149.1)

9/16–Fine

60–75 (81.4–101.7)

45–55 61.0–74.60

95–120 (128.8–162.7)

75–90 (101.7–122.0)

135–170 105–130 (183.0–230.5) (142.4–176.3)

5/8–Coarse

75–90 (101.7–122.0)

55–70 (74.6–94.9)

120–150 (162.7–203.3)

90–110 (122.0–149.1)

180–220 135–170 (244.0–298.3) (183.0–230.5)

5/8–Fine

80–100 (108.5–135.6)

75–80 (88.1–108.5)

145–180 (196.6–244.0)

105–130 (142.4–176.3)

195–240 145–180 (264.4–325.4) (196.6–244.0)

3/4–Coarse

130–160 (176.3–216.9)

95–120 (128.8–162.7)

21–260 (284.7–352.5)

160–200 (216.9–271.2)

300–380 225–280 (406.8–515) (305.1–379.61)

3/4–Fine

145–180 (196.6–244.01)

115–140 (155.9–189.8)

240–300 (325.4–406.1)

180–220 (244.0–298.3)

340–420 255–320 (460.1–569) (345.1–433.9)

7/8–Coarse

115–140 (155.9–189.8)

90–110 (122.0–149.1)

320–400 (433.9–542)

240–300 (325.4–406.8)

500–600 (678–814)

370–460 (502–624)

7/8–Fine

125–155 (169.5–210.2)

95–120 (128.8–162.7)

350–440 (474.5–598)

255–320 (345.7–433.9)

560–660 (759–895)

400–500 (542–678)

1–Coarse

180–200 (244.1–298.3)

130–160 (176.3–216.9)

480–580 (651–786)

350–440 (475–598)

800–900 (1085–1220)

580–680 (786–922)

1–Fine

200–250 (271.2–338.9)

140–175 (189.8–237.3)

560–660 (759–895)

400–490 (542–664)

920–1020 (1247–1383)

665–765 (902–1037)

(Nm)

F T. L B S. (Nm)

–8–8–

825 Loader Service Manual

DECIMAL AND MILLIMETER EQUIVALENTS FRACTIONS 1/64 1/32 3/64 1/16 5/64 3/32 7/64 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2

DECIMALS

MM

0.015625 0.03125 0.046875 0.0625 0.078125 0.09375 0.109375 0.1250 0.140625 0.15625 0.171875 0.1875 0.203125 0.21875 0.234375 0.2500 0.265625 0.28125 0.296875 0.3125 0.328125 0.34375 0.359375 0.3750 0.390625 0.40625 0.421875 0.4375 0.453125 0.46875 0.484375 0.5000

0.397 0.794 1.191 1.588 1.984 2.381 2.778 3.175 3.572 3.969 4.366 4.762 5.159 5.556 5.953 6.350 6.747 7.144 7.541 7.938 8.334 8.731 9.128 9.525 9.922 10.319 10.716 11.112 11.509 11.906 12.303 12.700

— — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — —

FRACTIONS

DECIMALS 33/64

17/32 35/64 9/16 37/64 19/32 39/64 5/8 41/64 21/32 43/64 11/16 45/64 23/32 47/64 3/4 49/64 25/32 51/64 13/16 53/64 27/32 55/64 7/8 57/64 29/32 59/64 15/16 61/64 31/32 63/64 1

1 mm = 0.03937’’

0.515625 0.53125 0.546875 0.5625 0.578125 0.59375 0.609375 0.6250 0.640625 0.65625 0.671875 0.6875 0.703125 0.71875 0.734375 0.7500 0.765625 0.78125 0.796875 0.8125 0.828125 0.84375 0.859375 0.8750 0.890625 0.90625 0.921875 0.9375 0.953125 0.96875 0.984375 1.000

— — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — —

MM 13.097 13.494 13.891 14.288 14.684 15.081 15.478 15.875 16.272 16.669 17.066 17.462 17.859 18.256 18.653 19.050 19.447 19.844 20.241 20.638 21.034 21.431 21.828 22.225 22.622 23.019 23.416 23.812 24.209 24.606 25.003 25.400

0.001 = 0.0254 mm

U.S. TO METRIC CONVERSION TO CONVERT

INTO

MULTIPLY BY

LINEAR MEASUREMENT

Miles Yards Feet Feet Inches Inches Inches

Kilometers Meters Meters Centimeters Meters Centimeters Millimeters

AREA

Square Miles Square Feet Square Inches Acre

Square Kilometers Square Meters Square Centimeters Hectare

VOLUME

Cubic Yards Cubic Feet Cubic Inches

Cubic Meters Cubic Meters Cubic Centimeters

0.7646 0.02832 16.39

WEIGHT

Tons (Short) Pounds Ounces (Avdp.)

Metric Tons Kilograms Grams

0.9078 0.4536 28.3495

PRESSURE

Pounds/Sq. In.

Kilopascal

6.895

WORK

Foot–Pounds

Newton–Meter

1.356

LIQUID VOLUME

Quarts Gallons

Liters Liters

0.9463 3.785

LIQUID FLOW

Gallons/Minute

Liters/Minute

3.785

TEMPERATURE

Fahrenheit

Celsius

1.609 0.9144 0.3048 30.48 0.0254 2.54 25.4 2.59 0.0929 6.452 0.4047

1.Subtract 32° 2. Multiply by 5/9 –8–9–

825 Loader Service Manual

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.

–8–10–

825 Loader Service Manual

825 LOADER SPECIFICATIONS

60 (1524)

155 (3937)

113 (2870)

45°

65 (1651) 9.75 (248) 96 (2440)

38 (965)

46.5 (1181) 57 (1448)

44 (1118)

8.5 (216) 32°

76 (1930)

94.25 120 (2394) (3048)

37 (940) 85 (2159)

131.5 (3340)

38.5°

21.25 (540)

26° 34 (864)

51.5 (1308)

60.75 (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

–8–11–

825 Loader Service Manual

SPECIFICATIONS (Cont’d) a 825ServiceManual#6549899–SpecificationsSection

LOADER HYDRAULICS Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine driven, gear type Pump Capacity . . . . . . . . . . . . . . . . . . . . . . 12.5 GPM (47,3 L/min.) @2500 RPM System Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2100 PSI (14478 kPa) Hydraulic/Hydrostatic Fluid (Type) . Use Only Clark Hydraulic/Hydrostatic Fluid (P/N 6563328) or Rando HDAZ Oil (Texaco Product 1629) Hydraulic Fluid Filter . . Two 10 Micron replaceable elements on the hydrostatic inlet, 25 Micron suction replaceable element Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doubleacting Bore Diameter Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 (57,1) Tilt Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 (57,1) Rod Diameter Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 (38,1) Tilt Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25 (31,8) Stroke Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.00 (787,4) Tilt Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.13 (435,1) Control Valve . . . . 3–spool, open center type lift, tilt & auxiliary with float on lift Fluid Lines . . . . . . . . . . . . . . . . . . . . SAE standard full flow tube, hoses & fittings Hydraulic Function Time Raise Lift Arms to Maximum Height . . . . . . . . . . . . . . . . . . . . . . . 4.8 seconds Lower Lift Arms from Maximum Height . . . . . . . . . . . . . . . . . . . . . 3.8 seconds 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)

Revised Aug. 82

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825 Loader Service Manual

ALPHABETICAL INDEX Paragraph Number

Page Number

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

9–1

ALPHABETICAL INDEX

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9–1 ALPHABETICAL INDEX Subject

Page

ADJUSTMENT OF SPEED RANGE LINKAGE . . . .

ALTERNATOR OUTPUT . . . . . . . . . . . . . . . . . . . . . . .

ALTERNATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . .

AXLE BEARING & SEAL REPLACEMENT . . . . . . .

AXLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Subject

Page

3–1 6–1 6–1 4–1 4–1

LIFT ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 LIFT VALVE SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 8–1 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . 7–1, 8–1

BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 BOB–TACH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 5–1

MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1

CHECKING HYDROSTATIC SYSTEM . . . . . . . . . . . 3–1 CHECKING RELIEF VALVES . . . . . . . . . . . . . . . . . . . 3–1 CONNECTING RODS AND PISTONS . . . . . . . . . . . 7–1 CONTROL LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 CONTROL PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 7–1, 8–1 CRANKSHAFT AND MAIN BEARINGS . . . . . . . . . . 7–1 DE–RATING FOR ALTITUDE . . . . . . . . . . . . . . . . . . .

DRAINING THE FLUID RESERVOIR . . . . . . . . . . . .

DRIVE CHAIN INSTALLATION . . . . . . . . . . . . . . . . . .

DRIVE CHAIN REMOVAL . . . . . . . . . . . . . . . . . . . . . .

8–1 1–1 4–1 4–1

ELECTRIC MOTOR FOR ROPS . . . . . . . . . . . . . . . .

ELECTRICAL CIRCUITRY . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SYSTEM MAINTENANCE . . . . . . . . .

ENGINE AIR INLET SYSTEM (Air Cleaner) . . . . . . .

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . .

ENGINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . .

ENGINE OIL AND FILTER REPLACEMENT . . . . . .

ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . .

5–1 6–1 1–1 1–1 1–1 1–1 1–1 7–1

FAN BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 FAN BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 1–1 FINAL DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 FINAL DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 4–1 FLUSHING THE COOLING SYSTEM . . . . . . . . . . . . 1–1 FLYWHEEL AND FLYWHEEL HOUSING . . . . . . . . . 7–1 FUEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 1–1 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1–1, 7–1, 8–1 FUEL SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . 1–1 FUEL TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 5–1 GEAR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 GEAR PUMP DISASSEMBLY . . . . . . . . . . . . . . . . . . 2–1

OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1, 2–1 PIVOT PIN & BUSHING REPLACEMENT . . . . . . . . . 5–1 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . 1–1 PROBLEM ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REDUCTION HOUSING ASSEMBLY . . . . . . . . . . . . .

REDUCTION HOUSING DISASSEMBLY . . . . . . . . . .

REDUCTION HOUSING REMOVAL . . . . . . . . . . . . . .

REGULATOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVING AIR FROM THE FUEL SYSTEM . . . . . .

ROPS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–1 4–1 4–1 4–1 6–1 1–1 5–1

SERVICE WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTING ENGINE AFTER RECONDITIONING . . .

STARTING PROCEDURE, AFTER REPAIR . . . . . . .

STEERING CONTROL LINKAGE . . . . . . . . . . . . . . . .

8–1 8–1 8–1 6–1 7–1 3–1 3–1

10 MICRON FINAL FILTER REPLACEMENT . . . . . .

TEMPERATURE & PRESSURE SWITCHES . . . . . .

TILTING THE ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIMING CASE AND DRIVE . . . . . . . . . . . . . . . . . . . . . .

TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . .

TIRE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . .

TIRE ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . .

TUBELINES, HOSES, FITTINGS . . . . . . . . . . . . . . . .

3–1 3–1 1–1 7–1 8–1 1–1 1–1 1–1 1–1 8–1 2–1

WHEEL MOUNTING NUTS . . . . . . . . . . . . . . . . . . . . . 1–1

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 –9–1–

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