SEBU7877-08 M.pdf

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MAINTENANCE INTERVALSOperation and Maintenance Manual Excerpt

SEBU7877-08February 2010

Operation andMaintenanceManual824H Wheel Dozer, 825H SoilCompactor and 826H LandfillCompactorASX1-Up (824H)AZW1-Up (825H)AWF1-Up (826H)

SAFETY.CAT.COM

SEBU7877-08 95Maintenance Section

Maintenance Interval Schedule

i03869829

Maintenance Interval ScheduleSMCS Code: 7000

When Required

Battery - Recycle .................................................. 99Battery or Battery Cable - Inspect/Replace .......... 99Circuit Breakers - Reset ...................................... 104Cleaner Bar Tips - Replace ................................. 106Display and Camera - Clean ................................ 117Engine Air Filter Primary Element - Clean/Replace .............................................................. 118Engine Air Filter Secondary Element - Replace .. 121Engine Air Precleaner - Clean ............................ 123Ether Starting Aid Cylinder - Replace ................. 132Fuel System - Prime ........................................... 132Fuses - Replace .................................................. 137High Intensity Discharge Lamp (HID) - Replace .. 138Oil Filter - Inspect ................................................ 143Radiator Core - Clean ......................................... 143Window Washer Reservoir - Fill .......................... 152Window Wiper - Inspect/Replace ........................ 152

Every 10 Service Hours or Daily

Axle Guard - Clean ............................................... 97Backup Alarm - Test .............................................. 98Cleaner Bar - Check/Adjust ................................ 105Cleaner Bar Support Bearing Oil - Check ........... 106Compactor Wheel Chopper Blades -Inspect/Replace ................................................ 107Compactor Wheel Plus Tips - Inspect/Replace .. 107Compactor Wheel Tamping Tips - Inspect/Replace ............................................................. 107Cooling System Coolant Level - Check ............... 110Cutting Edges and End Bits - Inspect/Replace .... 112Engine Air Filter Service Indicator - Inspect ........ 122Engine Compartment - Inspect/Clean ................. 123Engine Oil Level - Check .................................... 127Fuel System Primary Filter (Water Separator) -Drain ................................................................. 133Hydraulic System Oil Level - Check ................... 141Seat Belt - Inspect .............................................. 145Transmission Oil Level - Check .......................... 150Windows - Clean ................................................. 152

Every 50 Service Hours or Weekly

Bulldozer Stabilizer - Lubricate ........................... 102Cab Air Filter - Clean/Replace ............................ 102Fire Suppression System - Check ...................... 132Fuel Tank Water and Sediment - Drain ............... 136Fuel Tank Water and Sediment - Drain ............... 137Tire Inflation - Check ........................................... 148

Every 100 Service Hours or 2 Weeks

Axle Oscillation Bearings - Lubricate .................... 98Lift Cylinder Lower Bearings - Lubricate ............. 142

Lift Cylinder Upper Bearings - Lubricate ............. 143Steering Cylinder Bearings - Lubricate ............... 147

Initial 250 Service Hours

Electronic Unit Injector - Inspect/Adjust ............... 118Engine Oil Sample - Obtain ................................ 128Engine Oil and Filter - Change ........................... 129Engine Valve Lash - Check ................................. 131Engine Valve Rotators - Inspect ......................... 131

Every 250 Service Hours or Monthly

Alternator Air Vent Line and Screen - Clean ......... 97Battery - Clean ...................................................... 98Belt - Inspect/Adjust/Replace .............................. 100Brake Accumulator - Check ................................ 100Braking System - Test ......................................... 101Crankcase Guard Compartment and Power TrainGuard Compartment - Clean .............................. 112Differential and Final Drive Oil Level - Check ...... 115Engine Air Filter Service Indicator -Inspect/Replace ................................................ 122Engine Oil Sample - Obtain ................................ 128Hydraulic System Oil Sample - Obtain ............... 141

Initial 500 Hours (for New Systems, RefilledSystems, and Converted Systems)

Cooling System Coolant Sample (Level 2) -Obtain ................................................................ 111

Every 500 Service Hours or 3 Months

Cooling System Coolant Sample (Level 1) -Obtain ................................................................ 110Differential and Final Drive Oil Sample - Obtain .. 116Engine Oil (High Speed) and Oil Filter - Change .. 125Engine Oil and Filter - Change ........................... 129Fuel System Primary Filter (Water Separator)Element - Replace ............................................ 134Fuel System Secondary Filter - Replace ............ 135Fuel Tank Cap and Strainer - Clean ................... 136Hydraulic System Oil Filter - Replace ................. 140Transmission Oil Filter - Replace ........................ 149Transmission Oil Sample - Obtain ...................... 151

Every 1000 Service Hours or 6 Months

Articulation Bearings - Lubricate ........................... 97Battery Hold-Down - Tighten ................................. 99Case Drain Screen (Strainer) (Implement Pilot Valve)- Clean .............................................................. 103Case Drain Screen (Strainer) (Steering Pump,Hydraulic Fan Pump, Motor) - Clean ................ 103Drive Shaft Support Bearing - Lubricate .............. 118Rollover Protective Structure (ROPS) - Inspect .. 145Transmission Oil - Change ................................. 148

Every 1000 Service Hours or 1 Year

Service Brake Wear Indicator - Check ................ 146

96 SEBU7877-08Maintenance SectionMaintenance Interval Schedule

Every 2000 Service Hours or 1 Year

Brake Discs - Check ........................................... 101Differential and Final Drive Oil - Change ............. 113Electronic Unit Injector - Inspect/Adjust ............... 118Engine Valve Lash - Check ................................. 131Engine Valve Rotators - Inspect ......................... 131Hydraulic System Oil - Change ........................... 139Receiver Dryer (Refrigerant) - Replace .............. 144Steering Column Spline (Command Control Steering)- Lubricate ......................................................... 146

Every Year

Cooling System Coolant Sample (Level 2) -Obtain ................................................................ 111

Every 3 Years After Date of Installation orEvery 5 Years After Date of Manufacture

Seat Belt - Replace ............................................. 145

Every 4000 Service Hours or 2 Years

Hydraulic System Oil - Change ........................... 139


Turbocharger - Inspect ........................................ 151


Cooling System Coolant Extender (ELC) - Add .. 109Cooling System Water Temperature Regulator -Replace .............................................................. 111Electronic Unit Injector - Inspect/Adjust ............... 118Engine Water Pump - Inspect ............................. 132

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 107


Alternator Air Vent Line and Screen - Clean

i03811830

Alternator Air Vent Line andScreen - CleanSMCS Code: 1071-070-Z3; 1405-070-VN

S/N: AWF1-Up

g01451547Illustration 105

The alternator air vent line is located in the enginecompartment on the right side of the machine. Thescreen is located on the hood above the right sideengine compartment.

1. Loosen hose clamp (1).

2. Remove alternator air vent line (2) from thealternator. Clean out the area behind the alternatorguard in order to remove the dirt and debris thataccumulates on the air inlet side of the alternator.

3. Check the line for cleanliness.

4. Remove alternator screen (3).

5. Check alternator screen (3) for cleanliness.

6. Replace alternator screen (3).

7. Tighten hose clamp (1).

8. Reconnect alternator air vent line (2).

i02220086

Articulation Bearings -LubricateSMCS Code: 7057-086-BD; 7065-086-BD;7066-086-BD

Wipe off the fittings before any lubricant is applied.


Apply lubricant through one fitting on the upper pivotbearing.

Apply lubricant through one fitting on the lower pivotbearing.

i02853805

Axle Guard - Clean(If Equipped)SMCS Code: 7185-070

Be sure to clean any debris or cut any debris thatmay be in the axle or axle guard area. If there isdebris that is packed or wrapped in this area, removethe debris. Be sure that the wheel extensions are notrubbing on the frame. Rubbing and packed debrismay damage duo-cone seals. Rubbing and packeddebris may also cause excessive heat or sparks.

98 SEBU7877-08Maintenance SectionAxle Oscillation Bearings - Lubricate

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Axle Oscillation Bearings -LubricateSMCS Code: 3268-086-BD; 3278-086-BD


Open the access door on the right side of themachine. Two remote grease fittings are used inorder to lubricate the axle oscillation bearings.

Wipe all fittings before lubricant is applied. Applylubricant to fittings (1) and (2).

i02220089

Backup Alarm - TestSMCS Code: 7406-081

Turn the engine start switch key to the ON position inorder to perform the test.

Apply the service brake.

Move the transmission direction control lever to theREVERSE position.

The alarm should start to sound immediately. Thealarm will continue to sound until the transmissiondirection control lever is moved to the NEUTRALposition or to the FORWARD position.


The backup alarm is located behind the grill on theleft rear of the machine.

A three-position switch at the rear of the backupalarm regulates the sound of the alarm (high, low,and medium).

The alarm is set at the maximum sound level whenthe machine is shipped from the factory. The settingshould remain on high, unless the job site requires alower sound level.

i01481695

Battery - CleanSMCS Code: 1401-070


Open the battery compartment on the right rear sideof the machine.


Battery - Recycle

Clean the battery terminals and the surfaces ofthe batteries with a clean cloth. Coat the batteryterminals with petroleum jelly. Make sure that thebattery cables are installed securely.

i00993589

Battery - RecycleSMCS Code: 1401-561

Always recycle a battery. Never discard a battery.

Always return used batteries to one of the followinglocations:

• A battery supplier

• An authorized battery collection facility

• Recycling facility

i01481768

Battery Hold-Down - TightenSMCS Code: 7257-527


Open the battery compartment on the right rear sideof the machine.

Over time, the vibration of an operating machinecan cause the battery hold-downs to loosen. Tohelp to prevent loose batteries and the possibility ofloose cable connections, tighten the eight nuts onthe two hold-downs to a torque of 2.50 ± 0.25 N·m(22 ± 2 lb in).

i03657099

Battery or Battery Cable -Inspect/ReplaceSMCS Code: 1401-040; 1401-510; 1402-040;1402-510

Personal injury may occur from failure to properlyservice the batteries.

Batteries give off flammable fumes that can ex-plode. Electrolyte is an acid and can cause per-sonal injury if it contacts the skin or eyes.

Prevent sparks near the batteries. Sparks couldcause vapors to explode. Do not allow jumper ca-ble ends to contact each other or the engine. Im-proper jumper cable connections can cause an ex-plosion.

Always wear protective glasses when workingwith batteries.

1. Turn the engine start switch key OFF. Turn all ofthe switches OFF.

2. Turn the battery disconnect switch OFF. Removethe key.

3. Disconnect the negative battery cable from thedisconnect switch.

Note: Do not allow the disconnected battery cable tocontact the disconnect switch.

4. Disconnect the negative battery cable at thebattery.

5. Disconnect the positive battery cable at thebattery.

6. Inspect the battery terminals for corrosion. Inspectthe battery cables for wear or damage.

7. Make any necessary repairs. If necessary, replacethe battery cables or the battery.

8. Connect the positive battery cable at the battery.

9. Connect the negative battery cable at the battery.

10.Connect the battery cable at the batterydisconnect switch.

11. Install the key and turn the battery disconnectswitch ON.

100 SEBU7877-08Maintenance SectionBelt - Inspect/Adjust/Replace

Recycle the BatteryAlways recycle a battery. Never discard a battery.

Always return used batteries to one of the followinglocations:

• A battery supplier

• An authorized battery collection facility

• Recycling facility

i03700093

Belt - Inspect/Adjust/ReplaceSMCS Code: 1397-025; 1397-040; 1397-510

Your machine is equipped with a single serpentinebelt. Stop the engine. Open the rear hood. The belt islocated at the front of the engine.


(1) Alternator(2) Tensioner(3) Serpentine Belt(4) Square Drive Hole(5) Compressor(6) Drive Pulley

Inspect the condition of the serpentine belt. If the beltis cracked or frayed, replace the belt.

Insert a ratchet with a square drive into the hole (4)of the tensioner. Rotate the tensioner clockwise inorder to relieve tension. Remove the belt. Installthe new belt correctly, as shown. The tensioner willautomatically apply the correct amount of tension tothe new belt.

i01678666

Brake Accumulator - CheckSMCS Code: 4263-535

g00737672Illustration 112Engine Start Switch


Alert Indicator

1. Turn the engine start switch to the ON position (2).The alert indicator for brake oil pressure shouldcome on if the braking system is not at normaloperating pressure.

2. Start the engine (3). Run the engine at halfspeed for two minutes in order to increase theaccumulator pressure. The alert indicator forbrake oil pressure should go off.

3. Turn the engine start switch to the ON position(2). Apply the service brake pedal and releasethe service brake pedal until the alert indicator forbrake oil pressure comes on. This will decreasethe accumulator pressure. A minimum of fiveapplications of the service brake pedal arerequired.

SEBU7877-08 101Maintenance SectionBrake Discs - Check

4. If the alert indicator comes on after less thanfive applications of the brake, measure theaccumulator precharge pressure. An authorizedCaterpillar dealer can measure the nitrogen gaspressure in the accumulator. Use only dry nitrogengas for recharging.

i02220094

Brake Discs - CheckSMCS Code: 4255-535

Reference: For information about checking thethickness of the brake discs, refer to Testing andAdjusting, RENR8696, “824H Wheel Tractor, 825HSoil Compactor, and 826H Landfill CompactorBraking System” or consult your Caterpillar dealer.

i02301050

Braking System - TestSMCS Code: 4251-081; 4267-081

• Park the machine on a dry, level surface.

• Check the area around the machine. Make surethat the machine is clear of personnel and clear ofobstacles.

• Make sure that the steering frame lock is in theunlocked position.

• Fasten the seat belt before you test the brakes.

The following tests are used to determine whetherthe braking system is functional. These tests are notintended to measure the maximum brake holdingeffort. The required brake holding effort for sustaininga machine at a specific engine rpm varies from onemachine to another machine. The variations includedifferences in the engine setting, the power trainefficiency, the brake holding ability, etc.

Service Brake Holding Ability Test

Personal injury can result if the machine moveswhile testing.

If the machine begins to move during test, reducethe engine speed immediately and engage theparking brake.

1. Start the engine. Raise the work tool slightly. Applythe service brake. Release the parking brake.

2. Perform the following step for the 824H WheelTractor and the 825H Soil Compactor: Move thetransmission control to THIRD SPEED FORWARDwhile the service brakes are applied. Perform thefollowing step for the 826H Landfill Compactor:Move the transmission control to SECONDSPEED FORWARD while the service brakes areapplied. Make sure that the autoshift control is inthe OFF position.

NOTICEIn order to prevent engine damage, do not exceed1300 rpm when performing the Service Brake HoldingAbility Test for the 826H Landfill Compactor.

3. Gradually increase the engine speed to high idlefor the 824H and 825H machines. Graduallyincrease the engine speed to 1300 rpm for the826H Landfill Compactor. The machine shouldnot move.

4. Reduce the engine speed to low idle. Move thetransmission direction control to the NEUTRALposition. Engage the parking brake. Lower thework tool to the ground. Stop the engine.

If the machine moved during the test, consult yourCaterpillar dealer for a brake inspection. Make anynecessary repairs before the machine is returned tooperation.

Parking Brake Holding Ability Test

Personal injury can result if the machine moveswhile testing.

If the machine begins to move, reduce the enginespeed immediately and apply the service brakepedal.

This test is performed when the parking brake isengaged. If the machine begins to move, comparethe engine rpm to the engine rpm of a prior test. Thiswill indicate the amount of system deterioration.

1. Start the engine. Raise the work tool slightly.Engage the parking brake.

2. Perform the following step for the 824H WheelTractor and the 825H Soil Compactor: Movethe transmission control to THIRD SPEEDFORWARD. Perform the following step for the826H Landfill Compactor: Move the transmissioncontrol to SECOND SPEED FORWARD. Makesure that the autoshift control is in the OFFposition.

102 SEBU7877-08Maintenance SectionBulldozer Stabilizer - Lubricate

The parking brake indicator light should come on.

NOTICEIn order to prevent engine damage, do not exceed950 rpm when performing the Parking Brake HoldingAbility Test for the 826H Landfill Compactor.

3. Gradually increase the engine speed to high idlefor the 824H and 825H machines. Graduallyincrease the engine speed to 950 rpm for the826H Landfill Compactor. The machine shouldnot move.

4. Reduce the engine speed to low idle. Move thetransmission direction control to the NEUTRALposition. Lower the work tool to the ground. Stopthe engine.

If the machine moved during the test, consult yourCaterpillar dealer for a brake inspection. Make anynecessary repairs before the machine is returned tooperation.

i02220095

Bulldozer Stabilizer - LubricateSMCS Code: 6071-086-BD

S/N: AWF1-Up

S/N: ASX1-Up

Wipe off all fittings before any lubricant is applied.

g01120551Illustration 114824H Wheel Dozer

Apply lubricant through three fittings on the bulldozerstabilizer.

g01120552Illustration 115826H Landfill Compactor

Apply lubricant through two fittings on the bulldozerstabilizer.

i02220096

Cab Air Filter - Clean/ReplaceSMCS Code: 7342-070; 7342-510

Note: Clean the cab air filters more often if themachine is being operated in dusty conditions.


1. Open the access door (1) on the left side of thecab. Filter element (4) is located behind door (1).Remove the filter element (4).

2. Remove the filter cover behind the seat. Twothreaded knobs (2) are used in order to removethe cover. Remove the filter element (3).


Case Drain Screen (Strainer) (Implement Pilot Valve) - Clean

3. Clean the filter elements with pressure air orwash the filter elements in warm water with anonsudsing household detergent.

4. If water and detergent are used to clean the filterelements, rinse the filter elements in clean waterand allow the filter elements to air dry thoroughly.

Note: If either filter element is damaged, install anew filter element.

5. Install the filter elements. Install the filter coverand close the access door.

i02198183

Case Drain Screen (Strainer)(Implement Pilot Valve) - CleanSMCS Code: 5057-070-Z3

The screen (2) is located in the pilot line (1) thatconnects to the pilot valve (3). The pilot valve (3) islocated underneath the cab on the right side of themachine.


1. Shut off the engine.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, “CaterpillarTools and Shop Products Guide” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

2. Disconnect pilot line (1) from screen (2).

3. Remove the screen (2) from pilot valve (3).

4. Wash the screen (2) in a clean nonflammablesolvent.

5. Dry the screen (2) by using pressure air.

6. Inspect the screen (2) for damage. Replace thescreen (2), if necessary.

7. Install the screen (2) on the pilot valve(3).

8. Connect pilot line (1) to the screen (2).

i02197980

Case Drain Screen (Strainer)(Steering Pump, Hydraulic FanPump, Motor) - CleanSMCS Code: 4304-070-Z3; 5057-070-Z3

The screen (2) is located in the pump case drain line(1) near the hydraulic oil tank (3). The screen (4) islocated in hydraulic line (5) near the hydraulic oil tank(3). The hydraulic oil tank (3) is located on the rightside of the machine.


Rear view of hydraulic oil tank (3)

1. Shut off the engine.

104 SEBU7877-08Maintenance SectionCircuit Breakers - Reset




2. Disconnect line (1) and line (5) from the hydraulicoil tank (3).

3. Remove screen (2) from line (1). Remove screen(4) from line (5).

4. Wash screen (2) and screen (4) in a cleannonflammable solvent.

5. Dry screen (2) and screen (4) by using pressureair.

6. Inspect screen (2) and screen (4) for damage.Replace screens , if necessary.

7. Install screen (2) on line (1). Install screen (4) online (5).

8. Connect line (1) and line (5) to the hydraulic oiltank (3).

i02756458

Circuit Breakers - ResetSMCS Code: 1420-529

NOTICEReplace circuit breakers with the same type and sizeonly. Otherwise, electrical damage can result.

If it is necessary to reset circuit breakers frequently, anelectrical problem may exist. Contact your Caterpillardealer.

Note: Your machine may be equipped with “Type 1”Circuit breakers or your machine may be equippedwith “Type 2” circuit breakers.

Type 1


(1) Main Circuit – 80 Amperes

(2) Alternator – 80 Amperes

(3) Cab – 30 Amperes

(4) Engine Control – 15 Amperes

Type 2


(5) Main Circuit – 105 Amperes

(6) Start Relay – 40 Amperes


Cleaner Bar - Check/Adjust

(7) Cab – 30 Amperes

(8) Engine Control – 15 Amperes

Additional Circuit Breakers


Typical example

Two circuit breakers are also located in the operatorcompartment on the right rear side of the cab.

(9) Seat – 15 Amperes

(10) Fan – 15 Amperes

i02553696

Cleaner Bar - Check/AdjustSMCS Code: 7160-025; 7160-535

S/N: AWF1-Up

S/N: AZW1-Up


1. Measure the clearance between the ends of thescraper tips and the wheel drum. The correctclearance is between 12 mm (0.5 inch) and25.4 mm (1.00 inch).

2. If the clearance is greater than 25 mm (1.0 inch),loosen the two nuts (1) and slide the scraper arm(2) back to the proper clearance.

3. Tighten the nuts to a torque of 740 ± 80 N·m(545 ± 60 lb ft). After a few hours of operation,tighten the nuts again.

106 SEBU7877-08Maintenance SectionCleaner Bar Support Bearing Oil - Check

i01984661

Cleaner Bar Support BearingOil - CheckSMCS Code: 7160-535-OC

S/N: AZW1-Up


1. Position the rear wheel so that the filler plug is atthe highest point.

2. Remove the filler plug. Maintain the oil level to thebottom of the filler opening.

3. Clean the filler plug and install the filler plug.

4. Repeat the procedure for the other rear wheel.

i02553695

Cleaner Bar Tips - ReplaceSMCS Code: 7160-510-TIP

S/N: AWF1-Up

S/N: AZW1-Up


1. Remove two nuts (1), two bolts and the scraperarm (2) from the cleaner bar.

2. Drive the pin out of the tip from the retainer side ofthe tip. Remove the tip from the retainer.

3. Clean the adapter, the pin and the retainer.

4. Install the retainer in the groove in the side of theadapter.

5. Install a new tip over the retainer. Install the pin.

6. Install the scraper arm, two bolts and two nutson the cleaner bar. Slide the scraper arm so thatthe clearance between the tip and the wheeldrum is between 12 mm (0.5 inch) and 25.4 mm(1.00 inch).

Reference: For more information, refer toOperation and Maintenance Manual, “Cleaner Bar- Check/Adjust”.

7. Tighten the nuts to a torque of 740 ± 80 N·m(545 ± 60 lb ft). After a few hours of operation,tighten the nuts again.


Compactor Wheel Chopper Blades - Inspect/Replace

i01984957

Compactor Wheel ChopperBlades - Inspect/ReplaceSMCS Code: 4206-040-BG; 4206-510-BG

S/N: AWF1-Up


Inspect all chopper blades frequently. Replace anychopper blade before wear on the gusset occurs.

i02087334

Compactor Wheel Plus Tips -Inspect/ReplaceSMCS Code: 6806-040; 6806-510

S/N: AWF1-Up


Inspect the plus tips. Replace the plus tips, ifnecessary.

Reference: Refer to Special Instruction,SEHS9442-01, “8E1849 Plus Tip Wear GuageProcedure” for the correct procedure for theinspection of the plus tips. Refer to SpecialInstruction, SEHS9325-02, “Plus Tips WheelPattern Template” for the correct procedure for thereplacement of the plus tips.

i01984905

Compactor Wheel TampingTips - Inspect/ReplaceSMCS Code: 6806-040; 6806-510

S/N: AZW1-Up


Inspect all of the tamping tips. Replace any tips thatare worn to the wear cavity.

i02220098

Cooling System Coolant (ELC)- ChangeSMCS Code: 1350-044-NL

Reference: For information about adding Extenderto your cooling system, refer to Operation andMaintenance Manual, “Cooling System CoolantExtender (ELC) - Add” or consult your Caterpillardealer.

108 SEBU7877-08Maintenance SectionCooling System Coolant (ELC) - Change

If an Extended Life Coolant was previously used,flush the cooling system with clean water. No othercleaning agents are required. Use the followingprocedure to change the Extended Life Coolant.


The cooling system pressure cap (2) is located underthe access door (1) at the top rear of the machine.

Pressurized system: Hot coolant can cause seri-ous burn. To open cap, stop engine, wait until ra-diator is cool. Then loosen cap slowly to relievethe pressure.

1. Slowly loosen the cooling system pressure capin order to relieve system pressure. Remove thecooling system pressure cap.




2. Place the drain hose (4) into a suitable container.Open the drain valve (5) on the bottom of theradiator. Allow the coolant to drain into a suitablecontainer.

Note: The Landfill Compactor is equipped withbottom guards. The radiator guard needs to belowered in order to access the drain valve.

3. Flush the cooling system with clean water until thedraining water is clean. Close the drain valve.

4. Replace the water temperature regulator.

Reference: For the correct procedure, refer toOperation and Maintenance Manual, “CoolingSystem Water Temperature Regulator - Replace”.

NOTICETopping off or mixing Cat ELC with other products thatdo not meet Caterpillar EC-1 specifications reducesthe effectiveness of the coolant and shortens coolantservice life.

Use only Caterpillar products or commercial productsthat have passed the Caterpillar EC-1 specification forpre-mixed or concentrate coolants. Use only Extenderwith Cat ELC.

Failure to follow these recommendations can result inshortened cooling system component life.

5. Add the Extended Life Coolant.

Reference: For the refill capacity of the coolingsystem, refer to Operation and MaintenanceManual, “Capacities (Refill)”.

6. Start the engine. Run the engine without thecooling system pressure cap until the watertemperature regulator opens and the coolant levelstabilizes.

7. Maintain the coolant level in the sight gauge (3)on the upper right side of the radiator tank. Openthe left rear access door in order to access thesight gauge.

8. Install the cooling system pressure cap. Close theengine hood.


Cooling System Coolant Extender (ELC) - Add

i02225266

Cooling System CoolantExtender (ELC) - AddSMCS Code: 1352-544-NL





NOTICETopping off or mixing Cat ELC with other products thatdo not meet Caterpillar EC-1 specifications reducesthe effectiveness of the coolant and shortens coolantservice life.

Use only Caterpillar products or commercial productsthat have passed the Caterpillar EC-1 specification forpre-mixed or concentrate coolants. Use only Extenderwith Cat ELC.

Failure to follow these recommendations can result inshortened cooling system component life.

When a Caterpillar Extended Life Coolant (ELC) isused, an Extender must be added to the coolingsystem.

Use a 8T-5296 Coolant Test Kit to check theconcentration of the coolant.

Reference: For additional information about addingExtender, refer to Operation and MaintenanceManual, SEBU6250, “Caterpillar Machine FluidsRecommendations” or consult your Caterpillar dealer.


The cooling system pressure cap (2) is located underthe access door (1) at the top rear of the machine.Tilt the engine hood in order to access the coolingsystem pressure cap.

1. Slowly loosen the cooling system pressure cap inorder to relieve any system pressure. Remove thecooling system pressure cap.

2. If necessary, drain enough coolant from theradiator in order to allow the addition of Extenderto the cooling system. The cooling system drainvalve (5) is located on the lower left side of theradiator.

Note: Landfill Compactors are equipped with bottomguards. Lower the radiator guard in order to accessthe drain valve.

3. Add the Extender to the cooling system.

Reference: Refer to Operation and MaintenanceManual, “Capacities (Refill)” for the correctamount.

4. Check the coolant level. Open the left rear accessdoor in order to access the sight gauge (3).

Reference: Refer to Operation and MaintenanceManual, “Cooling System Level - Check” for thecorrect procedure.

5. Install the cooling system pressure cap. Close theengine hood.

110 SEBU7877-08Maintenance SectionCooling System Coolant Level - Check

i02225264

Cooling System Coolant Level- CheckSMCS Code: 1350-535-FLV


1. Open the access door on the left side of themachine. The coolant level sight gauge is locatedon top of the radiator.

2. Maintain the coolant level within the sight gauge.Add coolant, if necessary.

Note: If it is necessary to add coolant daily, inspectthe cooling system for leaks.

i02343243

Cooling System CoolantSample (Level 1) - ObtainSMCS Code: 1350-008; 1395-008; 7542

NOTICEAlways use a designated pump for oil sampling, anduse a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.

Note: Obtaining a Coolant Sample (Level 1) isoptional if the cooling system is filled with CatELC (Extended Life Coolant). Cooling systems thatare filled with Cat ELC should have a Coolant Sample(Level 2) that is obtained at the recommended intervalthat is stated in the Maintenance Interval Schedule.

Note: Obtain a Coolant Sample (Level 1) if thecooling system is filled with any other coolantinstead of Cat ELC. This includes the followingtypes of coolants.

Note: Level 1 results may indicate a need forLevel 2 Analysis.


Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In orderto receive the full effect of S·O·S analysis, youmust establish a consistent trend of data. In orderto establish a pertinent history of data, performconsistent samplings that are evenly spaced.Supplies for collecting samples can be obtained fromyour Caterpillar dealer.

1. Use the following guidelines for proper samplingof the coolant:

• Complete the information on the label for thesampling bottle before you begin to take thesamples.

• Keep the unused sampling bottles stored inplastic bags.

• Obtain coolant samples directly from the coolantsample port. You should not obtain the samplesfrom any other location.

• Keep the lids on empty sampling bottles untilyou are ready to collect the sample.

• Place the sample in the mailing tube immediatelyafter obtaining the sample in order to avoidcontamination.

• Never collect samples from expansion bottles.

• Never collect samples from the drain for asystem.

2. Submit the sample for Level 1 analysis.


Cooling System Coolant Sample (Level 2) - Obtain

Reference: For additional information about coolantanalysis, refer to Special Publication, SEBU6250,“Caterpillar Machine Fluids Recommendations” orconsult your Caterpillar dealer.

i02224620

Cooling System CoolantSample (Level 2) - ObtainSMCS Code: 1350-008; 1395-008; 7542


Obtain the sample of the coolant as close as possibleto the recommended sampling interval. Suppliesfor collecting samples can be obtained from yourCaterpillar dealer.

Reference: Refer to Operation and MaintenanceManual, “Cooling System Coolant Sample (Level 1)- Obtain” for the guidelines for proper sampling ofthe coolant.

Submit the sample for Level 2 analysis.

Reference: For additional information about coolantanalysis, refer to Special Publication, SEBU6250,“Caterpillar Machine Fluids Recommendations” orconsult your Caterpillar dealer.

i02223902

Cooling System WaterTemperature Regulator -ReplaceSMCS Code: 1355-510; 1393-010


NOTICEFailure to replace the engine's thermostat on a regu-larly scheduled basis could cause severe engine dam-age.

NOTICECaterpillar engines incorporate a shunt design coolingsystem and require operating the engine with a ther-mostat installed.

If the thermostat is installed wrong, it will cause theengine to overheat. Inspect gaskets before assemblyand replace if worn or damaged.


Replace water temperature regulator (1) in orderto reduce the chance of problems with the coolingsystem.

Replace the water temperature regulator and theseals while the cooling system is completely drainedor while the coolant is drained to a level below thewater temperature regulator housing.

Note: If you are only replacing the water temperatureregulator, drain the coolant to a level that is below thewater temperature regulator housing.

Reference: For the correct procedure for replacingthe water temperature regulator, refer to theDisassembly and Assembly manual for yourmachine's engine.

112 SEBU7877-08Maintenance SectionCrankcase Guard Compartment and Power Train Guard Compartment - Clean

i02853841

Crankcase GuardCompartment and PowerTrain Guard Compartment -CleanSMCS Code: 7151-070-CPA; 7153-070-CPA

Lower the guards for the crankcase and for the powertrain in order to remove accumulated debris. Checkfor debris on the engine and around the followingareas: engine, transmission, and exhaust system.Debris that is sitting in these areas is a fire hazard.

Note: Be sure that all personnel are clear of themachine before you lower the guards.


Remove the side panels in order to removethe following items from the front of the enginecompartment and from the side of the enginecompartment: accumulated debris, oil, grease, andspilled fuel.

Inspect the following items for damage: protectivescreen, guard for the crankcase, and guard for thepower train. Ensure that the hydraulic actuators forthe guards are functioning properly.

i01936280

Cutting Edges and End Bits -Inspect/ReplaceSMCS Code: 6801-040; 6801-510; 6804-040;6804-510


Check the cutting edges and the end bits for wear andfor damage. Use the following procedure to servicethe cutting edges and the end bits, if necessary.

1. Raise the blade and place blocking under theblade. Lower the blade onto the blocking. Stopthe engine.

2. Remove bolts (3), cutting edges (2) and end bits(1).

3. Clean all contact surfaces.

4. If the opposite side of the cutting edge is not worn,use the opposite side of the cutting edge. The endbits are not reversible.

If both sides are worn, install a new cutting edge.

5. Install bolts (3). Tighten the bolts to the specifiedtorque.

Reference: Refer to Specifications, SENR3130,“Torque Specifications”.

6. Strike the bolt heads with a hammer. Tighten thebolts again to the specified torque.

7. Start the engine. Raise the blade and remove theblocking. Lower the blade to the ground.

8. After a few hours of operation, check the bolts forproper torque.


Differential and Final Drive Oil - Change

i02224638

Differential and Final Drive Oil- ChangeSMCS Code: 3278-044; 4050-044




Front Differential and Front FinalDrives


1. Position the front wheels so that final drive drainplugs (2) are facing downward. Remove the finaldrive drain plugs and allow the oil to drain intoa suitable container. Clean the drain plugs andinstall the drain plugs.

g00864014Illustration 136Front view 824H, 525H, and 826H

2. Remove front differential drain plug (3) and allowthe oil to drain into a suitable container. Clean thedrain plug and install the drain plug.

3. Remove front differential filler plug (4). Fill the frontdifferential to the bottom of the filler plug opening.

Reference: For the correct amount of oil, refer toOperation and Maintenance Manual, “Capacities(Refill)”.


5. Position each front wheel so that front final drivefiller plugs (1) are flush with the centerline of eachfront wheel. Remove the front final drive fillerplugs.

6. Fill the front final drives to the bottom of the fillerplug opening.


Note: If the specified amount of oil will not fit in thefront final drives, install the filler plugs and operatethe machine on level ground for a few minutes. Thiswill equalize the oil level in the front differential and inthe front final drives. Then, add the remaining oil.

7. Clean the filler plugs and install the filler plugs.

8. Operate the machine for a few minutes andrecheck the oil level. The oil level should reach thebottom of the filler plug opening.

If the oil level is higher than the filler plug opening,do not allow the oil to drain to the level of the fillerplug opening.

114 SEBU7877-08Maintenance SectionDifferential and Final Drive Oil - Change

Rear Differential and Rear FinalDrives


1. Position the rear wheels so that final drive drainplugs (2) are facing downward. Remove the finaldrive drain plugs and allow the oil to drain intoa suitable container. Clean the drain plugs andinstall the drain plugs.


Rear view 824H


Rear view 825H and 826H

2. Remove rear differential drain plug (4) and allowthe oil to drain into a suitable container. Clean thedrain plug and install the drain plug.

3. Remove rear differential filler plug (3). Fill the reardifferential to the bottom of the filler plug opening.



5. Position each rear wheel so that rear final drivefiller plugs (1) are flush with the centerline of eachrear wheel. Remove the rear final drive filler plugs.

6. Fill the rear final drives to the bottom of the fillerplug opening.


Note: If the specified amount of oil will not fit in therear final drives, install the filler plugs and operate themachine on level ground for a few minutes. This willequalize the oil level in the rear differential and in therear final drives. Then, add the remaining oil.

7. Clean the filler plugs and install the filler plugs.

8. Operate the machine for a few minutes andrecheck the oil level. The oil level should reach thebottom of the filler plug opening.

If the oil level is higher than the filler plug opening,do not allow the oil to drain to the level of the fillerplug opening.


Differential and Final Drive Oil Level - Check

i02224639

Differential and Final Drive OilLevel - CheckSMCS Code: 3278-535-FLV; 4050-535-FLV




Wipe the surfaces around any openings before youcheck the oil or before you add oil.

Differentials


Front Differential Filler Plug 824H, 825H, and 826H

g00535225Illustration 141Rear Differential Filler Plug 824H

g01122282Illustration 142Rear Differential Filler Plug 825H and 826H

1. Remove the differential filler plug.

2. Check the oil level. The oil should be level with thebottom of the filler opening. Add oil, if necessary.

3. Clean the differential filler plug and install thedifferential filler plug.

4. Repeat the procedure for the remainingdifferential.

116 SEBU7877-08Maintenance SectionDifferential and Final Drive Oil Sample - Obtain

Final Drives


1. Position the wheel so that the final drive filler plugis level with the centerline of the wheel. Removethe final drive filler plug.

2. Check the oil level. The oil should be level with thebottom of the filler opening. Add oil, if necessary.

3. Clean the final drive filler plug and install the finaldrive filler plug.

4. Repeat the procedure for the remaining finaldrives.

i02339189

Differential and Final Drive OilSample - ObtainSMCS Code: 3278-008; 4050-008; 4070-008; 7542





1. Operate the machine for a few minutes beforeobtaining the oil sample. This will thoroughly mixthe oil for a more accurate sample.

g01122097Illustration 144Front Differential Filler Plug 824H, 825H, and 826H


Rear Differential Filler Plug 824H


Display and Camera - Clean

g01122282Illustration 146Rear Differential Filler Plug 825H and 826H

g00760182Illustration 147Final Drive Filler Plug

2. The differential and final drives are not equippedwith sampling valves. Obtaining an oil sample willrequire the use of a vacuum pump or equivalentin order to extract the oil from the component.Extract the oil through the filler openings on thedifferential and final drives.

Note: This procedure requires a sample for eachfinal drive and each differential. There will be atotal of three samples per axle and six samples forthis procedure in total. Make sure that you properlyrecord the location of each oil sample.

Reference: For more information, refer to SpecialPublication, SEBU6250, “Caterpillar MachineFluids Recommendations” and Special Publication,PEHP6001, “How To Take A Good Oil Sample”.

i02449906

Display and Camera - Clean(If Equipped with Work AreaVision System)SMCS Code: 7347-070; 7348-070

In order to maintain sufficient vision, keep the WorkArea Vision System (WAVS) camera lens and thedisplay clean.

Display

g01223034Illustration 148WAVS display

Use a soft, damp cloth in order to clean the display.The display has a soft plastic surface that can beeasily damaged by an abrasive material. The displayis not sealed. Do not immerse the display withliquid.

Camera


The WAVS camera is located on the rear of the machine nearthe taillights.

Use a damp cloth or water spray in order to cleanthe camera lens. The camera is a sealed unit. Thecamera is not affected by high pressure spray.

118 SEBU7877-08Maintenance SectionDrive Shaft Support Bearing - Lubricate

The camera is equipped with an internal heater tohelp counteract the effects of condensation, snow,or ice.

Note: For more information on WAVS, refer toOperation and Maintenance Manual, SEBU8157,“Work Area Vision System”.

i02225047

Drive Shaft Support Bearing -LubricateSMCS Code: 3267-086-BD

Wipe the fitting before you apply lubricant.


Two remote grease fittings are located on the rightside of the machine. Use the lower fitting in order tolubricate the drive shaft support bearing.

i02061807

Electronic Unit Injector -Inspect/AdjustSMCS Code: 1251-025; 1251-040; 1290-025;1290-040

The Electronic Control module produces highvoltage. To prevent personal injury make sure theElectronic Control Module is not powered and theunit injector solenoids are disconnected.

NOTICEThe camshafts must be correctly timed with the crank-shaft before an adjustment of the unit injector lashis made. The timing pins must be removed from thecamshafts before the crankshaft is turned or damageto the cylinder block will be the result.

The operation of Caterpillar engines with improperadjustments of the electronic unit injector can reduceengine efficiency. This reduced efficiency could resultin excessive fuel usage and/or shortened enginecomponent life.

Adjust the electronic unit injector at the same intervalas the valve lash adjustment.

Refer to your machine's Service Manual or yourCaterpillar dealer for the complete adjustmentprocedure.

i02962283

Engine Air Filter PrimaryElement - Clean/ReplaceSMCS Code: 1054-070-PY; 1054-510-PY

NOTICECaterpillar recommends certified air filter cleaning ser-vices that are available at Caterpillar dealers. TheCaterpillar cleaning process uses proven proceduresto assure consistent quality and sufficient filter life.

Observe the following guidelines if you attempt toclean the filter element:

Do not tap or strike the filter element in order to re-move dust.

Do not wash the filter element.

Use low pressure compressed air in order to removethe dust from the filter element. Air pressure must notexceed 207 kPa (30 psi). Direct the air flow up thepleats and down the pleats from the inside of the filterelement. Take extreme care in order to avoid damageto the pleats.

Do not use air filters with damaged pleats, gaskets, orseals. Dirt entering the engine will cause damage toengine components.



Engine Air Filter Primary Element - Clean/Replace

1. Open the engine hood. Access the air cleanerfrom the left side of the machine.


2. Loosen the clips which hold the air cleaner housingcover (1). Remove the air cleaner housing cover.

Note: The clips for the air cleaner housing may snapopen when you release the clips.

3. Remove the primary filter element (2) from the aircleaner housing. In order to remove the engine airfilter primary element, pull the element outward.While you pull the element outward, rock theelement.

NOTICEDo not use a filter if the pleats, the gaskets or the sealsare damaged.

4. Install a clean primary filter element over theengine air filter secondary element. Apply firmpressure to the end of the primary element asyou gently rock the filter element. This seats theprimary element.

5. Clean the cover for the air cleaner housing. Alignthe slot on the cover with the pin on the air cleanerhousing. Install the cover.

6. Close the engine hood.

Cleaning Primary Air FilterElements

NOTICECaterpillar recommends certified air filter cleaning ser-vices available at participating Caterpillar dealers. TheCaterpillar cleaning process uses proven proceduresto assure consistent quality and sufficient filter life.

Observe the following guidelines if you attempt toclean the filter element:

Do not tap or strike the filter element in order to re-move dust.

Do not wash the filter element.

Use low pressure compressed air in order to removethe dust from the filter element. Air pressure must notexceed 207 kPa (30 psi). Direct the air flow up thepleats and down the pleats from the inside of the filterelement. Take extreme care in order to avoid damageto the pleats.

Do not use air filters with damaged pleats, gaskets, orseals. Dirt entering the engine will cause damage toengine components.

The primary air filter element can be used up to sixtimes if the element is properly cleaned and properlyinspected. When the primary air filter element iscleaned, check for rips or tears in the filter material.The primary air filter element should be replaced atleast one time per year. This replacement should beperformed regardless of the number of cleanings.

NOTICEDo not clean the air filter elements by bumping or tap-ping. This could damage the seals. Do not use ele-ments with damaged pleats, gaskets, or seals. Dam-aged elements will allow dirt to pass through. Enginedamage could result.

Visually inspect the primary air filter elements beforecleaning. Inspect the air filter elements for damageto the seal, the gaskets, and the outer cover. Discardany damaged air filter elements.

There are two common methods that are used toclean primary air filter elements:

• Pressurized air

• Vacuum cleaning

120 SEBU7877-08Maintenance SectionEngine Air Filter Primary Element - Clean/Replace

Pressurized Air

Pressurized air can be used to clean primary air filterelements that have not been cleaned more than twotimes. Pressurized air will not remove deposits ofcarbon and oil. Use filtered, dry air with a maximumpressure of 207 kPa (30 psi).


Note: When the primary air filter elements arecleaned, always begin with the clean side (inside)in order to force dirt particles toward the dirty side(outside).

Aim the hose so that the air flows inside the elementalong the length of the filter in order to help preventdamage to the paper pleats. Do not aim the stream ofair directly at the primary air filter element. Dirt couldbe forced further into the pleats.

Vacuum Cleaning

Vacuum cleaning is another method for cleaningprimary air filter elements which require daily cleaningbecause of a dry, dusty environment. Cleaning withpressurized air is recommended prior to vacuumcleaning. Vacuum cleaning will not remove depositsof carbon and oil.

Inspecting the Primary Air FilterElements


Inspect the clean, dry primary air filter element. Usea 60 watt blue light in a dark room or in a similarfacility. Place the blue light in the primary air filterelement. Rotate the primary air filter element. Inspectthe primary air filter element for tears and/or holes.Inspect the primary air filter element for light that mayshow through the filter material. If it is necessary inorder to confirm the result, compare the primary airfilter element to a new primary air filter element thathas the same part number.

Do not use a primary air filter element that has anytears and/or holes in the filter material. Do not usea primary air filter element with damaged pleats,gaskets or seals. Discard damaged primary air filterelements.

Storing Primary Air Filter Elements

If a primary air filter element that passes inspectionwill not be used, the primary air filter element canbe stored for future use.



Engine Air Filter Secondary Element - Replace

Do not use paint, a waterproof cover, or plastic as aprotective covering for storage. An air flow restrictionmay result. To protect against dirt and damage, wrapthe primary air filter elements in Volatile CorrosionInhibited (VCI) paper.

Place the primary air filter element into a box forstorage. For identification, mark the outside of thebox and mark the primary air filter element. Includethe following information:

• Date of cleaning

• Number of cleanings

Store the box in a dry location.

i02225193

Engine Air Filter SecondaryElement - ReplaceSMCS Code: 1054-510-SE

NOTICEAlways replace the secondary filter element. Neverattempt to reuse it by cleaning.

The secondary filter element should be replaced at thetime the primary element is serviced for the third time.

The secondary filter element should also be replacedif the yellow piston in the filter element indicator en-ters the red zone after installation of a clean primaryelement, or if the exhaust smoke is still black.


1. Open the engine hood. Access the air cleanerfrom the left side of the machine.


2. Loosen the clips which hold air cleaner housingcover (1). Remove the air cleaner housing cover.

3. Remove primary filter element (2) from the aircleaner housing.

Reference: For the proper procedure, refer toOperation and Maintenance Manual, “Engine AirFilter Primary Element - Clean/Replace”.


4. Remove the secondary filter element.


122 SEBU7877-08Maintenance SectionEngine Air Filter Service Indicator - Inspect

5. Cover the air inlet opening. Clean the inside ofthe air cleaner housing.

6. Inspect the gasket between the air inlet pipe andthe air cleaner housing. Replace the gasket if thegasket is damaged.

7. Uncover the air inlet opening. Install a newsecondary filter element.

8. Install the primary filter element and the air cleanerhousing cover. Fasten the clips in order to securethe air cleaner housing cover.


i01968230

Engine Air Filter ServiceIndicator - InspectSMCS Code: 7452-040

Some engines are equipped with a differential gaugefor inlet air pressure. The differential gauge for inletair pressure displays the difference in the pressurethat is measured before the air cleaner element andthe pressure that is measured after the air cleanerelement. As the air cleaner element becomes dirty,the pressure differential rises.

g01001638Illustration 160The air filter service indicator is located near the air filter housing.

1. Observe the performance of the air filter serviceindicator. The air filter element should be cleanedor the air filter element should be replaced whenone of the following conditions occur:

• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.

2. If any component damage is present, replace theservice indicator.

3. If air leaks are present, replace the serviceindicator.

Note: When a new service indicator is installed,excessive force may crack the top of the serviceindicator. Tighten the service indicator to a torqueof 2 N·m (18 lb in).

i01968211

Engine Air Filter ServiceIndicator - Inspect/ReplaceSMCS Code: 7452-040; 7452-510

Some engines are equipped with a differential gaugefor inlet air pressure. The differential gauge for inletair pressure displays the difference in the pressurethat is measured before the air cleaner element andthe pressure that is measured after the air cleanerelement. As the air cleaner element becomes dirty,the pressure differential rises.

g01001638Illustration 161The air filter service indicator is located near the air filter housing.

Inspect1. Observe the performance of the air filter serviceindicator. The air filter element should be cleanedor the air filter element should be replaced whenone of the following conditions occur:

• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.

2. If any component damage is present, replace theservice indicator.

3. If air leaks are present, replace the serviceindicator.


Engine Air Precleaner - Clean

Test1. Check for ease of resetting. The service indicatorshould reset in less than three pushes.

2. Check the movement of the yellow core when theengine is accelerated to the engine rated speed.The yellow core should latch approximately at thegreatest vacuum that is attained.

If the service indicator does not reset easily, or if theyellow core does not latch at the greatest vacuum,the service indicator should be replaced. If the newservice indicator will not reset, the hole for the serviceindicator may be plugged.

ReplaceReplace the service indicator if the followingconditions exist:

• The machine is used in a severely dustyenvironment.

• The engine is overhauled.

• Major components are replaced.

Note: Replace the service indicator annuallyregardless of the operating conditions.

Note: When a new service indicator is installed,excessive force may crack the top of the serviceindicator. Tighten the service indicator to a torqueof 2 N·m (18 lb in).

i02225199

Engine Air Precleaner - CleanSMCS Code: 1055-070


1. Loosen the bolt on clamp (2). Remove hoodassembly (1).

2. Loosen the hose clamp and remove the hose frombody assembly (3).

3. Loosen clamp (5). Remove body assembly (3).

4. Clean all of the parts with compressed air or washall of the parts in warm water. Allow all of the partsto dry.

5. Install body assembly (3). Tighten the bolt onclamp (5) to a torque of 24 ± 7 N·m (18 ± 5 lb ft).

6. Install the hose and tighten the clamp.

7. Install hood assembly (1). Tighten the bolt onclamp (2).

i02915110

Engine Compartment -Inspect/CleanSMCS Code: 1000-040-CPA; 1000-070-CPA

Personal injury or death can result from fires.

Inspect the machine periodically for accumulationof debris and paper.

Remove the accumulation to prevent engine over-heating and fires.

Keep the equipment free from foreign material.Remove debris, oil, tools, and other items from thefollowing areas:

• Decks

• Walkways

• Steps

• Engine compartment

• Belly guards

• Radiator cores

• Filters

• Exhaust components

• Other areas

124 SEBU7877-08Maintenance SectionEngine Compartment - Inspect/Clean


Any areas that act as potential heat sources mustbe inspected. If debris is found, the area mustbe cleaned.

Note: When you inspect the machine, always lookfor burning debris or smoke.

All fuels, most lubricants, and some coolant mixturesare flammable. Flammable fluids that are leakingor spilled onto hot surfaces or onto electricalcomponents can cause a fire. Fire may causepersonal injury and property damage. Remove allflammable materials such as fuel, oil, and debris fromthe machine. Do not allow any flammable materialsto accumulate on the machine.

Note: Flammable items may come from the followingsources: leaking hoses, tubes or gaskets, fillingcontainers, soaked rags, and contaminated debris.

In order to avoid a fire, clean out any debris andpaper from the following areas: back of the engine,front of the engine, top of the engine, sides of theengine, and belly guards.


Inspect the engine compartment for debris when youenter the machine and when you exit the machine.Open all of the engine compartment doors. Inspectthe engine compartment for debris and leaks. Inorder to reduce the risk of a fire, clean out any debrisand paper from the above areas. Use pressurizedair from an air nozzle in order to blow out the enginecompartment.


Remove any trash buildup and debris. If necessary,lower the belly guards in order to fully clean theengine compartment. Be sure to clean any debrisor cut any debris that may be in the axle or axlewrap area. Be sure that the wheel extensions are notrubbing on the frame. If there is debris that is packedin this area, remove the debris. Rubbing and packeddebris may cause excessive heat or sparks.

Ensure that all necessary repairs are performedbefore you operate the machine.

Check all electrical wires and battery cables daily.Repair any wires that are loose or frayed before youoperate the machine. Clean all electrical connectionsand tighten all electrical connections.

Make sure that a fire extinguisher is on themachine. Make sure that you are familiar with theoperation of the fire extinguisher. Inspect the fireextinguisher and service the fire extinguisher. Obeythe recommendations on the instruction plate.

Exhaust shields (if equipped) protect hot exhaustcomponents from oil spray or fuel spray in case ofa break in a line, in a hose, or in a seal. Exhaustshields must be installed correctly.


Engine Oil (High Speed) and Oil Filter - Change

i02301059

Engine Oil (High Speed) andOil Filter - Change(If Equipped)SMCS Code: 1318-510-HZ

Selection of the Oil Change Interval

NOTICEA 500 hour engine oil change interval is available, pro-vided that the operating conditions and recommend-ed multigrade oil types are met. When these require-ments are not met, shorten the oil change interval to250 hours, or use an S·O·S oil sampling and analysisprogram to determine an acceptable oil change inter-val.

If you select an interval for oil and filter change that istoo long, you may damage the engine.

Caterpillar oil filters are recommended.

Recommended multigrade oil types are listed inTable 11. Do not use single grade oils.

Abnormally harsh operating cycles or harshenvironments can shorten the service life ofthe engine oil. Arctic temperatures, corrosiveenvironments, or extremely dusty conditions mayrequire a reduction in engine oil change intervalsfrom the recommendations in Table 11.

Reference: Refer to Special Publication, SEBU5898,“Cold Weather Recommendations” or your Caterpillardealer for more information if this product willexperience abnormally harsh operating cycles orharsh environments.

Table 11

824H Wheel Tractor825H Soil Compactor

826H Landfill CompactorEngine Oil Change Interval(1)

Operating Conditions

Severe

FuelSulfurfrom0.3% to0.5%

MultigradeOil Type

Normal(2) HighLoadFactor(3)above62.1 L(16.4US gal)per hrof fuel

(4)

Altitudeabove1830 m(6000 ft)

Cat DEOPreferred 500 hr 500 hr 500 hr 250 hr(6)

Cat ECF-111.0

minimumTBN(4)Preferred

500 hr 500 hr 500 hr 250 hr(6)

Cat ECF-1TBN(4)

below 11.0500 hr 500 hr 250 hr(5) 250 hr(6)

API CG-4 250 hr 250 hr(5) 250 hr(5) 250 hr(6)

(1) The traditional oil change interval for engines is 250 hours.The standard oil change interval in this machine is 500 hours, ifthe operating conditions and recommended oil types that arelisted in this table are met. Improvements in the engine allowthis engine oil change interval. This new standard interval is notpermitted for other machines. Refer to the applicable Operationand Maintenance Manuals for the other machines.

(2) Normal conditions include these factors: Fuel sulfur below0.3%, altitude below 1830 m (6000 ft), and good air filter andfuel filter maintenance. Normal conditions do not include highload factor, harsh operating cycles, or harsh environments.

(3) High load factors can shorten the service life of your engineoil. Continuous heavy load cycles and very little idle timeresult in increased fuel consumption and oil contamination.These factors deplete the oil additives more rapidly. If theaverage fuel consumption of your 824H Wheel Tractor,825H Soil Compactor, or 826H Landfill Compactor exceeds62.1 L (16.4 US gal) per hour, follow the “High Load Factor”recommendations in Table 11. To determine average fuelconsumption, measure average fuel consumption for a periodof 50 to 100 hours. If the application of the machine is changed,the average fuel consumption may change.

(4) For sulfur content above 0.5%, refer to Operation andMaintenance Manual, “Total Base Number (TBN) and FuelSulfur Levels for Direct Injection (DI) Diesel Engines” in the“Lubricant” section of this manual. Also, you may refer to thistopic in Special Publication, SEBU6250.

(5) In order to verify an oil change interval of 500 hours, refer to“Program A” below.

(6) Use “Program B” below to determine an appropriate interval.

Adjustment of the Oil Change Interval

Note: Your Caterpillar dealer has additionalinformation on these programs.

126 SEBU7877-08Maintenance SectionEngine 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 of500 hours. Oil sampling and analysis is done at 250hours and 500 hours for each of the three intervalsfor a total of six oil samples. The analysis includesoil viscosity and infrared (IR) analysis of the oil. Ifall of the results are satisfactory, the 500 hour oilchange interval is acceptable for the machine in thatapplication. Repeat Program A if you change theapplication of the machine.

If a sample does not pass the oil analysis, take oneof these actions:

• Shorten the oil change interval to 250 hours.

• Proceed to Program B.

• Change to a preferred oil type in Table 11.

Program B

Optimizing Oil Change Intervals

Begin with a 250 hour oil change interval. The oilchange intervals are adjusted by increments. Eachinterval is adjusted an additional 50 hours. Periodic oilsampling and analysis is done during each interval.The analysis includes oil viscosity and infrared (IR)analysis of the oil. Repeat Program B if you changethe application of the machine.

If an oil sample does not pass the analysis, shortenthe oil change interval, or change to a preferredmultigrade oil type in the listing above.

References

Reference: Special Publication, PEDP7035,“Optimizing Oil Change Intervals”

Reference: Special Publication, PEDP7036, “S·O·SFluid Analysis”

Reference: Special Publication, PEHP7076,“Understanding the S·O·S Services Tests”

Procedure for Changing the EngineOil and the Filter




Your machine may be equipped with a high speedarrangement for changing the engine oil. The highspeed arrangement allows service personnel tochange the oil from the engine access door on theleft side of the machine. The high speed arrangementallows the oil to be changed faster than conventionalmethods.

1. Open the engine hood.


2. Remove the cap that protects the male coupler.Connect an oil pump to the fitting. The fitting onthe machine is a male coupler.

3. Turn on the oil pump and withdraw the engine oilfrom the engine oil pan.


Engine Oil Level - Check


4. Use a strap type wrench to remove filter element(1). Inspect the filter.

Reference: For more information, refer toOperation and Maintenance Manual, “Oil Filter -Inspect”.

5. Clean the filter mounting base with a clean cloth.Make sure that the used filter gasket has beencompletely removed.


6. Apply a thin film of clean engine oil to the sealingsurface of the new filter element.

Note: There are rotation index marks on each engineoil filter that are spaced 90 degrees or 1/4 of a turnfrom each other. When you tighten engine oil filtersuse these marks as a guide.

7. Install the engine oil filters hand tight until the sealcontacts the filter base. Note the position of theindex marks on the filter in relation to a fixed pointon the filter base.

8. Tighten the filter according to the instructions thatare printed on the filter. Use the index marks asa guide.

9. Connect an oil pump to the male coupler for thehigh speed arrangement. Fill the crankcase withnew oil.

Reference: For more information, refer toOperation and Maintenance Manual, “Capacities(Refill)”.

10.Clean the end of the male coupler. Clean the capthat covers the male coupler and install the cap.

11.Start the engine and allow the oil to warm. Checkthe machine for oil leaks.

12.Check the engine oil level.

Reference: Refer to Operation and MaintenanceManual, “Engine Oil Level - Check” for the correctprocedure.

13.Stop the engine. Close the engine hood.

i02225925

Engine Oil Level - CheckSMCS Code: 1000-535-FLV

NOTICEDo not under fill or overfill engine crankcase with oil.Either condition can cause engine damage.




128 SEBU7877-08Maintenance SectionEngine Oil Sample - Obtain


1. Open the engine access door on the right rearside of the machine. The engine oil dipstick islocated on the right side of the engine near engineoil filter (1).

2. Remove the engine oil dipstick and wipe thedipstick with a clean cloth. Then, insert the dipstickand remove the dipstick again. This will ensurea more accurate measurement of the engine oillevel.

3. While the engine is stopped, check the “ENGINESTOPPED” side of the engine oil dipstick. Maintainthe oil level between the marks on the dipstick.

While the engine is running, check the “ENGINERUNNING” side of the engine oil dipstick. Maintainthe oil level between the marks on the dipstick.

4. If necessary, remove the oil filler plug and add oilthrough the oil filler tube.

5. Clean the oil filler plug and install the oil filler plug.

6. Close the engine access door.

i02225927

Engine Oil Sample - ObtainSMCS Code: 1348-008; 7542

Hot oil and components can cause personal in-jury.

Do not allow hot oil or components to contactskin.




Operate the machine for a few minutes before youobtain the fluid sample. This will thoroughly mix thefluid for a more accurate sample.




Engine Oil and Filter - Change

i02343257

Engine Oil and Filter - ChangeSMCS Code: 1318-510

Selection of the Oil Change Interval

NOTICEA 500 hour engine oil change interval is available, pro-vided that the operating conditions and recommend-ed multigrade oil types are met. When these require-ments are not met, shorten the oil change interval to250 hours, or use an S·O·S oil sampling and analysisprogram to determine an acceptable oil change inter-val.

If you select an interval for oil and filter change that istoo long, you may damage the engine.

Caterpillar oil filters are recommended.

Recommended multigrade oil types are listed in Table12. Do not use single grade oils.

Abnormally harsh operating cycles or harshenvironments can shorten the service life ofthe engine oil. Arctic temperatures, corrosiveenvironments, or extremely dusty conditions mayrequire a reduction in engine oil change intervalsfrom the recommendations in Table 12. Also referto Special Publication, SEBU5898, “Cold WeatherRecommendations”. Poor maintenance of air filtersor of fuel filters requires reduced oil change intervals.See your Caterpillar dealer for more information if thisproduct will experience abnormally harsh operatingcycles or harsh environments.

Table 12

824H Wheel Tractor825H Soil Compactor

826H Landfill CompactorEngine Oil Change Interval(1)

Operating Conditions

Severe

FuelSulfurfrom0.3%to0.5%

MultigradeOil Type

Normal(2) HighLoadFactor(3)above62.1 L(16.4 USgal) perhr offuel

(4)

Altitudeabove1830 m(6000 ft)

Cat DEOPreferred 500 hr 500 hr 500 hr 250 hr(6)

Cat ECF-111.0

minimumTBN(4)Preferred

500 hr 500 hr 500 hr 250 hr(6)

Cat ECF-1TBN(4)

below 11.0500 hr 500 hr 250

hr(5) 250 hr(6)

API CG-4 250 hr 250 hr(5) 250hr(5) 250 hr(6)

(1) The traditional oil change interval for engines is 250 hours.The standard oil change interval in this machine is 500 hours, ifthe operating conditions and recommended oil types that arelisted in this table are met. Improvements in the engine allowthis engine oil change interval. This new standard interval is notpermitted for other machines. Refer to the applicable Operationand Maintenance Manuals for the other machines.

(2) Normal conditions include these factors: Fuel sulfur below0.3%, altitude below 1830 m (6000 ft), and good air filter andfuel filter maintenance. Normal conditions do not include highload factor, harsh operating cycles, or harsh environments.

(3) High load factors can shorten the service life of your engineoil. Continuous heavy load cycles and very little idle timeresult in increased fuel consumption and oil contamination.These factors deplete the oil additives more rapidly. If theaverage fuel consumption of your 824H Wheel Tractor,825H Soil Compactor, or 826H Landfill Compactor exceeds62.1 L (16.4 US gal) per hour, follow the “High Load Factor”recommendations in Table 12. To determine average fuelconsumption, measure average fuel consumption for a periodof 50 to 100 hours. If the application of the machine is changed,the average fuel consumption may change.

(4) For sulfur content above 0.5%, refer to Special Publication,SEBU6250, “Total Base Number (TBN) and Fuel Sulfur Levelsfor Direct Injection (DI) Diesel Engines”.

(5) In order to verify an oil change interval of 500 hours, refer to“Program A” below.

(6) Use “Program B” below to determine an appropriate interval.

Adjustment of the Oil Change Interval

Note: Your Caterpillar dealer has additionalinformation on these programs.

130 SEBU7877-08Maintenance SectionEngine Oil and Filter - Change

Program A

Verification for an Oil Change Interval of 500 Hours

This program consists of three oil change intervals of500 hours. Oil sampling and analysis is done at 250hours and 500 hours for each of the three intervalsfor a total of six oil samples. The analysis includesoil viscosity and infrared (IR) analysis of the oil. Ifall of the results are satisfactory, the 500 hour oilchange interval is acceptable for the machine in thatapplication. Repeat Program A if you change theapplication of the machine.

If a sample does not pass the oil analysis, take oneof these actions:

• Shorten the oil change interval to 250 hours.

• Proceed to Program B.

• Change to a preferred oil type in Table 12.

Program B

Optimizing Oil Change Intervals

Begin with a 250 hour oil change interval. The oilchange intervals are adjusted by increments. Eachinterval is adjusted an additional 50 hours. Periodic oilsampling and analysis is done during each interval.The analysis includes oil viscosity and infrared (IR)analysis of the oil. Repeat Program B if you changethe application of the machine.

If an oil sample does not pass the analysis, shortenthe oil change interval, or change to a preferredmultigrade oil type in the listing above.

References

Reference: Special Publication, PEDP7035,“Optimizing Oil Change Intervals”

Reference: Special Publication, PEDP7036, “S·O·SFluid Analysis”

Reference: Special Publication, PEHP7076,“Understanding the S·O·S Services Tests”

Procedure for Changing the EngineOil and the Filter




1. Open the access door that is located on the leftside of the machine.


2. Open the crankcase drain valve (2). Allow theoil to drain into a suitable container. Close thecrankcase drain valve.

3. Remove the filter element (1) with a strap typewrench. Inspect the filter.

Reference: Refer to Operation and MaintenanceManual, “Oil Filter - Inspect”.

4. Clean the filter mounting base with a clean cloth.Make sure that the used filter gasket has beencompletely removed.


Engine Valve Lash - Check


5. Apply a thin film of clean engine oil to the sealingsurface of the new filter element.

Note: There are rotation index marks on each engineoil filter that are spaced 90 degrees or 1/4 of a turnfrom each other. When you tighten engine oil filtersuse these marks as a guide.

6. Install the engine oil filters hand tight until the sealcontacts the filter base. Note the position of theindex marks on the filter in relation to a fixed pointon the filter base.

7. Tighten the filter according to the instructions thatare printed on the filter. Use the index marks asa guide.

8. Remove the oil filler plug . Fill the crankcase withnew oil.

Reference: For more information, refer toOperation and Maintenance Manual, “Capacities(Refill)”.

9. Clean the oil filler plug and install the oil filler plug.

10.Start the engine and allow the oil to warm. Checkfor leaks.

11.Check the engine oil level in the sight gauge.

Reference: Refer to Operation and MaintenanceManual, “Engine Oil Level - Check” for the correctprocedure.

12.Stop the engine. Close the engine access doors.

i01181536

Engine Valve Lash - CheckSMCS Code: 1105-535

For the correct procedure, refer to the appropriateService Manual module for your machine's engine orconsult your Caterpillar dealer.

Note: A qualified mechanic should adjust the enginevalve lash because special tools and training arerequired.

i01935374

Engine Valve Rotators - InspectSMCS Code: 1109-040

When inspecting the valve rotators, protectiveglasses or face shield and protective clothingmust be worn, to prevent being burned by hot oilor spray.

Caterpillar recommends replacing valve rotators thatare operating improperly. An improperly operatingvalve rotator will shorten valve life because ofaccelerated wear on the valves. Also, metal particlesfrom a damaged valve rotator could fall into thecylinder and damage to the piston head and to thecylinder head may result.


Start the engine and run the engine at low idle. Watchthe top surface of each valve rotator. Whenever aninlet valve closes or an exhaust valve closes, eachvalve rotator should turn.

If a valve rotator fails to turn, consult your Caterpillardealer for service.

132 SEBU7877-08Maintenance SectionEngine Water Pump - Inspect

i02377495

Engine Water Pump - InspectSMCS Code: 1361-040

Failure of the engine water pump may cause severeengine overheating problems such as cracks in thecylinder head or piston seizure.

Visually inspect the water pump for leaks. If you findleaks, all of the seals on the water pump must bereplaced.

Reference: Refer to Disassembly and Assembly,RENR8686, “826H Landfill Compactor, 825HSoil Compactor and 824H Wheel Dozer EngineSupplement” for additional information about thewater pump.

i02225928

Ether Starting Aid Cylinder -Replace(If Equipped)SMCS Code: 1456-510-CD


1. Open the access door. The ether starting aidcylinder is mounted on the left side of the machinenext to the air cleaner.

2. Loosen retaining clamp (1) and unscrew etherstarting aid cylinder (2).

3. Remove the gasket. Install the new gasket that isprovided with each new ether starting aid cylinder.

4. Install new ether starting aid cylinder (2) handtight. Tighten retaining clamp (1) securely.


i02848898

Fire Suppression System -Check(If Equipped)SMCS Code: 7401-535

Many customers choose to have an aftermarket firesuppression system. If such a system is installed onthe machine, follow the guidelines below.

Inspect all lines and hoses for wear or fordeterioration. The hoses must be properly routed.The lines and hoses must have adequate supportand secure clamps. Tighten all connections to therecommended torque.

Refer to the OEM for the fire suppression system forthe procedure that is used to test for proper systemoperation.

i02226613

Fuel System - PrimeSMCS Code: 1250-548




The priming pump is located on the right side of themachine in the engine compartment.

1. Turn the ignition switch to the OFF position.


Fuel System Primary Filter (Water Separator) - Drain


2. Attach a piece of bulk hose to a sampling probe.Install the sampling probe with the piece of bulkhose onto valve assembly (2).

Note: Consult your Caterpillar dealer for the propertooling or refer to the parts manual for your machine.

3. Position a suitable container under the hose.

4. Turn the toggle switch (1) to the ON position.Toggle switch (1) is for the fuel priming pump.

5. Allow the air/fuel mixture to flow into the suitablecontainer until the fuel flows in a steady stream.

6. Turn the toggle switch (1) to the OFF position.

7. Remove the sampling probe with the piece of bulkhose from the valve assembly (2).

8. Start the engine. The engine should start. Theengine should run smoothly.

Note: Failure to tighten fittings could result in fuelleaks.

9. Clean residual fuel from the engine components.

i02962208

Fuel System Primary Filter(Water Separator) - DrainSMCS Code: 1263-543


Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.



“Type 1” Primary Filter (Water Separator)

g01469667Illustration 177“Type 2” Primary Filter (Water Separator)

Steel fuel filter

1. Open the engine hood.

134 SEBU7877-08Maintenance SectionFuel System Primary Filter (Water Separator) Element - Replace

2. The fuel filters are located on the right side of themachine in the engine compartment. The waterseparator bowl is located on the bottom of primaryfuel filter. Attach a hose to the bottom of the drainvalve in order to catch the fuel. Open the drainvalve on the bottom of the water separator bowl.Allow the water and the fuel to drain into a suitablecontainer.

3. Close the drain valve.

Note: The water separator is under suction duringnormal engine operation. Tighten the drain valvesecurely in order to prevent air leakage into the fuelsystem.


i02227003

Fuel System Primary Filter(Water Separator) Element -ReplaceSMCS Code: 1263-510-FQ




NOTICEDo 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 fuelsystem parts. The fuel system should be primed priorto starting the engine.


1. The water separator bowl is located on the bottomof the primary fuel filter. Open the drain valve onthe water separator bowl. Allow the water and thefuel to drain into a suitable container.

2. Use a strap type wrench to remove the filter fromthe filter mounting base.

3. Remove the water separator bowl from the filterelement. Clean the water separator bowl and theO-ring groove.

Note: The water separator bowl is reusable. Do notdiscard the water separator bowl.

4. Inspect the O-ring seal in the water separator bowlfor damage. Replace the O-ring seal, if necessary.

5. Lubricate the O-ring seal with clean diesel fuel orwith engine oil. Place the O-ring seal in the waterseparator bowl.

6. Install the water separator bowl onto the new filterelement by hand. Do not use tools to tighten thewater separator bowl.



Fuel System Secondary Filter - Replace

7. Lubricate the gasket of the new filter element withclean diesel fuel. Install a new filter hand tightuntil the seal of the fuel filter contacts the base.Note the position of the index marks on the filter inrelation to a fixed point on the filter base.

Note: There are rotation index marks on the fuel filterthat are spaced 90 degrees or 1/4 of a turn awayfrom each other. When you tighten the fuel filter, usethe rotation index marks as a guide.

8. Tighten the filter according to the instructionsthat are printed on the filter. Use the index marksas a guide. For non-Caterpillar filters, use theinstructions that are provided with the filter.

Note: You may need to use a Caterpillar strapwrench, or another suitable tool, in order to turnthe filter to the amount that is required for finalinstallation. Make sure that the installation tool doesnot damage the filter.

9. Tighten the drain valve on the water separatorbowl.

Note: The water separator element is under suctionduring normal engine operation. The drain valve mustbe tightened in order to prevent air leakage into thefuel system.

10.Prime the fuel system in order to fill the filterelement with fuel.

Reference: Refer to Operation and MaintenanceManual, “Fuel System Prime” for the correctprocedure.

i02227023

Fuel System Secondary Filter -ReplaceSMCS Code: 1261-510-SE




NOTICEDo 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 fuelsystem parts. The fuel system should be primed priorto starting the engine.


1. Use a strap type wrench to remove the secondaryfuel filter. The secondary fuel filter is locatedon the right side of the machine in the enginecompartment. Dispose of the used filter properly.

2. Clean the filter mounting base. Remove all of theused seal from the filter mounting base.

3. Lubricate the seal of the new fuel filter with cleandiesel fuel. Install a new secondary fuel filter handtight until the seal of the secondary fuel filtercontacts the base. Note the position of the indexmarks on the filter in relation to a fixed point onthe filter base.

Note: There are rotation index marks on the fuel filterthat are spaced 90 degrees or 1/4 of a turn awayfrom each other. When you tighten the fuel filter, usethe rotation index marks as a guide.

4. Tighten the filter according to the instructionsthat are printed on the filter. Use the index marksas a guide. For non-Caterpillar filters, use theinstructions that are provided with the filter.

Note: You may need to use a Caterpillar strapwrench, or another suitable tool, in order to turnthe filter to the amount that is required for finalinstallation. Make sure that the installation tool doesnot damage the filter.

5. Prime the fuel filters.

Reference: Refer to Operation and MaintenanceManual, “Fuel System - Prime” for the properprocedure.

136 SEBU7877-08Maintenance SectionFuel Tank Cap and Strainer - Clean

i01486926

Fuel Tank Cap and Strainer -CleanSMCS Code: 1273-070-Z2; 1273-070-STR


The fuel tank is located in the non-engine end frameof the frame.

1. Remove fuel tank cap (1) and strainer (3) from thefuel tank. Remove seal (2) from the cap.

2. Wash the strainer and the fuel tank cap in a clean,nonflammable solvent.

3. Install the strainer into the filler opening.

4. Inspect the seal for damage. Replace the seal, ifnecessary. Install the fuel tank cap.

i01493714

Fuel Tank Water and Sediment- DrainSMCS Code: 1273-543-M&S

S/N: AZW1-Up

S/N: ASX1-Up


The fuel tank drain valve is located under the fueltank.

1. Open the fuel tank drain valve. Allow the waterand sediment to drain into a suitable container.

2. Close the fuel tank drain valve.


Fuel Tank Water and Sediment - Drain

i02214705

Fuel Tank Water and Sediment- DrainSMCS Code: 1273-543-M&S

S/N: AWF1-Up

g01117658Illustration 183The valve assembly (1) for the fuel tank drain is located behind thefuel tank on the right side of the machine.

1. Open the fuel tank drain valve (2).

2. Use pump (3) in order to pump the water and thesediment into a suitable container.

3. Close the fuel tank drain valve (2).

i02926635

Fuses - ReplaceSMCS Code: 1417-510

The fuses are located in the operator compartmentbehind the seat.

NOTICEReplace the fuses with the same type and size only.Otherwise, electrical damage can result.

If it is necessary to replace fuses frequently, an electri-cal problem may exist. Contact your Caterpillar dealer

Your machine may not be equipped with all of thefuses that are discussed in this topic.

Note: Your machine is equipped with fuses that arethe following amperage: 10 Amp, 15 Amp, and 20Amp. The following illustrations are typical examples.

Fuse Block


Typical example

Fuse Panel


138 SEBU7877-08Maintenance SectionHigh Intensity Discharge Lamp (HID) - Replace


(1) 15 amperes(2) 20 amperes

The remainder of the fuses are all 10 amperes.

i02245859

High Intensity Discharge Lamp(HID) - Replace(If Equipped)SMCS Code: 1434-510

HID lamps operate at very high voltages. To avoidelectrical shock and personal injury, disconnectpower before servicing HID lamps.

HID bulbs become very hot during operation.Before servicing, remove power from lamp for atleast five minutes to ensure lamp is cool.

NOTICEAlthough HID bulb materials may change over time,HID bulbs produced at the time of the printing of thismanual contain mercury. When disposing of this com-ponent, or any waste that contains mercury, pleaseuse caution and comply with any applicable laws.

1. Remove the electrical power from the highintensity discharge lamp (HID). The electricalpower must be removed from the HID lamp forat least five minutes, in order to ensure that thebulb is cool.

2. Disassemble the housing for the HID lamp in orderto have access to the bulb.

Note: On some HID lamps, the bulb is an integralpart of the lens assembly. The bulb is not removedseparately from the lens assembly. Replace theentire lens assembly on these HID lamps.

3. Remove the bulb from the HID lamp.

4. Install the replacement bulb in the HID lamp.

If the bulb is an integral part of the lens assembly,install the replacement lens assembly in the HIDlamp.

Note: In order to avoid failure to the bulb that ispremature, avoid touching the bulb's surface withyour bare hands. Clean any fingerprints from the bulbwith alcohol prior to operation.

5. Reassemble the housing for the HID lamp. Ensurethat any printing on the lens is oriented correctlywith respect to the HID lamp's mounting positionon the machine.

6. Reattach the electrical power to the HID lamp.

7. Check the HID lamp for proper operation.

Note: Consult your Caterpillar dealer for additionalinformation on HID lamps.


Hydraulic System Oil - Change

i02199944

Hydraulic System Oil - ChangeSMCS Code: 5056-044

Selection of the Oil Change IntervalYour machine may be able to use a 4000 hourinterval for the hydraulic oil. The hydraulic oil is inthe system that is not integral to the service brakes,the clutches, the final drives, or the differentials.The standard change interval is 2000 hours. The oilshould be monitored during intervals of 500 hours.The extended 4000 hour interval can be used if thefollowing criteria are met.

Oil Filters

Caterpillar oil filters are recommended. The intervalfor changing the oil filter should be 500 hours.

Oil

The 4000 hour interval for changing the oil is for thefollowing oil types:

• Caterpillar Hydraulic Oil HYDO

• Caterpillar Transmission and Drive Train Oil(TDTO)

• Caterpillar TDTO (TMS)

• Caterpillar Diesel Engine Oil

• Caterpillar Biodegradable Hydraulic Oils HEES

• Caterpillar Multipurpose Tractor Oil (MTO)

• Heavy duty diesel engine oil with a minimum zinccontent of 900 ppm

Oils that are classified as being heavy duty are thefollowing: CF, CF-4, CG-4, and CH-4

Note: Industrial hydraulic oils are not recommendedin Caterpillar hydraulic systems. These oils are morelikely to cause corrosion and excessive wear.

Procedure for Changing theHydraulic Oil




Operate the machine for a few minutes in order towarm the hydraulic oil.

Park the machine on level ground. Lower the bucketto the ground and apply slight downward pressure.Engage the parking brake and stop the engine.


The hydraulic tank is located on the right side of themachine. Open the access door that is located on theplatform on the right side of the cab. Press hydraulictank breaker relief valve (1) in order to relieve anytank pressure.

1. Remove hydraulic tank filler cap (2) and the fillerstrainer. Wash the filler cap and the strainer in aclean, nonflammable solvent. Install the strainer.

2. Inspect the gasket on the filler cap for damage.Replace the gasket, if necessary.

140 SEBU7877-08Maintenance SectionHydraulic System Oil Filter - Replace

3. Remove the drain plug (4) from the bottom of thehydraulic tank. Wash the drain plug in a clean,nonflammable solvent.

4. Install a Pipe Nipple with a hose in order to unseatthe internal drain valve. Allow the hydraulic oil todrain into a suitable container.

NOTICENever start the engine while the hydraulic oil tank isbeing drained or while the hydraulic oil tank is empty.Excessive wear and damage to the hydraulic compo-nents can occur.

5. Remove the Pipe Nipple in order to close the drainvalve. Install the drain plug.

6. Replace the hydraulic oil filter.

Reference: Refer to Operation and MaintenanceManual, “Hydraulic System Oil Filter - Replace” forthe correct procedure.

7. Fill the hydraulic tank with clean oil. Make surethat the oil level is at the “FULL” mark on the sightgauge (3). Install the filler cap.

Reference: Refer to Operation and MaintenanceManual, “Capacities (Refill) ” for the correct typeof oil and for the correct amount of oil.

8. Start the engine and run the engine for at least tenseconds. Then, stop the engine and add hydraulicoil to the tank until the oil level is at the “FULL”mark on the sight gauge. Install the filler cap.

9. Start the engine and run the engine at low idle.Cycle the implements so that all hydraulic systemsare filled with oil.

Note: If the alert indicator for a low oil level comeson, stop the engine and immediately add oil to thehydraulic tank. The oil level should not be below thesuction ports in the hydraulic tank while the engineis running.

10.Add hydraulic oil to the tank until the oil level is atthe “FULL” mark on the sight gauge.

11.Stop the engine. Top off the hydraulic tank so thatthe oil level is at the “FULL” mark on the sightgauge. Install the filler cap.

Note: The oil must be free of air bubbles. If airbubbles are present in the hydraulic oil, air is enteringthe hydraulic system. Inspect the hydraulic suctionline and the hose clamps.

12. If necessary, tighten any loose clamps or anyloose connections. Replace any damaged hoses.

i02225240

Hydraulic System Oil Filter -ReplaceSMCS Code: 5068-510





1. Open the small access door on the right side of thecab platform. Press hydraulic tank breaker reliefvalve (1) in order to relieve any tank pressure.


Hydraulic System Oil Level - Check


Note: On the 826G Series II Landfill Compactor,remove the three bolts and swing the protective guardoutward in order to access the hydraulic oil filters.

2. Remove covers (2) and (3) for the hydraulic oilfilters.

3. Inspect the seal on each cover and replace thecover seal, if necessary.

4. Remove the two filter elements. Dispose of thefilter elements properly.

5. Remove the screen for each filter element. Washthe screens in a clean, nonflammable solvent.

6. Install the screens and the new filter elements.

7. Install the covers of the hydraulic oil filters.

8. Check the oil level.

Reference: Refer to Operation and MaintenanceManual, “Hydraulic System Oil Level - Check” forthe correct procedure.

i02225249

Hydraulic System Oil Level -CheckSMCS Code: 5056-535-FLV

The hydraulic tank is located on the right side of themachine.

g01122463Illustration 190The sight glass is located on the side of the hydraulic tank.

1. Check the level of the hydraulic oil when theengine is not running.

2. Maintain the oil level above the “ADD” mark. Addoil, if necessary.

i01963546

Hydraulic System Oil Sample- ObtainSMCS Code: 5050-008; 5056-008; 7542




1. Operate the machine for a few minutes beforeobtaining the oil sample. Operate the hydrauliccontrols. This will thoroughly mix the hydraulic oilfor a more accurate sample.

142 SEBU7877-08Maintenance SectionLift Cylinder Lower Bearings - Lubricate

g01019994Illustration 191Top View of the Machine

2. Use the sampling valve in order to obtain asample of the hydraulic oil. The sampling valve islocated on the right side of the machine behindthe hydraulic tank.


i02225252

Lift Cylinder Lower Bearings -LubricateSMCS Code: 5102-086-BD

S/N: AWF1-Up

S/N: ASX1-Up


1. Wipe off the fitting before any lubricant is applied.

2. A remote grease fitting is used in order to lubricatethe bearing. Apply grease to this fitting.


Lift Cylinder Upper Bearings - Lubricate

i01936379

Lift Cylinder Upper Bearings -LubricateSMCS Code: 5102-086-BD

S/N: AZW1-Up


1. Wipe off the fitting before any lubricant is applied.

2. Apply lubricant through the fitting.

i02106227

Oil Filter - InspectSMCS Code: 1308-507; 3004-507; 3067-507;5068-507

Inspect a Used Filter for Debris

g00100013Illustration 194The element is shown with debris.

Use a filter cutter to cut the filter element open.Spread apart the pleats and inspect the element formetal and for other debris. An excessive amount ofdebris in the filter element can indicate a possiblefailure.

If metals are found in the filter element, a magnet canbe used to differentiate between ferrous metals andnonferrous metals.

Ferrous metals can indicate wear on steel parts andon cast iron parts.

Nonferrous metals can indicate wear on thealuminum parts of the engine such as main bearings,rod bearings, or turbocharger bearings.

Small amounts of debris may be found in the filterelement. This could be caused by friction and bynormal wear. Consult your Caterpillar dealer in orderto arrange for further analysis if an excessive amountof debris is found.

Using an oil filter element that is not recommendedby Caterpillar can result in severe engine damageto engine bearings, to the crankshaft, and to otherparts. This can result in larger particles in unfilteredoil. The particles could enter the lubricating systemand the particles could cause damage.

i03715663

Radiator Core - CleanSMCS Code: 1353-070-KO


1. Open side doors (1) at the rear of the machine.The fan guard on the 826G Series II LandfillCompactor can be opened by using control (2).Latches (3) allow the fan shroud to be opened foradditional cleaning.

144 SEBU7877-08Maintenance SectionReceiver Dryer (Refrigerant) - Replace


2. Swing the hydraulic oil cooler and the airconditioner condenser (if equipped) away from theradiator.


3. You can use compressed air, high pressure water,or steam to remove dust and debris from theradiator fins. However, the use of compressed airis preferred.

4. Swing the hydraulic oil cooler and the airconditioner condenser (if equipped) back into theoperating position.

5. Close the radiator grill.

Reference: Refer to Special Publication, SEBD0518,“Know Your Cooling System” for the completeprocedure for cleaning the radiator core.

i02723802

Receiver Dryer (Refrigerant) -ReplaceSMCS Code: 7322-510

Personal injury can result from contact with refrig-erant.

Contact with refrigerant can cause frost bite. Keepface and hands away to help prevent injury.

Protective goggles must always be worn when re-frigerant lines are opened, even if the gauges in-dicate the system is empty of refrigerant.

Always use precaution when a fitting is removed.Slowly loosen the fitting. If the system is still un-der pressure, release it slowly in a well ventilatedarea.

Personal injury or death can result from inhalingrefrigerant through a lit cigarette.

Inhaling air conditioner refrigerant gas through alit cigarette or other smoking method or inhalingfumes released from a flame contacting air con-ditioner refrigerant gas, can cause bodily harm ordeath.

Do not smoke when servicing air conditioners orwherever refrigerant gas may be present.

Use a certified recovery and recycling cart to prop-erly remove the refrigerant from the air condition-ing system.

NOTICEIf the refrigerant system has been open to the outsideair (without being plugged) for more than 30 minutes,the receiver-dryer must be replaced. Moisture will en-ter an open refrigerant system and cause corrosionwhich will lead to component failure.

Refer to Service Manual, SENR5664, “AirConditioning and Heating System with R-134aRefrigerant for All Caterpillar Machines” for the properprocedure to change the receiver-dryer assemblyand for the procedure to reclaim the refrigerant gas.


Rollover Protective Structure (ROPS) - Inspect

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Rollover Protective Structure(ROPS) - InspectSMCS Code: 7323-040; 7325-040


Inspect the ROPS for bolts that are loose or damaged.Use original equipment parts only to replace boltsthat are damaged or missing. Tighten the fourcab mounting bolts to a torque of 850 ± 100 N·m(629 ± 74 lb ft).

Note: Apply oil to all bolt threads before installation.Failure to apply oil can result in improper bolt torque.

Do not repair the ROPS by welding reinforcementplates to the ROPS. Consult your Caterpillar dealerfor repair of cracks in any welds, in any castings, orin any metal section of the ROPS.

i02429589

Seat Belt - InspectSMCS Code: 7327-040

Always check the condition of the seat belt and thecondition of the seat belt mounting hardware beforeyou operate the machine. Replace any parts that aredamaged or worn before you operate the machine.

g00932801Illustration 199Typical example

Check the seat belt mounting hardware (1) for wearor for damage. Replace any mounting hardware thatis worn or damaged. Make sure that the mountingbolts are tight.

Check buckle (2) for wear or for damage. If the buckleis worn or damaged, replace the seat belt.

Inspect the seat belt (3) for webbing that is worn orfrayed. Replace the seat belt if the seat belt is wornor frayed.

Consult your Caterpillar dealer for the replacement ofthe seat belt and the mounting hardware.

Note:Within three years of the date of installation orwithin five years of the date of manufacture, replacethe seat belt. Replace the seat belt at the date whichoccurs first. A date label for determining the age ofthe seat belt is attached to the seat belt, the seat beltbuckle, and the seat belt retractor.

If your machine is equipped with a seat beltextension, also perform this inspection procedure forthe seat belt extension.

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Seat Belt - ReplaceSMCS Code: 7327-510

Within three years of the date of installation or withinfive years of the date of manufacture, replace theseat belt . Replace the seat belt at the date whichoccurs first. A date label for determining the age ofthe seat belt is attached to the seat belt, the seat beltbuckle, and the seat belt retractor.

146 SEBU7877-08Maintenance SectionService Brake Wear Indicator - Check


(1) Date of installation (retractor)(2) Date of installation (buckle)(3) Date of manufacture (tag) (fully extended web)(4) Date of manufacture (underside) (buckle)

Consult your Caterpillar dealer for the replacement ofthe seat belt and the mounting hardware.

If your machine is equipped with a seat beltextension, also perform this replacement procedurefor the seat belt extension.

i02301074

Service Brake Wear Indicator -CheckSMCS Code: 4255-535-IND

Reference: For brake disc wear information, referto Testing and Adjusting, RENR8696, “824H WheelTractor, 825H Soil Compactor, and 826H LandfillCompactor Braking System”.

i03392740

Steering Column Spline(Command Control Steering) -LubricateSMCS Code: 4310-086-SN; 4338-086-SN

Position the steering wheel in the straight aheadposition. Install the steering frame lock.

Note: The steering shaft must be removed in order tolubricate the shaft.

Lubricating the Steering Shaft


1. Remove nut (1) and the bolt from the lower end ofsteering shaft assembly (2).


2. Remove clamp bolt (5) at the upper end of steeringshaft assembly (2). Remove lever (4) and steeringshaft assembly (2) as a unit from the shaft key.

Note: Wipe off the fittings before any lubricant isapplied.


3. Apply 1P-0808 Multipurpose Grease through twofittings (6) on the U-joints.


Steering Cylinder Bearings - Lubricate

Note: Make sure that steering shaft assembly (2) isfully collapsed when you lubricate the slip joint. Ifsteering shaft assembly (2) is not fully collapsed, theslip joint may be overgreased. This could cause stiffsteering, damage to internal components, difficultyin the installation of the shaft assembly, and dragbetween the steering shaft and the plastic shield.

4. Apply 5P-0960 Molybdenum Grease through onefitting (7) for the slip joint until lubricant escapesfrom vent hole (8).


5. Install lever (4) and steering shaft assembly (2) asa unit on the shaft key. Install clamp bolt (5).

Note: Make sure that gap (A) remains between thelever and the mounting plate. Failure to maintain gap(A) during installation will cause inconsistent steeringresponse.

6. The bottom yoke of steering shaft assembly (2)and the shaft of pilot valve (3) must be centeredin the straight ahead position. Install the bolt andnut (1). Tighten the bolt to a torque of 55 ± 10 N·m(41 ± 7 lb ft).

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Steering Cylinder Bearings -LubricateSMCS Code: 4303-086-BD


Wipe all fittings before lubrication.

Two remote fittings (1) and (2) are used in order tolubricate the head end of the steering cylinders. Theremote fittings are located at the right rear of themachine in the access panel.

The rod end of the steering cylinders are lubricated bystandard fittings (3) that are located on the cylinders.

There are a total of four fittings.

148 SEBU7877-08Maintenance SectionTire Inflation - Check

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Tire Inflation - CheckSMCS Code: 4203-535-AI

S/N: ASX1-Up


Always obtain proper tire inflation pressures andmaintenance recommendations for the tires on yourmachine from your tire supplier. Measure the tirepressure on each tire.

Inflate the tires with nitrogen , if necessary.

Reference: Refer to the “Tire Inflation Information”section of the Operation and Maintenance Manualfor more information.

i02196415

Transmission Oil - ChangeSMCS Code: 3030-044




1. Operate the machine for a few minutes in order towarm the transmission oil.

2. Park the machine on a level surface. Lowerthe attachment to the ground and apply slightdownward pressure. Engage the parking brakeand stop the engine.


Note: Remove the transmission guard from thebottom of the machine in order to access themagnetic screen assembly.

3. Remove the transmission oil drain plug (2).Allow the transmission oil to drain into a suitablecontainer. Clean the drain plug and install thedrain plug.

4. Change the transmission oil filter.

Reference: Refer to Operation and MaintenanceManual, “Transmission Oil Filter - Replace” for thecorrect procedure.

5. Remove the bolts and the cover from the front leftside of the transmission case.

6. Remove magnetic screen tube assembly (3) andsuction screen (4) from the housing. Removethree magnets from the magnetic screen tubeassembly.

7. Wash the magnetic screen tube assembly and thesuction screen in a clean, nonflammable solvent.

NOTICEDo not drop or rap the magnets against any hard ob-jects. Replace any damaged magnets.

8. Use a cloth, a stiff bristle brush or pressure air toclean the magnets.


Transmission Oil Filter - Replace

9. Clean the cover and inspect the cover seal.Replace the seal if the seal is damaged.

10. Install three magnets on magnetic screen tubeassembly (3). Insert suction screen(4) andmagnetic screen tube assembly (3) in the housing.

11. Install the cover and four bolts.


12.Remove transmission oil filler cap (1) on the leftside of the machine. Fill the transmission with oilthrough the transmission oil filler tube.

Note: Landfill Compactors are equipped with guardsthat protect the filler tube and the sight glass. Thefiller tube is accessed through cap (5). The sight glasscan be viewed by lifting the small access door (6).

Reference: Refer to Operation and MaintenanceManual, “Capacities (Refill)”.

13. Clean the filler cap and install the filler cap.


14.Remove the transmission breather (8) from thetop of the transmission. Wash the transmissionbreather in a clean, nonflammable solvent. Allowthe transmission breather to dry. Then, install thetransmission breather.

15.Start the engine and run the engine at low idle.Apply the service brake. Slowly operate thetransmission controls in order to circulate the oil.

16.Move the transmission control to the NEUTRALposition. Engage the parking brake and stop theengine. Inspect the transmission for leaks.

17.Check the transmission oil level.

Reference: Refer to Operation and MaintenanceManual, “Transmission Oil Level - Check”.

i03040704

Transmission Oil Filter -ReplaceSMCS Code: 3004-510; 3067-510


Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.


1. Operate the machine in order to warm the oil.

2. Park the machine on level ground. Lower theattachment to the ground and apply slightdownward pressure. Engage the parking brakeand stop the engine.

150 SEBU7877-08Maintenance SectionTransmission Oil Level - Check


3. The transmission oil filter is located on the rightside of the machine. Open the small access door.

4. Remove the five bolts (1) and remove the cover(2).

5. Remove the used filter element. Be sure todispose of the used filter properly.

6. Install a new filter element and replace the cover.

7. Install the cover and the five bolts.

8. Close the access door.

9. Check the transmission oil level.

Reference: Refer to Operation and MaintenanceManual, “Transmission Oil Level - Check” for thecorrect procedure.

i02225934

Transmission Oil Level - CheckSMCS Code: 3030-535-FLV


The sight gauge for the transmission oil is located onthe left side of the machine.

When the engine is off and the transmission oil iscold, maintain the transmission oil level to “FULL”mark (1). When the engine is running at low idleand the transmission oil is warm, maintain thetransmission oil level between “FULL” mark (1) and“LOW” mark (2). Add oil, if necessary.



Transmission Oil Sample - Obtain

Landfill Compactors are equipped with additionalguards. Move the lever (4) and raise the access door(3) into the raised position, as shown. This will allowyou to view the sight glass.

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Transmission Oil Sample -ObtainSMCS Code: 3080-008; 7542




1. Operate the machine for a few minutes beforeobtaining the oil sample. This will thoroughly mixthe transmission oil for a more accurate sample.


2. Open the small access door. The transmission oilfilter is located on the right side of the machine.

3. Use the sampling valve in order to obtain a sampleof the transmission oil.


i02377574

Turbocharger - InspectSMCS Code: 1052-040

If the turbocharger fails during engine operation,severe damage to the turbocharger compressorwheel and to the entire engine can result.

Turbocharger bearing failures can cause largequantities of oil to enter the intake system and theexhaust system. Loss of engine oil can result inserious engine damage.

Do not continue to operate the engine when aturbocharger bearing failure is accompanied bya significant loss of engine performance. Enginesmoke and speeding up of the engine with no loadare characteristics of a loss of engine performance.

Reference: For additional information aboutinspecting the turbocharger, refer to SystemOperation, SENR9832, “C15 and C16 Engines ForCaterpillar Built Machines ”, “Air and Inlet ExhaustSystem”.

Reference: Refer to Disassembly and Assembly,RENR8686, “826H Landfill Compactor, 825HSoil Compactor and 824H Wheel Dozer EngineSupplement” for additional information about theturbocharger.

152 SEBU7877-08Maintenance SectionWindow Washer Reservoir - Fill

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Window Washer Reservoir -FillSMCS Code: 7306-544


The window washer reservoir is located on the leftside of the machine on the operator platform. Fill thewindow washer reservoir through the filler opening(1).

i01460440

Window Wiper -Inspect/ReplaceSMCS Code: 7305-040; 7305-510


Inspect the condition of the wiper blades. Replacethe wiper blades if the wiper blades are worn ordamaged. If the wiper blades streak the window,replace the wiper blades.

i00037755

Windows - CleanSMCS Code: 7310-070


Use commercially available window cleaningsolutions in order to clean the windows. Clean theoutside windows from the ground unless handholdsare available.

Documents

SEBU7877-08 M.pdf