Caterpillar 824G
Maintenance schedule, common problems & OEM parts breakdown
The Caterpillar 824G is a medium-class wheel dozer designed for high productivity in earthmoving, mining, and excavation applications. This series utilizes the Cat 3406C DITA engine (with 3406E ATAAC variants available in Series II) to deliver approximately 315 hp (235 kW). The machine features a four-speed forward and four-speed reverse transmission, an oscillating rear axle, and a standard operating weight of approximately 58,564 lb (26,620 kg), though this varies by configuration/series. It is offered with various blade capacities and tire configurations to suit specific jobsite requirements.
Across generations, the 824G evolved from the original G-series to the Series II, introducing advancements such as the Advanced Modular Cooling System (AMOCS) and improved electronic controls like the ADEM III module. These updates focused on enhancing serviceability, heat rejection, and operator comfort through redesigned cabs and steering systems. Today, the 8-series remains a staple in the used market due to its proven powertrain durability and the availability of widespread parts support through global dealer networks.
Below: full specifications, fluids & capacities, the factory service schedule, common service parts, verified fault codes, what owners discuss, attachment guidance, the complete assembly directory, and a serial-number reference. Complete parts lists with full OEM part numbers, exploded diagrams, quantities, and fitment data are available free in Heavy Parts AI.
Caterpillar 824G specifications
Engine
| Engine Model | Varies by series: 3406C DITA (Standard 824G); 3406E ATAAC Diesel (824G Series II) |
| Flywheel Power | 315 hp (Standard 824G); 339 hp (824G Series II) |
| Net Power | 339 hp (824G Series II) |
| Displacement | 891 cu in (14.6 L) |
| Bore x Stroke | 5.4 in (137 mm) x 6.5 in (165 mm) |
| Cylinders | 6 |
Weights
| Operating Weight (Standard 824G) | 58,564 lb (26,620 kg) |
| Operating Weight (824G Series II) | 63,325.6 lb (28,724 kg) |
Dimensions
| Height - Top of Cab | 12.35 ft (3,764 mm) (Standard 824G); 12.14 ft (3,693 mm) (824G Series II) |
| Length - With Blade on Ground | 26.31 ft (8,020 mm) (Standard 824G); 26.8 ft (8,160 mm) (824G Series II) |
| Wheelbase | 12.14 ft (3,700 mm) |
| Ground Clearance | 1.26 ft (383 mm) (Standard 824G); 1.3 ft (400 mm) (824G Series II) |
| Width Over Tires | 177.6 in (4,511 mm) (824G Series II) |
Performance
| Forward Speeds | 4 gears |
| Reverse Speeds | 4 gears |
| Max Speed - Forward | 20.6 mph (33.2 km/h) (Standard 824G); 20 mph (32.1 km/h) (824G Series II) |
| Max Speed - Reverse | 23.5 mph (37.8 km/h) (Standard 824G); 22.8 mph (36.7 km/h) (824G Series II) |
| Steering Angle | ±42° |
| Turning Circle - With Blade | 48 ft (14.6 m) |
| Axle Configuration | Front: Fixed/Planetary; Rear: Oscillating ±13° |
Blades
| Straight Blade - Capacity | 6.2 yd³ (4.67 m³) (Standard 824G); 6.7 yd³ (5.1 m³) (824G Series II) |
| Straight Blade - Width | 14.8 ft (4,507 mm) |
| Straight Blade - Height | 4.1 ft (1,250 mm) (Standard 824G); 4.1 ft (1,250 mm) (824G Series II) |
| Straight Blade - Digging Depth | 1.5 ft (430 mm) (Standard 824G); 1.41 ft (430 mm) (824G Series II) |
| Maximum Lift Above Ground | 3.6 ft (1,070 mm) (Standard 824G); 3.5 ft (1,070 mm) (824G Series II) |
Service Capacities
| Fuel Tank - Standard | 166 gal (630 L) |
| Cooling System | 21.4 gal (81 L) (Standard 824G); 21.9 gal (83 L) (824G Series II) |
| Hydraulic Tank | 23.3 gal (88 L) (Standard 824G); 23.2 gal (88 L) (824G Series II) |
| Transmission Oil | 16.4 gal (62 L) |
| Crankcase/Engine Oil | 9 gal (34 L) |
| Differential - Front | 23.8 gal (90 L) |
| Differential - Rear | 23.8 gal (90 L) |
Values vary by configuration, region, and serial range — confirm against your machine before planning transport or lifts.
824G fluids & capacities
| System | Capacity | Recommended fluid |
|---|---|---|
| Engine Crankcase (w/ filter) | 8.98 L (2.4 gal) to 9 L (2.4 gal) | Cat DEO (SAE 15W-40, SAE 10W-30); Cat DEO-ULS (SAE 15W-40, SAE 10W-30); Cat DEO-ULS Cold Weather (SAE 0W-40) |
| Cooling System | 81 L (21.4 gal) | Cat ELC (50/50 Premix); Cat DEAC (Concentrate); Cat NGEC (Premix 50/5/0) |
| Fuel Tank | 630 L (166 gal) to 630.3 L (166.5 gal) | |
| Transmission/Powertrain | 62 L (16.38 gal) to 62.1 L (16.4 gal) | Cat TDTO (SAE 10W, SAE 30, SAE 50); Cat TDTO-TMS (Synthetic Blend); Cat TDTO Cold Weather (0W-20) |
| Differential - Final Drives (Front) | 90 L (23.78 gal) to 90.1 L (23.8 gal) | Cat TDTO (SAE 10W, SAE 30, SAE 50); Cat GO (SAE 80W-90, SAE 85W-140); Cat FDAO (SAE 60); Cat FDAO SYN (SAE Multigrade) |
| Differential - Final Drives (Rear) | 90 L (23.78 gal) to 90.1 L (23.8 gal) | Cat TDTO (SAE 10W, SAE 30, SAE 50); Cat GO (SAE 80W-90, SAE 85W-140); Cat FDAO (SAE 60); Cat FDAO SYN (SAE Multigrade) |
| Hydraulic System/Tank | 87.8 L (23.2 gal) to 88 L (23.25 gal) | Cat HYDO Advanced 10; Cat HYDO Advanced 30 (for hot climates); Cat Bio HYDO Advanced |
| Grease | Cat Multipurpose Grease (low-load/low-speed); Cat Advanced 3Moly Grease (medium-load/medium-speed); Cat Ultra 5Moly Grease (high-load/high-speed); Cat Desert Gold Grease (hot-weather); Cat Arctic Platinum Grease (cold-weather) |
Capacities are refill values from factory literature — always fill to the dipstick/sight gauge, not the number.
Caterpillar 824G maintenance schedule
| Service interval | Tasks |
|---|---|
| Every 10 h |
|
| Every 250 h |
|
| Every 500 h |
|
| Every 1,000 h |
|
| Every 2,000 h |
|
Servicing the 824G beyond the schedule
Predictive Maintenance & Fluid Analysis
Utilize Cat S.O.S Services to monitor engine oil, hydraulic fluid, coolant, and transmission oil. Analyze wear metals like iron or copper and contaminants such as silicon to detect early component degradation. Regular sampling during PM3 and PM4 intervals allows for the detection of fuel dilution or coolant leaks before they cause catastrophic failure in the 3406C engine or hydraulic pumps.
Corrective & Common Repairs
Monitor hydraulic hoses for cracks, abrasion, or leaks to prevent pump and cylinder damage. Inspect the 29.5-25 L-3 tires regularly for inflation and wear to maintain traction. Address any issues with the oil-enclosed, multiple-disc brakes promptly to ensure heat rejection remains effective. Check all pins, bushings, and attachment points for excessive play that could impact blade control.
Overhaul & Rebuild Points
Plan major interventions during PM4 intervals, focusing on hydraulic oil changes and transmission service. Evaluate the condition of the 3406C engine components, including turbocharger inspection and valve train wear. During structural rebuilds, verify torque on ROPS bolts and examine the integrity of the push arms and blade trunnion mountings to ensure long-term chassis durability.
Seasonal & Environment Servicing
In high-dust or quarry environments, check air filters daily and clean radiator fins frequently to prevent overheating. In cold climates, utilize the engine's cold mode start-up strategy and inspect battery health. For machines operating in extreme heat, ensure the AMOCS radiator and cooling system are free of debris to maintain optimal temperature regulation for the powertrain.
824G fault codes & troubleshooting
| Code | Meaning | Likely cause | What to do |
|---|---|---|---|
| 110-0 | Engine Coolant Temperature — Above Normal | Low coolant level, thermostat failure | Inspect cooling system; refill coolant; test thermostat |
| 110-3 | Engine Coolant Temp Sensor — Voltage High | Open circuit or sensor failure | Check wiring; replace sensor if confirmed faulty |
| 174-3 | Engine Fuel Temperature — Voltage Above Normal | Open circuit in sensor wiring | Inspect harness and replace sensor if necessary |
| 190-8 | Engine Speed — Abnormal Frequency | Speed sensor air gap, sensor failure, or tone ring damage | Check sensor gap; test speed sensor and tone ring |
| 2458-2 | DPF #1 Differential Pressure — Erratic | Plugged pressure ports or failing sensor | Clean pressure ports; test sensor; verify DPF soot load |
| 41-3 | 8-Volt DC Supply — Voltage Above Normal | Short to power on 8V reference circuit | Inspect sensors sharing the 8V supply and isolate fault |
| 41-4 | 8-Volt DC Supply — Voltage Below Normal | Short to ground on 8V reference circuit | Disconnect sensors one at a time to locate short |
| 2348-9 | SAE J1939 Data Link #2 — Abnormal Update Rate | CAN bus wiring damage or termination fault | Check CAN wiring and measure termination resistance |
Codes and remedies are general guidance for this model family — always confirm with diagnostic tooling and your dealer before major repairs.
824G attachments & work tools
Blades
Straight blade configurations available with capacities ranging from 4.67 m³ (6.11 yd³) to 6.7 yd³ (5.1 m³). Standard straight blade dimensions include a width of 14.8 ft (4.51 m) and a height of 4.1 ft (1.23 m).
Rippers
Not documented for this exact serial range — verify with your dealer.
Winches
Not documented for this exact serial range — verify with your dealer.
Drawbars/Counterweights
Not documented for this exact serial range — verify with your dealer.
Cab/ROPS Guarding
Standard configuration includes internal ROPS meeting SAE and ISO standards. Cab features include a non-metallic, rustproof floor and larger windows for improved visibility.
Hydraulic Arrangement
System utilizes armrest-mounted levers sending electrical signals to a pivot valve on the front frame. Features high-capacity lift cylinders and XT-3 or XT-5 hydraulic hoses with O-ring face seals.
All 824G assemblies by section
Every catalogued assembly group for the Caterpillar 824G. Open an assembly to preview the parts inside — full OEM part numbers are available in Heavy Parts AI.
Attachments
Cp-2z9690 Basic Ar-Scoop-Part 1 Of 2
| 10***12 | Planet Pinion Carrier; (Sub For Th1025912), Carrier, Hose Assembly, . Carrier, Planet Pinion Carrie | 1 |
| 11***22 | Trunnion Group-Bulldozer | 1 |
| 12***33 | Counterweight Group | 1 |
Cp-2z9690 Basic Ar-Scoop-Part 2 Of 2
| 2Z***90 | Basic Ar-Scoop | 1 |
Cp-1260433 Counterweight Gp
| 12***33 | Counterweight Group | 1 |
Cp-2q7569 Cover Gp-Control Valve
| 2Q***69 | Cover Group-Control Valve | 1 |
Cp-4z6333 Cylinder Gp-Tilt Lh
| 4Z***33 | Cylinder Group-Tilt; -Custom | 1 |
Cp-4z6309 Cylinder Gp-Tilt Rh
| 4Z***09 | Cylinder Group-Tilt; Cylinder Group-Rh | 1 |
Cp-2q7389 Frame Assembly-Engine End
| 2Q***89 | Frame Assembly-Engine End | 1 |
Cp-2q7393 Frame Gp-Front
| 2Q***93 | Frame Group-Front; Frame Assembly-Non Engine End | 1 |
Cp-2q7398 Lines Gp-Lift Cylinder-Part 1 Of 4
| 2Q***98 | Lines Group-Lift Cylinder; Lines Group-Lift Cylinder | 1 |
Cp-2q7399 Lines Gp-Tilt Cylinder
| 2Q***99 | Lines Group-Tilt Cylinder | 1 |
Cp-2q7435 Mounting Gp-Lift Cylinder
| 2Q***35 | Mounting Group-Lift Cylinder | 1 |
Cp-2q7671 Pump & Mtg Gp-Hydraulic
| 2Q***71 | Pump & Mtg Group-Hydraulic; Pump Group-Mounting And | 1 |
| 4Z***44 | Pump Group-Vane | 1 |
| 5F***06 | Packing,Preformed Pump Mtg Part Of Kit P/N 5r***25 | 1 |
Frequently asked questions
What engine is used in the Caterpillar 824G?
The standard 824G utilizes the Cat 3406C DITA engine, while the 824G Series II features the Cat 3406E ATAAC Diesel engine.
What is the operating weight of this machine?
The operating weight is approximately 58,564 lb (26,620 kg) for the standard configuration, though it can reach up to 63,325.6 lb (28,724 kg) for the Series II.
What model replaced the 824G?
The provided documentation does not specify a direct successor model, though it lists the 824G as part of the non-current product lineup.
What 824G owners discuss
What are the primary engine specifications and potential power loss causes for the Caterpillar 824G?
How does the hydraulic system function on this machine and what should be monitored?
What are the common electrical and sensor-related issues observed in Caterpillar heavy machinery?
What are the typical transmission and drivetrain behaviors for the 824G?
What maintenance should be performed on the cooling system to prevent overheating?
What should be checked when inspecting a used Caterpillar 824G for purchase?
Compiled from owner and technician discussions across the industry — experiences vary by serial range and machine history.
Need a specific 824G part?
Search live OEM part data, check fitment, and cross-reference alternatives with Heavy Parts AI.