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

Installation Procedure

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Illustration 1	g03717195

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Illustration 2	g03717056

1. 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).

2. Use Tooling (B), Tooling (C), and the suitable lifting device in order to install engine (82), transmission (81), the torque converter, and the output transfer gears.
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   Illustration 3	g03717282

3. Lower the engine, the transmission, the torque converter, and the output transfer gears into position, as shown in Illustration 3. Attach a suitable lifting device to support assembly (89). The weight of support assembly (89) is approximately 55 kg (121 lb). Install bolts (88), the washers, and the spacers. Tighten bolts (88) to a torque of 520 ± 70 N·m (384 ± 52 lb ft). Repeat this step for the opposite side of the machine. Lower the engine, the transmission, the torque converter, and the output transfer gears.
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   Illustration 4	g03717276
   Left side of the machine.

4. Install nut (87), the washers, and the bolt. Repeat this step for the opposite side of the machine.
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   Illustration 5	g03717232

5. Install bolts (86) and the washers.
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   Illustration 6	g03717256

6. Install bolts (85) and the washers.
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   Illustration 7	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.

7. Use Tooling (D) in order to position guard (83) to the machine. The weight of guard (83) is approximately 67 kg (148 lb). Install bolts (84) and the washers.
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   Illustration 8	g03716821

8. Connect hose (80).
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   Illustration 9	g03716807

9. Connect hose assemblies (79).
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   Illustration 10	g03716797

10. Connect hose assembly (78).

11. Install elbow (77).
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    Illustration 11	g03716784

12. Connect hoses (74) and hose (76). Connect hose assembly (75).
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    Illustration 12	g03716779

13. Connect hose (73). Install elbow (72).
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    Illustration 13	g03716749

14. Connect cable assembly (70) and ground cable (71) to the alternator.
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    Illustration 14	g03716742

15. Connect hose assemblies (68). Connect clip (69).
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    Illustration 15	g03716129

16. Connect hose assemblies (67).
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    Illustration 16	g03716304

17. Connect harness assemblies (53). Install nut (66) (not shown). Tighten nut (66) to a torque of 6.0 + 1.5 - 1.0 N·m (53.10 + 13.28 - 8.85 lb in).
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    Illustration 17	g03716293

18. Install panel assembly (65).
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    Illustration 18	g03716244

19. Install tube (64) and tighten clamp (63) to a torque of 7.5 ± 1.0 N·m (66.38 ± 8.85 lb in).
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    Illustration 19	g03716234

20. Install hose (62), elbows (61), hose (60), and hump hose (59).
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    Illustration 20	g03716189

21. Attach a suitable lifting device to support assembly (57). The weight of support assembly (57) is approximately 93 kg (205 lb).

22. Use the suitable lifting device in order to position support assembly (57). Install four bolts (58) (not shown), the nuts, and the washers.
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    Illustration 21	g03720489

23. Connect clips (56).
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    Illustration 22	g03716102

24. Connect harness assembly (53).
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    Illustration 23	g03716096

25. Connect harness assembly (53).
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    Illustration 24	g03716088

26. Install bolts (55) in order to connect harness assembly (53) to the frame.
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    Illustration 25	g03716083

27. Connect harness assembly (53). Connect clips (54) in order to connect harness assembly (53) from the frame.
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    Illustration 26	g03716053

28. Install bolts (52) in order to connect the harness assembly from the frame.
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    Illustration 27	g03716047

29. Connect hose assembly (51).

30. Connect harness assemblies (49). Connect clamp (50) to the machine frame.
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    Illustration 28	g03716043

31. Connect filter bracket assembly (48) and the filter to the machine frame.
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    Illustration 29	g03716038

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    Illustration 30	g03716028

32. Position filter bracket assembly (45) and install bolts (47) and bolts (46).
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    Illustration 31	g03716015

33. Install hose (43). Install tube assemblies (42) and (44).
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    Illustration 32	g03716012

34. Apply Tooling (E) to the threads of bolt (40).

35. Install yoke (41) and the O-ring seal. Install bolt (40) and the washer. Tighten bolt (40) to a torque of 475 ± 60 N·m (350 ± 44 lb ft).
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    Illustration 33	g03716004
    View of the bottom of the transfer case.

36. Connect hose assembly (38).

37. Connect tube assembly (39).
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    Illustration 34	g03715997

38. Connect hose assembly (37). Repeat this step for the opposite side of the machine.
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    Illustration 35	g03715992

39. Install cover (36). Repeat this step for the opposite side of the machine.
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    Illustration 36	g03667521

40. Attach a suitable lifting device to pump stack (34). The weight of pump stack (34) is approximately 82 kg (181 lb). Use the suitable lifting device in order to position pump stack (34). Install bolts (35).
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    Illustration 37	g03667516

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    Illustration 38	g03667416

41. Install hose assembly (31) and hose assembly (33) as one unit.

42. Connect hose assembly (32).

43. Connect tube assembly (30).
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    Illustration 39	g03667414

44. Connect hose assembly (29).
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    Illustration 40	g03667392

45. Position hose assemblies (28). Connect clamps (25).

46. Install hose assembly (27). Attach cable strap (26).

47. Connect hose assemblies (24).
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    Illustration 41	g03667491

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    Illustration 42	g03667469

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    Illustration 43	g03667491

48. 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). Use Tooling (A) and the suitable lifting device in order to lift plate assembly (22) into position.

49. Install nuts (23).
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    Illustration 44	g03667447

50. Connect hose assemblies (21).
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    Illustration 45	g03667422

51. Install bracket (20). Connect clamp (19).

52. Connect harness assemblies (18).

53. Connect hose assembly (17).
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    Illustration 46	g03667209

54. Install hose assembly (16).

55. Connect hose assembly (15).
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    Illustration 47	g03667205

56. Install hose assemblies (11) and (12).

57. Install clamps (13).

58. Connect hose assemblies (10) and (14).
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    Illustration 48	g03667198

59. Install tube assembly (9).

60. Install clamps (8).

61. Install hose assemblies (7).
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    Illustration 49	g03715572

62. Install hose assembly (4).

63. Attach cable straps (5).

64. Connect hose assemblies (3) and hose assembly (6).
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    Illustration 50	g03667106

65. Install hose assemblies (1).

66. Install clamps (2).

67. Fill the transmission oil. Refer to Operation and Maintenance Manual, "Transmission Oil - Change" for the correct filling procedure.

68. Turn the battery disconnect switch to the ON position.

End By:

1. Install the implement pump.

2. Install the rear drive shaft.

3. Install the center drive shaft.

4. Install the clean emissions module or the muffler.

5. Install the expansion tank.

6. Install the air cleaner.

7. Install the hydraulic tank.