826K Landfill Compactor, 825K Soil Compactor and 824K Wheel Dozer Engine Supplement Engine, Torque Converter, Transmission and Output Transfer Gears

Engine, Torque Converter, Transmission and Output Transfer Gears - Remove

826K Landfill Compactor, 825K Soil Compactor and 824K Wheel Dozer Engine Supplement [UENR3838]

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826K Landfill Compactor, 825K Soil Compactor and 824K Wheel Dozer Engine Supplement Engine, Torque Converter, Transmission and Output Transfer Gears - Install

ENGINE ARRANGEMENT

ENGINE AR

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826K Landfill Compactor, 825K Soil Compactor and 824K Wheel Dozer Engine Supplement Engine, Torque Converter, Transmission and Output Transfer Gears - Remove

826K Landfill Compactor, 825K Soil Compactor and 824K Wheel Dozer Engine Supplement Engine, Torque Converter, Transmission and Output Transfer Gears - Install

826K Landfill Compactor, 825K Soil Compactor and 824K Wheel Dozer Engine Supplement Engine - Remove and Install

1.1. Removal Procedure

Removal Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	439-3940	Bracket As	2
B	439-3939	Link Bracket As	4
B	386-6034	Hoist Leveler As	1
C	6V-6146	Load Leveler Gp	1
D	1U-7505	Hydraulic Jack	1

Start By:

Remove the hydraulic tank.
Remove the air cleaner.
Remove the expansion tank.
Remove the clean emissions module or the muffler.
Remove the center drive shaft.
Remove the rear drive shaft.
Remove the implement pump.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat^® products. Dispose of all fluids according to local regulations and mandates.

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NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Turn the battery disconnect switch to the OFF position.
Drain the transmission oil. Refer to Operation and Maintenance Manual, "Transmission Oil - Change" for the correct draining procedures.
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Illustration 1 g03667106
Remove clamps (2).
Remove hose assemblies (1).
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Illustration 2 g03715572
Disconnect hose assemblies (3) and hose assembly (6).
Cut cable straps (5).
Remove hose assembly (4).
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Illustration 3 g03667198
Remove hose assemblies (7).
Remove clamps (8).
Remove tube assembly (9).
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Illustration 4 g03667205
Disconnect hose assemblies (10) and (14).
Remove clamps (13).
Remove hose assemblies (11) and (12).
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Illustration 5 g03667209
Disconnect hose assembly (15).
Remove hose assembly (16).
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Illustration 6 g03667422
Disconnect hose assembly (17).
Disconnect harness assemblies (18).
Disconnect clamp (19) from the machine frame. Remove bracket (20).
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Illustration 7 g03667447
Disconnect hose assemblies (21).
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Illustration 8 g03667469
Attach Tooling (A) and a suitable lifting device to plate assembly (22). The combined weight of plate assembly (22) and all of the valves and hose assemblies is approximately 90 kg (198 lb).
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Illustration 9 g03667491

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Illustration 10 g03667494
Remove nuts (23). Use Tooling (A) and the suitable lifting device in order to lift plate assembly (22) and position plate assembly (22) out of the way, as shown in Illustration 10.
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Illustration 11 g03667392
Disconnect hose assemblies (24).
Cut cable strap (26). Remove hose assembly (27).
Disconnect clamps (25). Move hose assemblies (28) out of the way.
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Illustration 12 g03667414
Disconnect hose assembly (29).
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Illustration 13 g03667416

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Illustration 14 g03667516
Disconnect tube assembly (30).
Disconnect hose assembly (31) and hose assembly (32).
Note: Hose assembly (31) and hose assembly (33) are attached together and should be removed as one unit.
Remove hose assembly (33).
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Illustration 15 g03667521
Attach a suitable lifting device to pump stack (34). The weight of pump stack (34) is approximately 82 kg (181 lb). Remove bolts (35). Use the suitable lifting device in order to remove pump stack (34).
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Illustration 16 g03715992
Remove cover (36). Repeat this step for the opposite side of the machine.
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Illustration 17 g03715997
Disconnect hose assembly (37). Repeat this step for the opposite side of the machine.
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Illustration 18 g03716004

View of the bottom of the transfer case.
Disconnect hose assembly (38).
Disconnect tube assembly (39).
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Illustration 19 g03716012
Remove bolt (40) and the washer. Remove yoke (41) and the O-ring seal.
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Illustration 20 g03716015
Remove hose (43). Remove tube assemblies (42) and (44).
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Illustration 21 g03716028

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Illustration 22 g03716038
Remove bolts (46) and bolts (47). Move filter bracket assembly (45) and the filters out of the way.
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Illustration 23 g03716043
Disconnect filter bracket assembly (48) and the filter from the machine frame. Move filter bracket assembly (48) and the filter out of the way.
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Illustration 24 g03716047
Disconnect harness assemblies (49). Disconnect clamp (50) from the machine frame.
Disconnect hose assembly (51).
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Illustration 25 g03716053
Remove bolts (52) in order to disconnect the harness assembly from the frame.
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Illustration 26 g03716083
Disconnect harness assembly (53). Disconnect clips (54) in order to disconnect harness assembly (53) from the frame.
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Illustration 27 g03716088
Remove bolts (55) and the washers in order to disconnect harness assembly (53) from the frame.
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Illustration 28 g03716096
Disconnect harness assembly (53).
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Illustration 29 g03716102
Disconnect harness assembly (53). Move harness assembly (53) out of the way.
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Illustration 30 g03720489
Disconnect clips (56).
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Illustration 31 g03716189
Attach a suitable lifting device to support assembly (57). The weight of support assembly (57) is approximately 93 kg (205 lb).
Remove four bolts (58) (not shown), the nuts, and the washers. Use the suitable lifting device in order to remove support assembly (57).
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Illustration 32 g03716234
Remove hump hose (59), hose (60), elbows (61), and hose (62).
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Illustration 33 g03716244
Loosen clamp (63) and remove tube (64).
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Illustration 34 g03716293
Remove panel assembly (65).
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Illustration 35 g03716304
Remove nut (66) (not shown). Disconnect harness assemblies (53).
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Illustration 36 g03716129
Disconnect hose assemblies (67).
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Illustration 37 g03716742
Disconnect hose assemblies (68). Disconnect clip (69).
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Illustration 38 g03716749
Disconnect cable assembly (70) and ground cable (71) from the alternator.
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Illustration 39 g03716779
Remove elbow (72). Disconnect hose (73).
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Illustration 40 g03716784
Disconnect hoses (74) and hose (76). Disconnect hose assembly (75).
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Illustration 41 g03716797
Remove elbow (77).
Disconnect hose assembly (78).
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Illustration 42 g03716807
Disconnect hose assemblies (79).
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Illustration 43 g03716821
Disconnect hose (80).
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Illustration 44 g03717056

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Illustration 45 g03717195
Attach Tooling (B) to transmission (81). Attach Tooling (B) to Tooling (C) and a suitable lifting device. Attach a suitable lifting device to the lifting points on engine (82) and to Tooling (C). The combined weight of engine (82), transmission (81), the torque converter, and the output transfer gears is approximately 3334 kg (7350 lb).
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Illustration 46 g03717253

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Do not lower the bottom guard while under the machine. Injury could occur if the bottom guard slips off of the jack while it is being lowered.
Position Tooling (D) under guard (83). The weight of guard (83) is approximately 67 kg (148 lb).
Remove bolts (84) and the washers. Use Tooling (D) in order to remove guard (83).
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Illustration 47 g03717256
Remove bolts (85) and the washers.
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Illustration 48 g03717232
Remove bolts (86) and the washers.
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Illustration 49 g03717276

Left side of the machine.
Remove nut (87), the washers, and the bolt. Repeat this step for the opposite side of the machine.
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Illustration 50 g03717282
Raise the engine, the transmission, the torque converter, and the output transfer gears until support assembly (89) is visible, as shown in Illustration 50. Attach a suitable lifting device to support assembly (89). The weight of support assembly (89) is approximately 55 kg (121 lb). Remove bolts (88) and the washers, and the spacers. Use the suitable lifting device in order to remove support assembly (89). Repeat this step for the opposite side of the machine.
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Illustration 51 g03717056

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Illustration 52 g03717195
Use Tooling (B), Tooling (C), and the suitable lifting device in order to remove engine (82), transmission (81), the torque converter, and the output transfer gears.