Documente Academic
Documente Profesional
Documente Cultură
January 2005
Vol. 1, No. 2
SERVICE TRAINING
TECHNICAL PRESENTATION
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.
TABLE OF CONTENTS
INTRODUCTION ........................................................................................................................5
ENGINE........................................................................................................................................7
ATTACHMENTS .......................................................................................................................12
CONCLUSION...........................................................................................................................14
HANDOUTS...............................................................................................................................17
POSTTEST .................................................................................................................................19
NOTES
SERV7105-01 -5- NPI
Vol. 1, No. 2, 2005
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
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.
SERV7105-01 -8- NPI
Vol. 1, No. 2, 2005
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.
SERV7105-01 -9- NPI
Vol. 1, No. 2, 2005
Ground Bolt
Coolant Temperature Sender
Timing
Inlet Air Temperature Sender Calibration
Sensor
Differential Fuel
Atmospheric Pressure Sensor Pressure Switch
The above illustration shows the engine mounted electrical components on the 824H, 825H,
and 826H.
SERV7105-01 - 10 - NPI
Vol. 1, No. 2, 2005
Cylinder
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.
SERV7105-01 - 11 - NPI
Vol. 1, No. 2, 2005
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).
SERV7105-01 - 12 - NPI
Vol. 1, No. 2, 2005
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.
SERV7105-01 - 13 - NPI
Vol. 1, No. 2, 2005
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.
SERV7105-01 - 15 - NPI
Vol. 1, No. 2, 2005
Dark Gray - Cutaway Section Red / White Stripes - 1st Pressure Reduction
Purple - Pneumatic Pressure Red / Pink Stripes - Secondary Source Oil Pressure
Yellow - Moving or Activated Components Orange - Pilot, Signal or Torque Converter Oil
This illustration identifies the meanings of the colors used in the hydraulic schematics and
cross-sectional views shown throughout this presentation.
SERV7105-01 - 16 - NPI
Vol. 1, No. 2, 2005 Handout No. 1
SERV7105-01 - 17 - NPI
Vol. 1, No. 2, 2005 Handout No. 2
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
____ 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.
Place a check in the blank after locating each of the following identification plates.
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
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
SERV7105-01 - 20 - NPI
Vol. 1, No. 2, 2005 Handout No. 5
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
1. c
2. a
3. b
4. d
5. a
6. a
7. b
8. b
9. b
10. b