Bobcat 825 Skid-Steer Loader Repair Manual

The Bobcat 825 Skid-Steer Loader, produced from 1977 to 1983, is engineered for power and reliability in demanding environments such as construction, agriculture, and landscaping. Equipped with a 40 hp Deutz 3-cylinder air-cooled diesel engine, the 825 delivers a rated operating capacity of 1,500 lbs with a tipping load of 3,000 lbs, all within a compact frame for excellent maneuverability on tight job sites.

The comprehensive service manual for the Bobcat 825 begins with thorough Maintenance Safety guidance, emphasizing safe servicing practices. The Contents section provides quick reference to major topics, starting with a foreword introducing operators and technicians to the loader’s systems and specifications.

In the Preventive Maintenance section, you’ll find step-by-step procedures for inspections, including rear grill access, tilting the operator guard, and detailed maintenance of engine systems such as oil, filters, air cleaner, cooling system, fan belts, and fuel system components. This section also addresses electrical system checks, hydraulic fluid servicing, final drive chain maintenance, tire rotation, and proper lubrication to maximize uptime.

The Hydraulic System chapters cover hydraulic and hydrostatic schematics, troubleshooting, pump and control valve service, hydraulic cylinder repair, and detailed inspection procedures. Tubelines, hoses, and fittings are explained with illustrations for correct assembly, while sections on oil cooler servicing and float detent repair ensure precise hydraulic performance.

In the Hydrostatic System, the manual provides a complete guide to understanding the drive system, from control linkage adjustments and steering control removal to testing charge pressure, checking relief valves, and step-by-step instructions for disassembly, inspection, and reassembly of the hydrostatic pump and motor. Proper starting procedures after repair are included to prevent damage on first startup.

The Final Drive System chapters offer clear procedures for removal, disassembly, inspection, and reassembly of the reduction housing, drive chains, axles, and sprockets. Adjustments for internal and external drive chain setups are provided, along with park brake service instructions.

The Main Frame section details removal and installation of major components, including the ROPS (Roll-Over Protective Structure), Bob-Tach, lift arms, and fuel tank variations by serial number, as well as the ROPS tilting system — both electric and mechanical versions.

The manual’s extensive Electrical System chapters feature detailed schematics, circuit analysis, problem diagnostics, and complete alternator and starter servicing, from removal to inspection of individual components such as rotors, stators, diodes, and regulator systems.

The Engine Service section offers an exhaustive overhaul guide for the Deutz F3L912 engine. Topics include cylinder head maintenance, valve service, piston and connecting rod replacement, crankshaft inspection, timing gear alignment, lubrication system servicing, cooling system repairs including water pump and thermostat replacement, and complete fuel system service including injector and pump timing.

The Specifications section compiles all technical data in one place, with detailed wear limits, torque specs, gear backlash tolerances, lubrication details, and loader performance specifications. Conversion charts, special tool lists, and both U.S. and metric units ensure accuracy during repairs.

Finally, the manual concludes with an Alphabetical Index, Service Bulletins, and a record of Service Manual Revisions, ensuring technicians have the most current information for effective maintenance and repair.

This manual is an indispensable resource for anyone servicing the Bobcat 825, combining clear, step-by-step instructions, detailed diagrams, and essential technical data to keep your skid-steer loader operating safely and reliably.