SERV7105-01
January 2005
Vol. 1, No. 2
SERVICE TRAINING
TECHNICAL PRESENTATION
824H WHEEL DOZER,
825H SOIL COMPACTOR, AND
826H LANDFILL COMPACTOR
INTRODUCTION
New Product Introduction
(NPI)
824H WHEEL DOZER,
825H SOIL COMPACTOR, AND
826H LANDFILL COMPACTOR
INTRODUCTION
AUDIENCE
Level II - Service personnel who understands the principles of machine system operation,
diagnostic equipment, and procedures for testing and adjusting.
CONTENT
This presentation provides new and different New Product Introduction (NPI) information on
the 824H Wheel Dozer, 825H Soil Compactor, and 826H Landfill Compactor. This
presentation may be used for self-paced and self-directed training.
OBJECTIVES
After learning the information in this presentation, the technician will be able to:
1. locate and identify the new components on the 824H Wheel Dozer, 825H Soil
Compactor, and 826H Landfill Compactor; and
2. explain the operation of the new components in the systems.
Estimated Time: 1 Hour
Illustrations: 18
Handouts: 6
Form: SERV7105-01
Date: 1/05
© 2005 Caterpillar Inc.
SERV7105-01 -3- NPI
Vol. 1, No. 2, 2005
TABLE OF CONTENTS
INTRODUCTION ........................................................................................................................5
SIMILARITIES AND DIFFERENCES .......................................................................................6
ENGINE........................................................................................................................................7
AUTOMATIC BLADE POSITIONING (ABP) SYSTEM........................................................11
ATTACHMENTS .......................................................................................................................12
COOLING PACKAGE ...............................................................................................................13
CONCLUSION...........................................................................................................................14
HYDRAULIC SCHEMATIC COLOR CODE...........................................................................15
HANDOUTS...............................................................................................................................17
POSTTEST .................................................................................................................................19
POSTTEST ANSWERS .............................................................................................................21
SERV7105-01 -4- NPI
Vol. 1, No. 2, 2005
NOTES
SERV7105-01 -5- NPI
Vol. 1, No. 2, 2005
824H WHEEL DOZER,
825H SOIL COMPACTOR, AND
826H LANDFILL COMPACTOR
INTRODUCTION
2 C
INTRODUCTION
The 824H Wheel Dozer, 825H Soil Compactor, and 826H Landfill Compactor have been
updated to enhance performance and to meet the Tier III EPA regulations.
The serial number prefix of the 824H Wheel Dozer is ASX, the serial number prefix for the
825H Soil Compactor is AZW, and the serial number prefix for the 826H Landfill Compactor is
AWF. The 824H Wheel Dozer is a direct replacement for the 824G Series II Wheel Dozer.
The 825H Soil Compactor is a direct replacement for the 825G Series II Soil Compactor. The
826H Landfill Compactor is a direct replacement for the 825G Series II Landfill Compactor.
SERV7105-01 -6- NPI
Vol. 1, No. 2, 2005
SIMILARITIES AND DIFFERENCES
The most significant change to the 824H, 825H, and 826H is the engine. The engine is
changing from the Caterpillar 3406E to the Caterpillar C15 ACERT.
The diagnostic lines group is standard on the 824H, 825H, and 826H. The diagnostics line
group provides remote pressure taps for testing the power train hydraulic system.
The Automatic Blade Positioning (ABP) is now standard on the 824H and 826H. ABP is a
systems that adjusts the blade to set points as the machine is shifted between forward and
reverse.
The cooling package is changed on the 824H, 825H, and 826H. The 824G Series II, 825G
Series II, and 826G Series II are equipped with the Advanced Modular Cooling System
(AMOCS). The 824H, 825H, and 826H are equipped with the Next Generation Modular
Radiator (NGMR) cores.
SERV7105-01 -7- NPI
Vol. 1, No. 2, 2005
ENGINE
The 824H, 825H, and 826H are equipped with the Caterpillar C15 ACERT engine, serial
number prefix LHX. The displacement of the C15 ACERT engine is 15.2 liters with a rated
power of 349 hp at 1800 rpm. The performance test specification for the C15 ACERT engine in
the 824H, 825H, and 826H is 0K5275.
The C15 ACERT engine is equipped with a larger muffler (1) and an A4E4 Engine Electronic
Control Module (ECM) (not shown).
The C15 ACERT engine is equipped with a wastegated turbocharger (2). The turbocharger is
cooled with engine coolant. The engine oil filter (3) is also shown.
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2 3
1
The secondary fuel filter (1) and primary fuel filter/water separator (2) can be accessed from the
right side of the machine. The primary fuel filter/water separator is equipped with an electric
lift pump (3).
The hydraulic fan pump (4) is also located on the right side of the machine.
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Vol. 1, No. 2, 2005
C15 ACERT ENGINE SYSTEM BLOCK DIAGRAM
ENGINE MOUNTED COMPONENTS
6 Drivers
Injector
Connector
3 Returns
Electronic Unit A4E4
Injectors ECM
Crankshaft Speed / Timing Sensor
To Machine Wiring
Harness
Camshaft Speed / Timing Sensor
Ground Bolt
Coolant Temperature Sender
Fuel Temperature Sender Fuel Pressure Sensor
Timing
Inlet Air Temperature Sender Calibration
Sensor
Differential Fuel
Atmospheric Pressure Sensor Pressure Switch
Turbo Outlet Pressure Sensor Oil Pressure Sensor
The above illustration shows the engine mounted electrical components on the 824H, 825H,
and 826H.
SERV7105-01 - 10 - NPI
Vol. 1, No. 2, 2005
C15 ACERT EUI SYSTEM
A4E4
Electronic MACHINE MOUNTED COMPONENTS
Control Module
(ECM)
Ground Disconnect Switch
Bolt
24 V
Main Key Start
15 Amp Power Relay Switch
Breaker
Tachometer Output
Fuel Filter Restriction
Indicator Lamp
Throttle Accelerator
Air Filter Restriction Sensor Pedal
Indicator Lamp
Ether Start Aid
Indicator Lamp
Turbo Inlet Pressure Sensor Ground Level Shutdown
Transmission Lube Fan Control Valve
Temperature Sender
+ Battery Relay Ether Start Valve
Cylinder
Caterpillar Monitoring System Engine
15
10 20
Service Tool Connector
5
25
Cat Data Link
X100
0 Mp h
Km/h 30 44
The above illustration shows the machine mounted electrical components that are inputs and
outputs of the Engine ECM on the 824H, 825H, and 826H.
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Vol. 1, No. 2, 2005
AUTOMATIC BLADE POSITIONING (ABP) SYSTEM
ABP is standard equipment on the 824H and 826H. ABP is a system that automates much of
the repetitive work of positioning the blade on the machine. ABP uses the cylinder position
sensor (arrow) of the kickout system and the transmission directional switch to determine the
blade position. Once the blade heights are set by the operator, ABP will position the blade to
those determined heights without the operator moving the joystick.
When the operator selects REVERSE, the blade is automatically positioned to the raise height
that was set by the operator. The operation of the system is the same when the operator selects
FORWARD with the transmission direction switch.
The calibration of the cylinder position sensor follows the lift linkage strategy. The cylinder
position cylinder can be calibrated with Caterpillar Electronic Technician (Cat ET) or with the
4C8195 service tool and Caterpillar Monitoring System (CMS).
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3 7 8
2
9
1
10
4
11
5
6
ATTACHMENTS
The diagnostic lines group for the power train hydraulic system is standard equipment on the
824H, 825H, and 826H. The diagnostic lines group remote pressure taps are located behind the
cab on the right side of the machine. The remote pressure taps include:
- Transmission first speed clutch pressure (1)
- Transmission reverse clutch pressure (2)
- Transmission forward clutch pressure (3)
- Transmission second speed clutch pressure (4)
- Transmission third speed clutch pressure (5)
- Transmission fourth speed clutch pressure (6)
- Torque converter inlet pressure (7)
- Torque converter outlet pressure (8)
- Transmission lube pressure (9)
- Steering pump outlet pressure (10)
The power train filter (11) is located by the diagnostic lines group.
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09
COOLING PACKAGE
The cooling package on the 824H, 825H, and 826H is equipped with seven NGMR cores
(arrow) to cool the engine coolant. The NGMR cores have six fins per inch and utilize single
pass cooling.
SERV7105-01 - 14 - NPI
Vol. 1, No. 2, 2005
10
CONCLUSION
This presentation has provided New Product Introduction (NPI) information for the Caterpillar
824H Wheel Dozer, 825H Soil Compactor, and 826H Landfill Compactor. All new components
and their locations were identified and discussed.
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Vol. 1, No. 2, 2005
HYDRAULIC SCHEMATIC COLOR CODE
Black - Mechanical Connection. Seal Red - High Pressure Oil
Dark Gray - Cutaway Section Red / White Stripes - 1st Pressure Reduction
Light Gray - Surface Color Red Crosshatch - 2nd Reduction in Pressure
White - Atmosphere Or Air (No Pressure) Pink - 3rd Reduction in Pressure
Purple - Pneumatic Pressure Red / Pink Stripes - Secondary Source Oil Pressure
Yellow - Moving or Activated Components Orange - Pilot, Signal or Torque Converter Oil
Cat Yellow - (R estricted Usage) Orange / White Stripes -
Identification of Components Reduced Pilot, Signal or TC Oil Pressure
Within a Moving Group
Orange / Crosshatch - 2nd Reduction In
Brown - Lubricating Oil Pilot, Signal or TC Oil Pressure
Green - Tank, Sump, o r Return Oil Blue - Trapped Oil
Green / White Stripes -
Scavenge / Suction Oil or Hydraulic Void
HYDRAULIC SCHEMATIC COLOR CODE
This illustration identifies the meanings of the colors used in the hydraulic schematics and
cross-sectional views shown throughout this presentation.
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Vol. 1, No. 2, 2005 Handout No. 1
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Vol. 1, No. 2, 2005 Handout No. 2
Machine Orientation Checklist
Directions: Use this sheet when performing the machine orientation lab exercise.
Place a check in the blank if the fluid level is acceptable.
____ Engine oil level
____ Hydraulic system oil level
____ Hood actuator system oil level
____ Power train hydraulic system oil level
____ Final drive and differential oil level
____ Cooling system fluid level
____ Fuel level
Place a check in the blank if acceptable or after task was performed.
____ Check the Caterpillar Monitoring System for abnormal machine conditions
____ Check seat belt
____ Check the air filter precleaners
Place a check in the blank if the indicator, switch, or control is working correctly.
____ Key start switch
____ Engine coolant temperature gauge
____ Fuel level gauge
____ Power train oil temperature gauge
____ Hydraulic oil temperature gauge
____ Neutralizer disabled indicator light
____ Turn signal indicator lights (2)
____ Horn
____ Front and rear work lights
____ Windshield wipers (if equipped)
____ Heating and air conditioner controls (if equipped)
____ Back-up alarm
SERV7105-01 - 18 - NPI
Vol. 1, No. 2, 2005 Handout No. 3
Machine Orientation Checklist - continued
Place a check in the blank after locating and reading the following warnings label on the
machine.
____ ROPS
____ Parking brake
____ No clearance (articulation joint)
____ Radiator
____ Batteries
____ Unit injectors
____ Do not operate
Place a check in the blank after locating each of the following controls.
____ Throttle pedal
____ Left brake pedal
____ Right brake pedal
____ Tilt lever
____ Lift lever
____ Parking brake knob
____ Steering Wheel
____ Battery disconnect switch
Place a check in the blank after locating each of the following identification plates.
____ Product Identification Number (PIN)
____ Engine serial number
____ Transmission serial number
____ Blade serial number
SERV7105-01 - 19 - NPI
Vol. 1, No. 2, 2005 Handout No. 4
Machine Posttest
Directions: Answer each question with the best possible answer.
1. The 824H, 825H, and 826H are equipped with which engine?
a. 3406E
b. C18 ACERT
c. C15 ACERT
d. 3456
2. The 824H, 825H, and 826H are equipped with a water cooled turbocharger.
a. True
b. False
3. The diagnostic lines group is an attachment on 824H, 825H, and 826H.
a. True
b. False
4. The 824H, 825H, and 826H are equipped with which style radiator core?
a. AMOCS
b. Folded
c. Single Panel
d. NGMR
5. The 824H and 826H are equipped with Automatic Blade Positioning.
a. True
b. False
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Vol. 1, No. 2, 2005 Handout No. 5
Machine Posttest - Continued
6. The Next Generation Modular Radiator (NGMR) cores have six fins per inch and utilize
single pass cooling
a. True
b. False
7. The 824H, 825H, and 826H are equipped with what type Engine ECM?
a. ADEM III
b. A4E4
c. ADEM IV
d. A4M1
8. Where is the power train oil filter located on the 824H, 825H, and 826H?
a. Left side of the machine, by the fuel tank
b. Behind the cab
c. In the return line, near the power train oil cooler
d. Just forward of the hydraulic tank
9. What does the Automatic Blade Positioning system use to determine blade position?
a. Machine kickout set points and engine rpm
b. Directional control level and cylinder position sensor
c. Joystick lever position and machine speed
d. Cylinder position sensor and Machine ECM
10. The Automatic Blade Positioning system calibrations must be done using the 4C-8195
Control Service Tool.
a. True
b. False
SERV7105-01 - 21 - NPI
Vol. 1, No. 2, 2005 Posttest Answers
Machine Posttest Answers
Quiz Answers:
1. c
2. a
3. b
4. d
5. a
6. a
7. b
8. b
9. b
10. b
