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

Removal Procedure

Start By:

1. Connect the steering frame lock.

2. Remove the air cleaner.

3. Remove the clean emissions module or the muffler.

4. Remove the power train guard.

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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the cooling system pressure cap is cool enough to touch with your bare hand. Remove the cooling system pressure cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.

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Personal injury can result from contact with refrigerant. Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury. Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant. Always use precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area. Personal injury or death can result from inhaling refrigerant through a lit cigarette. Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death. Do not smoke when servicing air conditioners or wherever refrigerant gas may be present. Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.

1. Turn the battery disconnect switch to the OFF position.

2. Drain the coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct draining and filling procedures.

3. Recover/Charge the air conditioning system. Refer to Service Manual, SENR5664, " All Products Air Conditioning and Heating R134a for All AVSpare Machines" for the recovery and charging procedure. Refer to Special Publication, NENG2500, "Air Conditioning Tools" for the correct tools.
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   Illustration 1	g03720106

4. Disconnect harness assembly (1). Disconnect clips (2) in order to disconnect harness assembly (1) from the frame.
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   Illustration 2	g03720125

5. Disconnect harness assembly (1).
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   Illustration 3	g03720127

6. Disconnect clips (3).
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   Illustration 4	g03720135

7. Attach a suitable lifting device to support assembly (4). The weight of support assembly (4) is approximately 93 kg (205 lb).

8. Remove four bolts (5) (not shown), the nuts, and the washers. Use the suitable lifting device in order to remove support assembly (4).
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   Illustration 5	g03720189

9. Remove hump hose (6), hoses (7), and elbows (8).
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   Illustration 6	g03720714

10. Loosen clamp (9) and remove tube (10).
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    Illustration 7	g03720720

11. Remove panel assembly (11). Repeat this step for the opposite side of the machine.
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    Illustration 8	g03720722

12. Remove nut (12) (not shown). Disconnect harness assemblies (1).
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    Illustration 9	g03720726

13. Disconnect hose assemblies (13).
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    Illustration 10	g03720729

14. Disconnect hose assemblies (14). Disconnect clip (15).
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    Illustration 11	g03720735

15. Disconnect cable assembly (16) and ground cable (17) from the alternator.
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    Illustration 12	g03720756

16. Remove elbow (18) and tube assembly (19). Disconnect hose (20).
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    Illustration 13	g03720759

17. Disconnect hoses (21) and (23). Disconnect hose assembly (22).
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    Illustration 14	g03720767

18. Remove elbow (24).

19. Disconnect hose assembly (25).
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    Illustration 15	g03720772

20. Disconnect hose assemblies (26).
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    Illustration 16	g03720827

21. Remove tube assembly (27) and the O-ring seals.

22. Remove tube assemblies (28) and (30) and the O-ring seals. Remove hose (29).
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    Illustration 17	g03720888

23. Cut cable strap (31).

24. Disconnect harness assembly (33).

25. Remove tube assembly (32).
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    Illustration 18	g03720775

26. Disconnect hose assemblies (34).

27. Remove tubes (35).

28. Disconnect hose (36).
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    Illustration 19	g03720899

29. Attach Tooling (A) and a suitable lifting device to the lifting points on engine (37). The weight of engine (37) is approximately 1815 kg (4001 lb).
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    Illustration 20	g03720893

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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.

30. Position Tooling (B) under guard (38). The weight of guard (38) is approximately 67 kg (148 lb).

31. Remove bolts (39) and the washers. Use Tooling (B) in order to remove guard (38).
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    Illustration 21	g03720909

32. Remove bolts (40) (not shown) and the washers.
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    Illustration 22	g03720911

33. Remove bolts (41) and the washers that hold the torque converter to engine (37).
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    Illustration 23	g03720899

34. Use Tooling (A) and the suitable lifting device in order to remove engine (37) from the machine.

Installation Procedure

1. Install engine (37) in the reverse order of removal.

   1. Tighten nut (12) to a torque of 6.0 + 1.5 - 1.0 N·m (53.10 +13.28 - 8.85 lb in).