LiteratureInformation
Thismanualshouldbestoredintheoperator'scompartmentintheliteratureholderorseatback literaturestoragearea.
Thismanualcontainssafetyinformation,operationinstructions,transportationinformation, lubricationinformation,andmaintenanceinformation.
Somephotographsorillustrationsinthispublicationshowdetailsorattachmentsthatcanbedifferent fromyourmachine.Guardsandcoversmighthavebeenremovedforillustrativepurposes.
Continuingimprovementandadvancementofproductdesignmighthavecausedchangestoyour machinewhicharenotincludedinthispublication.Read,study,andkeepthismanualwiththe machine.
Wheneveraquestionarisesregardingyourmachine,orthispublication,pleaseconsultyourCat dealerforthelatestavailableinformation.
Safety
Thesafetysectionlistsbasicsafetyprecautions.Inaddition,thissectionidentifiesthetextand locationsofwarningsignsandlabelsusedonthemachine.
Readandunderstandthebasicprecautionslistedinthesafetysectionbeforeoperatingorperforming lubrication,maintenance,andrepaironthismachine.
Operation
Theoperationsectionisareferenceforthenewoperatorandarefresherfortheexperiencedoperator. Thissectionincludesadiscussionofgauges,switches,machinecontrols,attachmentcontrols, transportation,andtowinginformation.
Photographsandillustrationsguidetheoperatorthroughcorrectproceduresofchecking,starting, operating,andstoppingthemachine.
Operatingtechniquesoutlinedinthispublicationarebasic.Skillandtechniquesdevelopasthe operatorgainsknowledgeofthemachineanditscapabilities.
Maintenance
Themaintenancesectionisaguidetoequipmentcare.TheMaintenanceIntervalSchedule(MIS)lists theitemstobemaintainedataspecificserviceinterval.Itemswithoutspecificintervalsarelisted underthe"WhenRequired"serviceinterval.TheMaintenanceIntervalScheduleliststhepage numberforthestep-by-stepinstructionsrequiredtoaccomplishthescheduledmaintenance.Usethe MaintenanceIntervalScheduleasanindexor"onesafesource"forallmaintenanceprocedures.
MaintenanceIntervals
Usetheservicehourmetertodetermineservicingintervals.Calendarintervalsshown(daily,weekly, monthly,etc.)canbeusedinsteadofservicehourmeterintervalsifthecalendarintervalsprovide moreconvenientservicingschedulesandapproximatetheindicatedservicehourmeterreading. Performtherecommendedserviceattheintervalthatoccursfirst.
Undersevere,dusty,orwetoperatingconditions,morefrequentlubricationthanisspecifiedinthe maintenanceintervalschartmightbenecessary.
Performserviceonitemsatmultiplesoftheoriginalrequirement.Forexample,atevery500service hoursor3months,alsoservicethoseitemslistedunderevery250servicehoursormonthlyandevery 10servicehoursordaily.
CertifiedEngineMaintenance
Propermaintenanceandrepairareessentialtokeeptheengineandmachinesystemsoperating correctly.Astheheavy-dutyoff-roaddieselengineowner,youareresponsiblefortheperformanceof therequiredmaintenancelistedintheOwnerManual,OperationandMaintenanceManual,and ServiceManual.
Itisprohibitedforanypersonengagedinthebusinessofrepairing,servicing,selling,leasing,or tradingenginesormachinestoremove,alter,ortorenderinoperative,anyemission-relateddeviceor elementofdesigninstalledonorinanengineormachinethatisincompliancewithallapplicable regulationsoftheintendedcountrytowhichithasbeenshipped.Certainelementsofthemachineand enginesuchastheexhaustsystem,fuelsystem,electricalsystem,intakeairsystem,andcooling systemmaybeemission-relatedandshouldnotbealteredunlessapprovedbyCaterpillar.
MachineCapacity
Additionalattachmentsormodificationsmayexceedmachinedesigncapacitywhichcanadversely affectperformancecharacteristics.Includedwouldbestabilityandsystemcertificationssuchas brakes,steering,androlloverprotectivestructures(ROPS).ContactyourCatdealerforfurther information.
ProductIdentificationNumber
EffectiveFirstQuarter2001theProductIdentificationNumber(PIN)haschangedfrom8to17 characters.Toprovideuniformequipmentidentification,constructionequipmentmanufacturersare movingtocomplywiththelatestversionoftheproductidentificationnumberingstandard.Non-road machinePINsaredefinedbyISO10261.ThenewPINformatwillapplytoallmachinesand generatorsets.ThePINplatesandframemarkingwilldisplaythe17characterPIN.Thenewformat willlooklikethefollowing:
This is the sample of the manual if you need complete manual Click Here to download
Illustration1g03891925
Where:
1.WorldManufacturingCode(characters1-3)
2.MachineDescriptor(characters4-8)
3.CheckCharacter(character9)
4.MachineIndicatorSection(MIS)orProductSequenceNumber(characters10-17).Thesewere previouslyreferredtoastheSerialNumber.
MachinesandgeneratorsetsproducedbeforeFirstQuarter2001willmaintaintheir8characterPIN format.
Componentssuchasengines,transmissions,axles,andworktoolswillcontinuetousean8character SerialNumber(S/N).
Copyright1993-2024CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
FriJan523:17:27UTC+05302024
Product:SOILCOMPACTOR
Model:825HSOILCOMPACTORAZW
Configuration:825HSoilCompactorAZW00001-UP(MACHINE)POWEREDBYC15Engine
OperationandMaintenanceManual
824HWheelDozer,825HSoilCompactorand826HLandfillCompactor MediaNumber-SEBU7877-12PublicationDate-01/10/2013DateUpdated-31/10/2013
EngineAirFilterServiceIndicator-Inspect
SMCS-7452-040
Someenginesareequippedwithadifferentialgaugeforinletairpressure.Thedifferentialgauge forinletairpressuredisplaysthedifferenceinthepressurethatismeasuredbeforetheaircleaner elementandthepressurethatismeasuredaftertheaircleanerelement.Astheaircleanerelement becomesdirty,thepressuredifferentialrises.
Theairfilterserviceindicatorislocatedneartheairfilterhousing.
1.Observetheperformanceoftheairfilterserviceindicator.Theairfilterelementshouldbe cleanedortheairfilterelementshouldbereplacedwhenoneofthefollowingconditions occur:
i01968230
Theyellowdiaphragmenterstheredzone.
Theredpistonlocksinthevisibleposition.
2.Ifanycomponentdamageispresent,replacetheserviceindicator.
3.Ifairleaksarepresent,replacetheserviceindicator.
Note:Whenanewserviceindicatorisinstalled,excessiveforcemaycrackthetopoftheservice indicator.Tightentheserviceindicatortoatorqueof2N·m(18lbin).
Copyright1993-2024CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
FriJan523:27:47UTC+05302024
Product:SOILCOMPACTOR
Model:825HSOILCOMPACTORAZW
Configuration:825HSoilCompactorAZW00001-UP(MACHINE)POWEREDBYC15Engine
OperationandMaintenanceManual
824HWheelDozer,825HSoilCompactorand826HLandfillCompactor MediaNumber-SEBU7877-12PublicationDate-01/10/2013DateUpdated-31/10/2013
EngineAirFilterServiceIndicator-Inspect/Replace
SMCS-7452-040;7452-510
Someenginesareequippedwithadifferentialgaugeforinletairpressure.Thedifferentialgauge forinletairpressuredisplaysthedifferenceinthepressurethatismeasuredbeforetheaircleaner elementandthepressurethatismeasuredaftertheaircleanerelement.Astheaircleanerelement becomesdirty,thepressuredifferentialrises. Illustration1g01001638
Theairfilterserviceindicatorislocatedneartheairfilterhousing.
i01968211
1.Observetheperformanceoftheairfilterserviceindicator.Theairfilterelementshouldbe cleanedortheairfilterelementshouldbereplacedwhenoneofthefollowingconditions occur:
Theyellowdiaphragmenterstheredzone. Theredpistonlocksinthevisibleposition.
2.Ifanycomponentdamageispresent,replacetheserviceindicator.
3.Ifairleaksarepresent,replacetheserviceindicator.
Test
1.Checkforeaseofresetting.Theserviceindicatorshouldresetinlessthanthreepushes.
2.Checkthemovementoftheyellowcorewhentheengineisacceleratedtotheenginerated speed.Theyellowcoreshouldlatchapproximatelyatthegreatestvacuumthatisattained.
Iftheserviceindicatordoesnotreseteasily,oriftheyellowcoredoesnotlatchatthegreatest vacuum,theserviceindicatorshouldbereplaced.Ifthenewserviceindicatorwillnotreset,the holefortheserviceindicatormaybeplugged.
Replace
Replacetheserviceindicatorifthefollowingconditionsexist:
•Themachineisusedinaseverelydustyenvironment.
•Theengineisoverhauled.
•Majorcomponentsarereplaced.
Note:Replacetheserviceindicatorannuallyregardlessoftheoperatingconditions.
Note:Whenanewserviceindicatorisinstalled,excessiveforcemaycrackthetopoftheservice indicator.Tightentheserviceindicatortoatorqueof2N·m(18lbin).
Copyright1993-2024CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
FriJan523:27:34UTC+05302024
Product:SOILCOMPACTOR
Model:825HSOILCOMPACTORAZW
Configuration:825HSoilCompactorAZW00001-UP(MACHINE)POWEREDBYC15Engine
OperationandMaintenanceManual
824HWheelDozer,825HSoilCompactorand826HLandfillCompactor MediaNumber-SEBU7877-12PublicationDate-01/10/2013DateUpdated-31/10/2013
EngineAirPrecleaner-Clean
SMCS-1055-070
Illustration1g01122446
1.Loosentheboltonclamp(2).Removehoodassembly(1).
2.Loosenthehoseclampandremovethehosefrombodyassembly(3).
3.Loosenclamp(5).Removebodyassembly(3).
4.Cleanallofthepartswithcompressedairorwashallofthepartsinwarmwater.Allowall ofthepartstodry.
5.Installbodyassembly(3).Tightentheboltonclamp(5)toatorqueof24±7N·m(18±5lb ft).
i02225199
6.Installthehoseandtightentheclamp.
7.Installhoodassembly(1).Tightentheboltonclamp(2).
Copyright1993-2024CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
FriJan523:27:27UTC+05302024
Product:SOILCOMPACTOR
Model:825HSOILCOMPACTORAZW
Configuration:825HSoilCompactorAZW00001-UP(MACHINE)POWEREDBYC15Engine
OperationandMaintenanceManual
824HWheelDozer,825HSoilCompactorand826HLandfillCompactor
MediaNumber-SEBU7877-12PublicationDate-01/10/2013DateUpdated-31/10/2013
EngineAirFilterSecondaryElement-Replace
SMCS-1054-510-SE
NOTICE
Alwaysreplacethesecondaryfilterelement.Neverattempttoreuseit bycleaning.
Thesecondaryfilterelementshouldbereplacedatthetimethe primaryelementisservicedforthethirdtime.
Thesecondaryfilterelementshouldalsobereplacediftheyellow pistoninthefilterelementindicatorenterstheredzoneafter installationofacleanprimaryelement,oriftheexhaustsmokeisstill black.
i02225193
Illustration1g01122326
1.Opentheenginehood.Accesstheaircleanerfromtheleftsideofthemachine.
Illustration2g00281967
2.Loosentheclipswhichholdaircleanerhousingcover(1).Removetheaircleanerhousing cover.
3.Removeprimaryfilterelement(2)fromtheaircleanerhousing.
Reference:Fortheproperprocedure,refertoOperationandMaintenanceManual,"EngineAir FilterPrimaryElement-Clean/Replace".
Illustration3g00864077
4.Removethesecondaryfilterelement.
Illustration4g00864079
5.Covertheairinletopening.Cleantheinsideoftheaircleanerhousing.
6.Inspectthegasketbetweentheairinletpipeandtheaircleanerhousing.Replacethegasketif thegasketisdamaged.
7.Uncovertheairinletopening.Installanewsecondaryfilterelement.
8.Installtheprimaryfilterelementandtheaircleanerhousingcover.Fastentheclipsinorderto securetheaircleanerhousingcover.
9.Closetheenginehood.
FriJan523:27:24UTC+05302024
Product:SOILCOMPACTOR
Model:825HSOILCOMPACTORAZW
Configuration:825HSoilCompactorAZW00001-UP(MACHINE)POWEREDBYC15Engine
OperationandMaintenanceManual
824HWheelDozer,825HSoilCompactorand826HLandfillCompactor MediaNumber-SEBU7877-12PublicationDate-01/10/2013DateUpdated-31/10/2013
EngineCompartment-Inspect/Clean
SMCS-1000-040-CPA;1000-070-CPA
Personalinjuryordeathcanresultfromfires. Inspectthemachineperiodicallyforaccumulationofdebrisandpaper. Removetheaccumulationtopreventengineoverheatingandfires.
Keeptheequipmentfreefromforeignmaterial.Removedebris,oil,tools,andotheritemsfrom thefollowingareas:
•Decks
•Walkways
•Steps
•Enginecompartment
•Bellyguards
•Radiatorcores
•Filters
•Exhaustcomponents
•Otherareas
i02915110
Anyareasthatactaspotentialheatsourcesmustbeinspected.Ifdebrisisfound,thearea mustbecleaned.
Note:Whenyouinspectthemachine,alwayslookforburningdebrisorsmoke.
Allfuels,mostlubricants,andsomecoolantmixturesareflammable.Flammablefluidsthatare leakingorspilledontohotsurfacesorontoelectricalcomponentscancauseafire.Firemaycause personalinjuryandpropertydamage.Removeallflammablematerialssuchasfuel,oil,anddebris fromthemachine.Donotallowanyflammablematerialstoaccumulateonthemachine.
Note:Flammableitemsmaycomefromthefollowingsources:leakinghoses,tubesorgaskets, fillingcontainers,soakedragsandcontaminateddebris.
Inordertoavoidafire,cleanoutanydebrisandpaperfromthefollowingareas:backofthe engine,frontoftheengine,topoftheengine,sidesoftheengineandbellyguards.
Illustration2g01308085
Inspecttheenginecompartmentfordebriswhenyouenterthemachineandwhenyouexitthe machine.Openalloftheenginecompartmentdoors.Inspecttheenginecompartmentfordebris andleaks.Inordertoreducetheriskofafire,cleanoutanydebrisandpaperfromtheabove areas.Usepressurizedairfromanairnozzleinordertoblowouttheenginecompartment.
Illustration3g01308091
Removeanytrashbuildupanddebris.Ifnecessary,lowerthebellyguardsinordertofullyclean theenginecompartment.Besuretocleananydebrisorcutanydebristhatmaybeintheaxleor axlewraparea.Besurethatthewheelextensionsarenotrubbingontheframe.Ifthereisdebris thatispackedinthisarea,removethedebris.Rubbingandpackeddebrismaycauseexcessive heatorsparks.
Ensurethatallnecessaryrepairsareperformedbeforeyouoperatethemachine.
Checkallelectricalwiresandbatterycablesdaily.Repairanywiresthatarelooseorfrayedbefore youoperatethemachine.Cleanallelectricalconnectionsandtightenallelectricalconnections.
Makesurethatafireextinguisherisonthemachine.Makesurethatyouarefamiliarwiththe operationofthefireextinguisher.Inspectthefireextinguisherandservicethefireextinguisher. Obeytherecommendationsontheinstructionplate.
Exhaustshields(ifequipped)protecthotexhaustcomponentsfromoilsprayorfuelsprayincase ofabreakinaline,inahose,orinaseal.Exhaustshieldsmustbeinstalledcorrectly.
Copyright1993-2024CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
FriJan523:27:15UTC+05302024
Product:SOILCOMPACTOR
Model:825HSOILCOMPACTORAZW
Configuration:825HSoilCompactorAZW00001-UP(MACHINE)POWEREDBYC15Engine
OperationandMaintenanceManual
824HWheelDozer,825HSoilCompactorand826HLandfillCompactor MediaNumber-SEBU7877-12PublicationDate-01/10/2013DateUpdated-31/10/2013
EngineOil(HighSpeed)andOilFilter-Change-If Equipped
SMCS-1318-510-HZ
SelectionoftheOilChangeInterval
NOTICE
A500hourengineoilchangeintervalisavailable,providedthatthe operatingconditionsandrecommendedmultigradeoiltypesaremet. Whentheserequirementsarenotmet,shortentheoilchangeinterval to250hours,oruseanS·O·Soilsamplingandanalysisprogramto determineanacceptableoilchangeinterval.
Ifyouselectanintervalforoilandfilterchangethatistoolong,you maydamagetheengine. Caterpillaroilfiltersarerecommended.
RecommendedmultigradeoiltypesarelistedinTable1.Donotusesinglegradeoils.
Abnormallyharshoperatingcyclesorharshenvironmentscanshortentheservicelifeofthe engineoil.Arctictemperatures,corrosiveenvironments,orextremelydustyconditionsmay requireareductioninengineoilchangeintervalsfromtherecommendationsinTable1.
Reference:RefertoSpecialPublication,SEBU5898,"ColdWeatherRecommendations"oryour Caterpillardealerformoreinformationifthisproductwillexperienceabnormallyharshoperating cyclesorharshenvironments.
i02301059
824HWheelTractor
825HSoilCompactor
826HLandfillCompactor
EngineOilChangeInterval(1)
OperatingConditions
MultigradeOil Type
(1)Thetraditionaloilchangeintervalforenginesis250hours.Thestandardoilchangeintervalinthismachineis 500hours,iftheoperatingconditionsandrecommendedoiltypesthatarelistedinthistablearemet. Improvementsintheengineallowthisengineoilchangeinterval.Thisnewstandardintervalisnotpermittedfor othermachines.RefertotheapplicableOperationandMaintenanceManualsfortheothermachines.
(2)Normalconditionsincludethesefactors:Fuelsulfurbelow0.3%,altitudebelow1830m(6000ft)andgoodair filterandfuelfiltermaintenance.Normalconditionsdonotincludehighloadfactor,harshoperatingcycles,or harshenvironments.
(3)Highloadfactorscanshortentheservicelifeofyourengineoil.Continuousheavyloadcyclesandverylittleidle timeresultinincreasedfuelconsumptionandoilcontamination.Thesefactorsdepletetheoiladditivesmore rapidly.Iftheaveragefuelconsumptionofyour824HWheelTractor,825HSoilCompactor,or826HLandfill Compactorexceeds62.1L(16.4USgal)perhour,followthe"HighLoadFactor"recommendationsinTable1. Todetermineaveragefuelconsumption,measureaveragefuelconsumptionforaperiodof50to100hours.Ifthe applicationofthemachineischanged,theaveragefuelconsumptionmaychange.
(4)Forsulfurcontentabove0.5%,refertoOperationandMaintenanceManual,"TotalBaseNumber(TBN)and FuelSulfurLevelsforDirectInjection(DI)DieselEngines"inthe"Lubricant"sectionofthismanual.Also,you mayrefertothistopicinSpecialPublication,SEBU6250.
(5)Inordertoverifyanoilchangeintervalof500hours,referto"ProgramA"below.
(6)Use"ProgramB"belowtodetermineanappropriateinterval. AdjustmentoftheOilChangeInterval
Note:YourCaterpillardealerhasadditionalinformationontheseprograms. ProgramA
VerificationforanOilChangeIntervalof500Hours
Thisprogramconsistsofthreeoilchangeintervalsof500hours.Oilsamplingandanalysisisdone at250hoursand500hoursforeachofthethreeintervalsforatotalofsixoilsamples.The analysisincludesoilviscosityandinfrared(IR)analysisoftheoil.Ifalloftheresultsare satisfactory,the500houroilchangeintervalisacceptableforthemachineinthatapplication. RepeatProgramAifyouchangetheapplicationofthemachine.
Ifasampledoesnotpasstheoilanalysis,takeoneoftheseactions:
•Shortentheoilchangeintervalto250hours.
•ProceedtoProgramB.
•ChangetoapreferredoiltypeinTable1.
ProgramB
OptimizingOilChangeIntervals
Beginwitha250houroilchangeinterval.Theoilchangeintervalsareadjustedbyincrements. Eachintervalisadjustedanadditional50hours.Periodicoilsamplingandanalysisisdoneduring eachinterval.Theanalysisincludesoilviscosityandinfrared(IR)analysisoftheoil.Repeat ProgramBifyouchangetheapplicationofthemachine.
Ifanoilsampledoesnotpasstheanalysis,shortentheoilchangeinterval,orchangetoapreferred multigradeoiltypeinthelistingabove.
References
Reference:SpecialPublication,PEDP7035,"OptimizingOilChangeIntervals"
Reference:SpecialPublication,PEDP7036,"S·O·SFluidAnalysis"
Reference:SpecialPublication,PEHP7076,"UnderstandingtheS·O·SServicesTests"
ProcedureforChangingtheEngineOilandtheFilter
NOTICE
Caremustbetakentoensurethatfluidsarecontainedduring performanceofinspection,maintenance,testing,adjustingandrepair oftheproduct.Bepreparedtocollectthefluidwithsuitablecontainers beforeopeninganycompartmentordisassemblinganycomponent containingfluids.
RefertoSpecialPublication,NENG2500,"CaterpillarToolsandShop ProductsGuide"fortoolsandsuppliessuitabletocollectandcontain fluidsonCaterpillarproducts.
Disposeofallfluidsaccordingtolocalregulationsandmandates.
Yourmachinemaybeequippedwithahighspeedarrangementforchangingtheengineoil.The highspeedarrangementallowsservicepersonneltochangetheoilfromtheengineaccessdooron theleftsideofthemachine.Thehighspeedarrangementallowstheoiltobechangedfasterthan conventionalmethods.
1.Opentheenginehood.
Illustration1g01122818
2.Removethecapthatprotectsthemalecoupler.Connectanoilpumptothefitting.The fittingonthemachineisamalecoupler.
3.Turnontheoilpumpandwithdrawtheengineoilfromtheengineoilpan.
Illustration2g01122819
4.Useastraptypewrenchtoremovefilterelement(1).Inspectthefilter.
Reference:Formoreinformation,refertoOperationandMaintenanceManual,"OilFilterInspect".
5.Cleanthefiltermountingbasewithacleancloth.Makesurethattheusedfiltergaskethas beencompletelyremoved.
Illustration3g00101318
6.Applyathinfilmofcleanengineoiltothesealingsurfaceofthenewfilterelement.
Note:Therearerotationindexmarksoneachengineoilfilterthatarespaced90degreesor 1/4ofaturnfromeachother.Whenyoutightenengineoilfiltersusethesemarksasaguide.
7.Installtheengineoilfiltershandtightuntilthesealcontactsthefilterbase.Notetheposition oftheindexmarksonthefilterinrelationtoafixedpointonthefilterbase.
8.Tightenthefilteraccordingtotheinstructionsthatareprintedonthefilter.Usetheindex marksasaguide.
9.Connectanoilpumptothemalecouplerforthehighspeedarrangement.Fillthecrankcase withnewoil.
Reference:Formoreinformation,refertoOperationandMaintenanceManual,"Capacities (Refill)".
10.Cleantheendofthemalecoupler.Cleanthecapthatcoversthemalecouplerandinstallthe cap.
11.Starttheengineandallowtheoiltowarm.Checkthemachineforoilleaks.
12.Checktheengineoillevel.
Reference:RefertoOperationandMaintenanceManual,"EngineOilLevel-Check"for thecorrectprocedure.
13.Stoptheengine.Closetheenginehood.
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FriJan523:27:06UTC+05302024
This is the sample of the manual if you need complete manual Click Here to download
