Sebu7877-08 M PDF
Sebu7877-08 M PDF
Sebu7877-08 M PDF
2010 Caterpillar
All Rights Reserved
SEBU7877-08
February 2010
Operation and
Maintenance
Manual
824H Wheel Dozer, 825H Soil
Compactor and 826H Landfill
Compactor
ASX1-Up (824H)
AZW1-Up (825H)
AWF1-Up (826H)
SAFETY.CAT.COM
SEBU7877-08
95
Maintenance Section
Maintenance Interval Schedule
i03869829
When Required
Battery - Recycle .................................................. 99
Battery or Battery Cable - Inspect/Replace .......... 99
Circuit Breakers - Reset ...................................... 104
Cleaner Bar Tips - Replace ................................. 106
Display and Camera - Clean ................................ 117
Engine Air Filter Primary Element - Clean/
Replace .............................................................. 118
Engine Air Filter Secondary Element - Replace .. 121
Engine Air Precleaner - Clean ............................ 123
Ether Starting Aid Cylinder - Replace ................. 132
Fuel System - Prime ........................................... 132
Fuses - Replace .................................................. 137
High Intensity Discharge Lamp (HID) - Replace .. 138
Oil Filter - Inspect ................................................ 143
Radiator Core - Clean ......................................... 143
Window Washer Reservoir - Fill .......................... 152
Window Wiper - Inspect/Replace ........................ 152
102
102
132
136
137
148
96
Maintenance Section
Maintenance Interval Schedule
Every Year
Cooling System Coolant Sample (Level 2) Obtain ................................................................ 111
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Maintenance Section
Alternator Air Vent Line and Screen - Clean
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i02220086
S/N: AWF1-Up
Illustration 106
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98
Maintenance Section
Axle Oscillation Bearings - Lubricate
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Illustration 108
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Illustration 107
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Battery - Clean
SMCS Code: 1401-070
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Maintenance Section
Battery - Recycle
Battery - Recycle
i03657099
A battery supplier
Illustration 110
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100
Maintenance Section
Belt - Inspect/Adjust/Replace
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A battery supplier
An authorized battery collection facility
Recycling facility
i03700093
Belt - Inspect/Adjust/Replace
SMCS Code: 1397-025; 1397-040; 1397-510
Your machine is equipped with a single serpentine
belt. Stop the engine. Open the rear hood. The belt is
located at the front of the engine.
Illustration 112
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Illustration 113
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Alert Indicator
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Alternator
Tensioner
Serpentine Belt
Square Drive Hole
Compressor
Drive Pulley
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Maintenance Section
Brake Discs - Check
102
Maintenance Section
Bulldozer Stabilizer - Lubricate
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Illustration 115
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S/N: AWF1-Up
S/N: ASX1-Up
Wipe off all fittings before any lubricant is applied.
Illustration 114
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Illustration 116
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103
Maintenance Section
Case Drain Screen (Strainer) (Implement Pilot Valve) - Clean
Illustration 117
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Illustration 118
Rear view of hydraulic oil tank (3)
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104
Maintenance Section
Circuit Breakers - Reset
SEBU7877-08
Type 1
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
2. Disconnect line (1) and line (5) from the hydraulic
oil tank (3).
3. Remove screen (2) from line (1). Remove screen
(4) from line (5).
Illustration 119
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Type 2
Illustration 120
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Maintenance Section
Cleaner Bar - Check/Adjust
i02553696
S/N: AWF1-Up
S/N: AZW1-Up
Illustration 121
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Typical example
Illustration 122
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106
Maintenance Section
Cleaner Bar Support Bearing Oil - Check
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i02553695
S/N: AWF1-Up
S/N: AZW1-Up
S/N: AZW1-Up
Illustration 123
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Illustration 124
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2. Drive the pin out of the tip from the retainer side of
the tip. Remove the tip from the retainer.
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Maintenance Section
Compactor Wheel Chopper Blades - Inspect/Replace
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Illustration 125
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Illustration 127
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Illustration 126
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108
Maintenance Section
Cooling System Coolant (ELC) - Change
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Illustration 128
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Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve
the pressure.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
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109
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
i02225266
Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve
the pressure.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Illustration 129
NOTICE
Topping off or mixing Cat ELC with other products that
do not meet Caterpillar EC-1 specifications reduces
the effectiveness of the coolant and shortens coolant
service life.
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110
Maintenance Section
Cooling System Coolant Level - Check
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Illustration 130
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Illustration 131
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Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
NOTICE
Failure to replace the engine's thermostat on a regularly scheduled basis could cause severe engine damage.
i02224620
NOTICE
Caterpillar engines incorporate a shunt design cooling
system and require operating the engine with a thermostat installed.
Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve
the pressure.
Illustration 132
g01122814
112
Maintenance Section
Crankcase Guard Compartment and Power Train Guard Compartment - Clean
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Crankcase Guard
Compartment and Power
Train Guard Compartment Clean
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Illustration 134
g00771980
Check the cutting edges and the end bits for wear and
for damage. Use the following procedure to service
the cutting edges and the end bits, if necessary.
1. Raise the blade and place blocking under the
blade. Lower the blade onto the blocking. Stop
the engine.
Illustration 133
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Maintenance Section
Differential and Final Drive Oil - Change
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Illustration 136
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Illustration 135
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114
Maintenance Section
Differential and Final Drive Oil - Change
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Illustration 137
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Illustration 138
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Illustration 139
Rear view 825H and 826H
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Maintenance Section
Differential and Final Drive Oil Level - Check
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Illustration 141
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Differentials
Illustration 142
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116
Maintenance Section
Differential and Final Drive Oil Sample - Obtain
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Final Drives
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Illustration 143
g00760182
2. Check the oil level. The oil should be level with the
bottom of the filler opening. Add oil, if necessary.
3. Clean the final drive filler plug and install the final
drive filler plug.
4. Repeat the procedure for the remaining final
drives.
i02339189
Illustration 144
g01122097
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both
dealers and customers.
Illustration 145
Rear Differential Filler Plug 824H
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117
Maintenance Section
Display and Camera - Clean
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Display
Illustration 146
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Illustration 148
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WAVS display
Illustration 147
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Camera
Illustration 149
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118
Maintenance Section
Drive Shaft Support Bearing - Lubricate
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Illustration 150
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Illustration 151
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119
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
Illustration 152
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Pressurized air
Vacuum cleaning
120
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
Pressurized Air
Pressurized air can be used to clean primary air filter
elements that have not been cleaned more than two
times. Pressurized air will not remove deposits of
carbon and oil. Use filtered, dry air with a maximum
pressure of 207 kPa (30 psi).
SEBU7877-08
Illustration 154
Illustration 153
g00281692
Vacuum Cleaning
Vacuum cleaning is another method for cleaning
primary air filter elements which require daily cleaning
because of a dry, dusty environment. Cleaning with
pressurized air is recommended prior to vacuum
cleaning. Vacuum cleaning will not remove deposits
of carbon and oil.
g00281693
Illustration 155
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Maintenance Section
Engine Air Filter Secondary Element - Replace
Date of cleaning
Number of cleanings
Illustration 157
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Illustration 158
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Illustration 156
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Illustration 159
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122
Maintenance Section
Engine Air Filter Service Indicator - Inspect
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Illustration 161
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The air filter service indicator is located near the air filter housing.
Inspect
Illustration 160
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The air filter service indicator is located near the air filter housing.
SEBU7877-08
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Maintenance Section
Engine Air Precleaner - Clean
Test
1. Check for ease of resetting. The service indicator
should reset in less than three pushes.
2. Check the movement of the yellow core when the
engine is accelerated to the engine rated speed.
The yellow core should latch approximately at the
greatest vacuum that is attained.
If the service indicator does not reset easily, or if the
yellow core does not latch at the greatest vacuum,
the service indicator should be replaced. If the new
service indicator will not reset, the hole for the service
indicator may be plugged.
Replace
i02915110
Decks
Walkways
Steps
Engine compartment
Belly guards
Radiator cores
Filters
Exhaust components
Illustration 162
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Other areas
124
Maintenance Section
Engine Compartment - Inspect/Clean
SEBU7877-08
Illustration 163
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Illustration 165
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Illustration 164
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125
Maintenance Section
Engine Oil (High Speed) and Oil Filter - Change
i02301059
Table 11
Severe
Normal(2)
Multigrade
Oil Type
High
Load
Factor(3)
above
62.1 L
(16.4
US gal)
per hr
of fuel
Fuel
Sulfur
from
0.3% to
0.5%
Altitude
above
1830 m
(6000 ft)
(4)
Cat DEO
Preferred
500 hr
500 hr
500 hr
250 hr(6)
Cat ECF-1
11.0
minimum
TBN(4)
Preferred
500 hr
500 hr
500 hr
250 hr(6)
Cat ECF-1
TBN(4)
below 11.0
500 hr
500 hr
250 hr(5)
250 hr(6)
API CG-4
250 hr
250 hr(5)
250 hr(5)
250 hr(6)
(1)
126
Maintenance Section
Engine Oil (High Speed) and Oil Filter - Change
Program A
Verification for an Oil Change Interval of 500 Hours
This program consists of three oil change intervals of
500 hours. Oil sampling and analysis is done at 250
hours and 500 hours for each of the three intervals
for a total of six oil samples. The analysis includes
oil viscosity and infrared (IR) analysis of the oil. If
all of the results are satisfactory, the 500 hour oil
change interval is acceptable for the machine in that
application. Repeat Program A if you change the
application of the machine.
If a sample does not pass the oil analysis, take one
of these actions:
SEBU7877-08
Illustration 166
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Maintenance Section
Engine Oil Level - Check
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Illustration 168
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128
Maintenance Section
Engine Oil Sample - Obtain
SEBU7877-08
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Illustration 169
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Illustration 170
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129
Maintenance Section
Engine Oil and Filter - Change
i02343257
Table 12
Operating Conditions
Severe
Normal(2)
Multigrade
Oil Type
High
Load
Factor(3)
above
62.1 L
(16.4 US
gal) per
hr of
fuel
Fuel
Sulfur
from
0.3%
to
0.5%
Altitude
above
1830 m
(6000 ft)
(4)
Cat DEO
Preferred
500 hr
500 hr
500 hr
250 hr(6)
Cat ECF-1
11.0
minimum
TBN(4)
Preferred
500 hr
500 hr
500 hr
250 hr(6)
Cat ECF-1
TBN(4)
below 11.0
500 hr
500 hr
250
hr(5)
250 hr(6)
API CG-4
250 hr
250 hr(5)
250
hr(5)
250 hr(6)
(1)
130
Maintenance Section
Engine Oil and Filter - Change
Program A
Verification for an Oil Change Interval of 500 Hours
This program consists of three oil change intervals of
500 hours. Oil sampling and analysis is done at 250
hours and 500 hours for each of the three intervals
for a total of six oil samples. The analysis includes
oil viscosity and infrared (IR) analysis of the oil. If
all of the results are satisfactory, the 500 hour oil
change interval is acceptable for the machine in that
application. Repeat Program A if you change the
application of the machine.
If a sample does not pass the oil analysis, take one
of these actions:
SEBU7877-08
Program B
Optimizing Oil Change Intervals
Begin with a 250 hour oil change interval. The oil
change intervals are adjusted by increments. Each
interval is adjusted an additional 50 hours. Periodic oil
sampling and analysis is done during each interval.
The analysis includes oil viscosity and infrared (IR)
analysis of the oil. Repeat Program B if you change
the application of the machine.
If an oil sample does not pass the analysis, shorten
the oil change interval, or change to a preferred
multigrade oil type in the listing above.
References
Reference: Special Publication, PEDP7035,
Optimizing Oil Change Intervals
Reference: Special Publication, PEDP7036, SOS
Fluid Analysis
Reference: Special Publication, PEHP7076,
Understanding the SOS Services Tests
Illustration 171
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Maintenance Section
Engine Valve Lash - Check
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Illustration 173
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Start the engine and run the engine at low idle. Watch
the top surface of each valve rotator. Whenever an
inlet valve closes or an exhaust valve closes, each
valve rotator should turn.
If a valve rotator fails to turn, consult your Caterpillar
dealer for service.
132
Maintenance Section
Engine Water Pump - Inspect
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i02848898
Illustration 174
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Maintenance Section
Fuel System Primary Filter (Water Separator) - Drain
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Illustration 176
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Illustration 177
Type 2 Primary Filter (Water Separator)
Steel fuel filter
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134
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
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Illustration 178
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NOTICE
Do not fill fuel filters with fuel before installing them.
The fuel will not be filtered and could be contaminated.
Contaminated fuel will cause accelerated wear to fuel
system parts. The fuel system should be primed prior
to starting the engine.
Illustration 179
g00101318
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Maintenance Section
Fuel System Secondary Filter - Replace
NOTICE
Do not fill fuel filters with fuel before installing them.
The fuel will not be filtered and could be contaminated.
Contaminated fuel will cause accelerated wear to fuel
system parts. The fuel system should be primed prior
to starting the engine.
Illustration 180
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136
Maintenance Section
Fuel Tank Cap and Strainer - Clean
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i01493714
Illustration 181
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Illustration 182
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Maintenance Section
Fuel Tank Water and Sediment - Drain
i02214705
Fuse Block
Illustration 184
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Typical example
Fuse Panel
Illustration 183
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The valve assembly (1) for the fuel tank drain is located behind the
fuel tank on the right side of the machine.
Fuses - Replace
SMCS Code: 1417-510
The fuses are located in the operator compartment
behind the seat.
NOTICE
Replace the fuses with the same type and size only.
Otherwise, electrical damage can result.
If it is necessary to replace fuses frequently, an electrical problem may exist. Contact your Caterpillar dealer
Your machine may not be equipped with all of the
fuses that are discussed in this topic.
Note: Your machine is equipped with fuses that are
the following amperage: 10 Amp, 15 Amp, and 20
Amp. The following illustrations are typical examples.
Illustration 185
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138
Maintenance Section
High Intensity Discharge Lamp (HID) - Replace
SEBU7877-08
NOTICE
Although HID bulb materials may change over time,
HID bulbs produced at the time of the printing of this
manual contain mercury. When disposing of this component, or any waste that contains mercury, please
use caution and comply with any applicable laws.
1. Remove the electrical power from the high
intensity discharge lamp (HID). The electrical
power must be removed from the HID lamp for
at least five minutes, in order to ensure that the
bulb is cool.
2. Disassemble the housing for the HID lamp in order
to have access to the bulb.
Note: On some HID lamps, the bulb is an integral
part of the lens assembly. The bulb is not removed
separately from the lens assembly. Replace the
entire lens assembly on these HID lamps.
3. Remove the bulb from the HID lamp.
4. Install the replacement bulb in the HID lamp.
Illustration 186
g01381050
(1) 15 amperes
(2) 20 amperes
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Maintenance Section
Hydraulic System Oil - Change
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Oil Filters
Caterpillar oil filters are recommended. The interval
for changing the oil filter should be 500 hours.
Oil
The 4000 hour interval for changing the oil is for the
following oil types:
Illustration 187
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140
Maintenance Section
Hydraulic System Oil Filter - Replace
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Illustration 188
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Illustration 189
141
Maintenance Section
Hydraulic System Oil Level - Check
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Illustration 190
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142
Maintenance Section
Lift Cylinder Lower Bearings - Lubricate
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Illustration 191
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Illustration 192
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Maintenance Section
Lift Cylinder Upper Bearings - Lubricate
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S/N: AZW1-Up
Illustration 193
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i02106227
Illustration 195
Illustration 194
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144
Maintenance Section
Receiver Dryer (Refrigerant) - Replace
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Illustration 196
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Illustration 197
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NOTICE
If the refrigerant system has been open to the outside
air (without being plugged) for more than 30 minutes,
the receiver-dryer must be replaced. Moisture will enter an open refrigerant system and cause corrosion
which will lead to component failure.
Refer to Service Manual, SENR5664, Air
Conditioning and Heating System with R-134a
Refrigerant for All Caterpillar Machines for the proper
procedure to change the receiver-dryer assembly
and for the procedure to reclaim the refrigerant gas.
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Maintenance Section
Rollover Protective Structure (ROPS) - Inspect
i01457460
Illustration 199
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Typical example
Illustration 198
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146
Maintenance Section
Service Brake Wear Indicator - Check
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Illustration 200
(1) Date
(2) Date
(3) Date
(4) Date
g01152685
of installation (retractor)
of installation (buckle)
of manufacture (tag) (fully extended web)
of manufacture (underside) (buckle)
Illustration 201
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1. Remove nut (1) and the bolt from the lower end of
steering shaft assembly (2).
Illustration 202
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Illustration 203
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Maintenance Section
Steering Cylinder Bearings - Lubricate
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Illustration 204
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Illustration 205
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148
Maintenance Section
Tire Inflation - Check
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S/N: ASX1-Up
Illustration 206
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Illustration 207
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Maintenance Section
Transmission Oil Filter - Replace
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Illustration 208
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Illustration 209
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150
Maintenance Section
Transmission Oil Level - Check
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Illustration 210
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Illustration 211
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Illustration 212
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Maintenance Section
Transmission Oil Sample - Obtain
i02225261
i02377574
Turbocharger - Inspect
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
1. Operate the machine for a few minutes before
obtaining the oil sample. This will thoroughly mix
the transmission oil for a more accurate sample.
Illustration 213
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152
Maintenance Section
Window Washer Reservoir - Fill
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i01460440
Illustration 214
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Illustration 215
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Windows - Clean
SMCS Code: 7310-070
Illustration 216
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