Caterpillar 826G II 825G II 824G II Compactor Dozer Workshop Repair Service Manual PDF - MCAT824GII826GII.zip
A full workshop repair manual, complete with electrical wiring diagrams, covering the Caterpillar 826G Series II Landfill Compactor, 825G Series II Soil Compactor, and 824G Series II Wheel Dozer — packed with all the technical detail needed to service, troubleshoot, fix, and rebuild these machines the way professional technicians do.
Inside the Caterpillar 826G Series II Landfill Compactor, 825G Series II Soil Compactor, and 824G Series II Wheel Dozer workshop service repair manual, you'll find:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
RENR2372 - Troubleshooting (3176C; 3406E and 3456 Engines for 816F; 826G Series II; and 836G Landfill Compactors; 815F and 825G Series II Soil Compactors; 814F; 824G Series II; and 834G Wheel Dozers; and for the 988G Wheel Loader).pdf
RENR4373 - Disassembly and Assembly (826G Series II Landfill Compactor; 825G Series II Soil Compactor and 824G Series II Wheel Tractor Machine Systems).pdf
RENR6009 - Schematic (825G SERIES II SOIL COMPACTOR HYDRAULIC SYSTEM).pdf
RENR6025 - Disassembly and Assembly (826G Series II Landfill Compactor; 825G Series II Soil Compactor and 824G Series II Wheel Dozer Engine Supplement).pdf
RENR6026 - Specifications (824G Series II Wheel Dozer; 825G Series II Soil Compactor and 826G Series II Landfill Compactor Power Train).pdf
RENR6027 - Systems Operation (824G Series II Wheel Tractor; 825G Series II Soil Compactor and 826G Series II Landfill Compactor Power Train).pdf
RENR6028 - Testing and Adjusting (826G Series II Landfill Compactor; 825G Series II Soil Compactor and 824G Series II Wheel Dozer).pdf
RENR6028 - Troubleshootingg (826G Series II Landfill Compactor; 825G Series II Soil Compactor and 824G Series II Wheel Dozer).pdf
RENR6029 - Disassembly and Assembly (826G Series II Landfill Compactor; 825G Series II Soil Compactor and 824G Series II Wheel Dozer Power Train).pdf
RENR6030 - Specifications (824G Series II Wheel Tractor; 825G Series II Soil Compactor and 826G Series II Landfill Compactor Steering System).pdf
RENR6031 - Systems Operation (824G Series II Wheel Tractor; 825G Series II Soil Compactor and 826G Series II Landfill Compactor Steering System).pdf
RENR6032 - Testing and Adjusting (824G Series II Wheel Tractor; 825G Series II Soil Compactor and 826G Series II Landfill Compactor Steering System).pdf
RENR6033 - Specifications (824G Series II Wheel Tractor; 825G Series II Soil Compactor and 826G Series II Landfill Compactor Braking System).pdf
RENR6034 - Systems Operation (824G Series II Wheel Tractor; 825G Series II Soil Compactor and 826G Series II Landfill Compactor Braking System).pdf
RENR6035 - Testing and Adjusting (824G Series II Wheel Dozer; 825G Series II Soil Compactor and 826G Series II Landfill Compactor Braking System).pdf
RENR6036 - Specifications (824G Series II Wheel Tractor; 825G Series II Soil Compactor and 826G Series II Landfill Compactor Electrohydraulic System).pdf
RENR6037 - Systems Operation (824G Series II Wheel Dozer; 825G Series II Soil Compactor and 826G Series II Landfill Compactor Electrohydraulic System).pdf
RENR6038 - Testing and Adjusting (824G Series II Wheel Dozer; 825G Series II Soil Compactor and 826G Series II Landfill Compactor Electrohydraulic System).pdf
RENR6038 - Troubleshooting (824G Series II Wheel Dozer; 825G Series II Soil Compactor and 826G Series II Landfill Compactor Electrohydraulic System).pdf
PRODUCT DETAILS:
Total Pages: 2,502 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
RENR2372 - Troubleshooting (3176C; 3406E and 3456 Engines for 816F; 826G Series II; and 836G Landfill Compactors; 815F and 825G Series II Soil Compactors; 814F; 824G Series II; and 834G Wheel Dozers; and for the 988G Wheel Loader)....1
System Overview....6
Electronic Service Tools....8
Electronic Display Module - If Equipped....18
Replacing the ECM....19
Self-Diagnostics....22
Sensors and Electrical Connectors....24
Engine Wiring Information....29
Programming Parameters....32
Factory Passwords....33
Factory Passwords Worksheet....34
Flash Programming....35
System Configuration Parameters....37
Alternator - Noisy Operation....42
Can Not Reach Top Engine RPM....43
Coolant in Engine Oil....46
Coolant Temperature Is Too High....49
ECM Will Not Accept Factory Passwords....53
ECM Will Not Communicate with Other Systems or Display Modules....55
Electronic Service Tool Will Not Communicate with ECM....56
Elevated Idle....60
Engine Cranks but Will Not Start....62
Engine Has Early Wear....65
Engine Misfires; Runs Rough or Is Unstable....68
Engine Oil in Cooling System....72
Engine Oil Temperature Is Too High....74
Engine Stalls at Low RPM....76
Engine Vibration....79
Engine Will Not Crank....81
Excessive Black Smoke....85
Excessive Engine Oil Consumption....89
Excessive Fuel Consumption....91
Excessive Valve Lash....94
Excessive White Smoke....96
Exhaust Temperature Is Too High....100
Fuel in Cooling System....102
Fuel Dilution of Engine Oil....104
Intermittent Engine Shutdown....106
Intermittent Low Power or Power Cutout....109
Low Engine Oil Pressure....113
Low Power_Poor or No Response to Throttle....116
Mechanical Noise (Knock) in Engine....120
Noise Coming from Cylinder....123
Poor Acceleration or Response....126
Valve Rotator or Spring Lock Is Free....129
Diagnostic Codes....130
CID 0001 FMI 11 Cylinder #1 Injector fault....133
CID 0002 FMI 11 Cylinder #2 Injector fault....134
CID 0003 FMI 11 Cylinder #3 Injector fault....135
CID 0004 FMI 11 Cylinder #4 Injector fault....136
CID 0005 FMI 11 Cylinder #5 Injector fault....137
CID 0006 FMI 11 Cylinder #6 Injector fault....138
CID 0041 FMI 03 8 Volt DC Supply short to +batt....139
CID 0041 FMI 04 8 Volt DC Supply short to ground....140
CID 0091 FMI 08 Throttle Position signal abnormal....141
CID 0094 FMI 03 Fuel Pressure open_short to +batt....142
CID 0094 FMI 04 Fuel Pressure short to ground....143
CID 0100 FMI 03 Engine Oil Pressure open_short to +batt....144
CID 0100 FMI 04 Engine Oil Pressure short to ground....145
CID 0110 FMI 03 Engine Coolant Temperature open_short to +batt....146
CID 0110 FMI 04 Engine Coolant Temperature short to ground....147
CID 0168 FMI 00 System Voltage High....148
CID 0168 FMI 01 System Voltage Low....149
CID 0168 FMI 02 System Voltage intermittent_erratic....150
CID 0172 FMI 03 Intake Manifold Air Temp open_short to +batt....151
CID 0172 FMI 04 Intake Manifold Air Temp short to ground....152
CID 0174 FMI 03 Fuel Temperature open_short to +batt....153
CID 0174 FMI 04 Fuel Temperature short to ground....154
CID 0190 FMI 02 Loss of Engine Speed Signal....155
CID 0190 FMI 11 Engine Speed Sensor mechanical failure....156
CID 0248 FMI 09 Cat Data Link not communicating....157
CID 0253 FMI 02 Personality Module mismatch....158
CID 0254 FMI 12 Electronic Control Module Error....160
CID 0261 FMI 13 Engine Timing Calibration required....161
CID 0262 FMI 03 5 Volt Sensor DC Power Supply short to +batt....162
CID 0262 FMI 04 5 Volt Sensor DC Power Supply short to ground....163
CID 0267 FMI 02 Incorrect Engine Shutdown Switch inputs....164
CID 0268 FMI 02 Check Programmable Parameters....165
CID 0273 FMI 03 Turbo Outlet Pressure open_short to +batt....166
CID 0273 FMI 04 Turbo Outlet Pressure short to ground....167
CID 0274 FMI 03 Atmospheric Pressure open_short to +batt....168
CID 0274 FMI 04 Atmospheric Pressure short to ground....169
CID 0291 FMI 05 Engine Cooling Fan Solenoid open circuit....170
CID 0291 FMI 06 Engine Cooling Fan Solenoid short to ground....171
CID 0296 FMI 09 Unable to communicate with Transmission ECM....172
CID 0320 FMI 02 Speed_Timing Sensor Loss of Signal....173
CID 0320 FMI 11 Speed_Timing Sensor mechanical failure....174
CID 0342 FMI 02 Loss of Secondary Engine Speed signal....175
CID 0342 FMI 11 Secondary Engine Speed Sensor mechanical failure....176
CID 0485 FMI 05 Engine Fan Rev Solenoid open circuit....177
CID 0485 FMI 06 Engine Fan Rev Solenoid short to ground....178
CID 0486 FMI 02 Engine Fan Reverse Switch inputs incorrect....179
CID 0545 FMI 05 Ether Start Relay open_short to +batt....180
CID 0545 FMI 06 Ether Start Relay short to ground....181
CID 0562 FMI 09 Unable to Communicate with Cat Monitoring System....182
CID 1582 FMI 03 Trans Lube Oil Temp Sensor open_short to +batt....183
CID 1582 FMI 04 Trans Lube Oil Temp Sensor short to ground....184
CID 1589 FMI 03 Turbo Inlet Air Pressure Sensor open_shrt to +bat....185
CID 1589 FMI 04 Turbo Inlet Air Pressure Sensor short to ground....186
Event Codes....187
E015 High Engine Coolant Temperature Derate....190
E017 High Engine Coolant Temperature Warning....192
E025 High Inlet Air Temperature Derate....194
E027 High Inlet Air Temperature Warning....196
E039 Low Engine Oil Pressure Derate....198
E053 Low Fuel Pressure Warning....206
E096 High Fuel Pressure....212
E100 Low Engine Oil Pressure Warning....218
E190 Engine Overspeed Warning....225
E265 User Defined Shutdown....226
E272 Inlet Air Restriction Warning....227
5 Volt Engine Pressure Sensor Supply Circuit - Test....231
Cat Data Link Circuit - Test....238
Compression Brake Solenoid Circuit - Test....242
Digital Sensor Supply Circuit - Test....251
Electrical Connectors - Inspect....256
Electrical Power Supply Circuit - Test....266
Engine Fan Control Solenoid Circuit - Test....272
Engine Fan Reversing Solenoid Circuit - Test....276
Engine Pressure Sensor Open or Short Circuit - Test....282
Engine Shutdown Switch Circuit - Test....291
Engine Speed_Timing Sensor Circuit - Test....296
Engine Temperature Sensor Open or Short Circuit - Test....307
Ether Injection System - Test....315
Injector Solenoid Circuit - Test....327
Throttle Position Sensor Circuit - Test....343
Engine Speed_Timing Sensor - Calibrate....349
Injector Code - Calibrate....357
RENR4373 - Disassembly and Assembly (826G Series II Landfill Compactor; 825G Series II Soil Compactor and 824G Series II Wheel Tractor Machine Systems)....359
Steering Frame Lock - Separate and Connect....362
System Pressure - Release....366
Hydraulic Tank - Remove....368
Hydraulic Tank - Disassemble....372
Hydraulic Tank - Assemble....379
Hydraulic Tank - Install....386
Piston Pump (Steering) - Remove....389
Piston Pump (Steering) - Disassemble....392
Piston Pump (Steering) - Assemble....400
Piston Pump (Steering) - Install....409
Steering Shaft - Remove and Install....412
Steering Wheel - Remove and Install....418
Pilot Valve (Steering) - Remove....423
Pilot Valve (Steering) - Disassemble....425
Pilot Valve (Steering) - Assemble....432
Pilot Valve (Steering) - Install....438
Steering Control Valve - Remove....440
Steering Control Valve - Disassemble....442
Steering Control Valve - Assemble....448
Steering Control Valve - Install....453
Steering Cylinder - Remove....455
Steering Cylinder - Install....458
Brake Accumulator - Remove and Install....460
Accumulator Charging Valve (Brake) - Remove and Install....463
Brake Control Valve (Service) - Remove and Install....467
Brake Control Valve (Parking) - Remove and Install....469
Parking Brake Actuator - Remove and Install....473
Parking Brake - Remove....478
Parking Brake - Install....482
Gear Pump (Pilot and Braking) - Remove....486
Gear Pump (Pilot and Braking) - Install....489
Vane Pump (Implement) - Remove....491
Vane Pump (Implement) - Disassemble....494
Vane Pump (Implement) - Assemble....504
Vane Pump (Implement) - Install....513
Piston Pump (Hydraulic Fan) - Remove....516
Piston Pump (Hydraulic Fan) - Disassemble....518
Piston Pump (Hydraulic Fan) - Assemble....532
Piston Pump (Hydraulic Fan) - Install....545
Fan and Piston Motor (Hydraulic Fan) - Remove....546
Piston Motor (Hydraulic Fan) - Disassemble....548
Piston Motor (Hydraulic Fan) - Assemble....553
Fan and Piston Motor (Hydraulic Fan) - Install....558
Electrohydraulic Control - Remove....560
Electrohydraulic Control - Install....564
Main Control Valve - Remove....567
Main Control Valve - Disassemble....570
Main Control Valve - Assemble....577
Main Control Valve - Install....584
Pilot Valve (Oil Manifold) - Remove....587
Pilot Valve (Oil Manifold) - Disassemble....590
Pilot Valve (Oil Manifold) - Assemble....594
Pilot Valve (Oil Manifold) - Install....598
Push Arms and Blade - Remove....601
Push Arms and Blade - Install....605
Stabilizer Link - Remove and Install....608
Lift Cylinder - Remove....610
Lift Cylinder - Disassemble....613
Lift Cylinder - Assemble....615
Lift Cylinder - Install....618
Tilt Cylinder - Remove....620
Tilt Cylinder - Disassemble....622
Tilt Cylinder - Assemble....624
Tilt Cylinder - Install....627
Cab - Remove....629
Cab - Install....634
Operator Platform - Remove....638
Operator Platform - Install....641
Instrument Panel (Lower) - Remove....644
Instrument Panel (Lower) - Install....647
Instrument Panel (Upper) - Remove....650
Instrument Panel (Upper) - Install....652
Window Wiper and Wiper Motor (Front) - Remove....653
Window Wiper and Wiper Motor (Front) - Install....660
Window Wiper and Wiper Motor (Rear) - Remove....669
Window Wiper and Wiper Motor (Rear) - Install....672
Seat - Remove....677
Seat - Install....679
Evaporator Coil and Heater Coil - Remove....683
Evaporator Coil and Heater Coil - Install....690
Front Frame from Rear Frame - Separate....696
Front Frame to Rear Frame - Connect....706
RENR6009 - Schematic (825G SERIES II SOIL COMPACTOR HYDRAULIC SYSTEM)....717
RENR6025 - Disassembly and Assembly (826G Series II Landfill Compactor; 825G Series II Soil Compactor and 824G Series II Wheel Dozer Engine Supplement)....719
Steering Frame Lock - Separate and Connect....721
System Pressure - Release....725
Hood and Engine Enclosure - Remove....727
Hood and Engine Enclosure - Install....732
Hood Panels (Front and Rear) - Remove....737
Hood Panels (Front and Rear) - Install....739
Belt Tensioner - Remove and Install....741
Alternator - Remove and Install....745
Electric Starting Motor - Remove and Install - Engine in Chassis....749
Fuel Filter Base and Priming Pump - Remove - Engine in Chassis....754
Fuel Filter Base and Priming Pump - Install - Engine in Chassis....756
Fuel Transfer Pump - Remove and Install - Engine in Chassis....757
Fuel Tank - Remove....759
Fuel Tank - Install....767
Fan and Piston Motor (Hydraulic Fan) - Remove....775
Piston Motor (Hydraulic Fan) - Disassemble....777
Piston Motor (Hydraulic Fan) - Assemble....782
Fan and Piston Motor (Hydraulic Fan) - Install....787
Crankshaft Front Seal - Remove - Engine in Chassis....789
Crankshaft Front Seal - Install - Engine in Chassis....793
Radiator Core - Remove and Install....797
Radiator - Remove....801
Radiator - Install....808
Fan Group (Includes Fan; Fan Shroud; and Hydraulic Fan Motor) - Remove and Install....814
Engine Compartment Shield - Remove....819
Engine Compartment Shield - Install....823
Hydraulic Oil Cooler - Remove and Install....827
Aftercooler Core - Remove and Install....831
Engine Oil Cooler - Remove - Engine in Chassis....837
Engine Oil Cooler - Install - Engine in Chassis....840
Air Cleaner - Remove and Install....842
Muffler - Remove and Install....853
Refrigerant Compressor - Remove and Install....857
Refrigerant Condenser - Remove and Install....861
Engine - Remove....865
Engine - Install....875
RENR6026 - Specifications (824G Series II Wheel Dozer; 825G Series II Soil Compactor and 826G Series II Landfill Compactor Power Train)....882
Torque Converter....883
Torque Converter and Pump Drive Housing....886
Relief Valve (Torque Converter Outlet)....889
Speed Sensor (Torque Converter Output)....891
Temperature Sensor (Torque Converter Oil)....892
Transmission Oil Pump....893
Oil Filter (Power Train)....896
Bypass Switch (Power Train Oil Filter)....899
Pinout Specifications for Electronic Control (Power Train)....900
Transmission Hydraulic Control....905
Relief Valve (Transmission Hydraulic Control)....907
Modulating Valve (Transmission Clutch)....909
Temperature Sensor (Transmission Oil)....912
Temperature Sensor (Transmission Lubrication Oil)....913
Transmission Planetary....914
Output Transfer Gears....918