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.

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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	g03721014

7. Disconnect clamps (5) and remove hose assembly (4).
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   Illustration 5	g03721016

8. Open door assembly (6).
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   Illustration 6	g03721019

9. Loosen clamp (7). Remove bolts (8) and the washers.
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   Illustration 7	g03721021

10. Remove clamp (9) and remove duct assembly (10).
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    Illustration 8	g03721023

11. Attach a suitable lifting device to support assembly (11). The weight of support assembly (11) is approximately 93 kg (205 lb).

12. Remove four bolts (12) (not shown), the nuts, and the washers. Use the suitable lifting device in order to remove support assembly (11).
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    Illustration 9	g03721028

13. Remove hump hose (13), hoses (14), and elbows (15).
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    Illustration 10	g03721030

14. Loosen clamp (16) and remove tube (17).
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    Illustration 11	g03720967

15. Remove panel assembly (18). Repeat this step for the opposite side of the machine.
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    Illustration 12	g03721032

16. Remove nut (19) (not shown). Disconnect harness assemblies (1).
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    Illustration 13	g03721033

17. Disconnect hose assemblies (20).
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    Illustration 14	g03721036

18. Disconnect hose assemblies (21). Disconnect clip (22).
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    Illustration 15	g03721039

19. Disconnect cable assembly (23) and ground cable (24) from the alternator.
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    Illustration 16	g03721044

20. Remove elbow (25) and tube assembly (26). Disconnect hose (27).
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    Illustration 17	g03721005

21. Disconnect hose (28) and (30). Disconnect hose assembly (29).
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    Illustration 18	g03721840

22. Remove elbow (31).

23. Disconnect hose assembly (32).
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    Illustration 19	g03721844

24. Disconnect hose assemblies (33).
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    Illustration 20	g03721897

25. Remove tube assembly (34) and the O-ring seals.

26. Remove tube assemblies (35) and (37) and the O-ring seals. Remove hose (36).
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    Illustration 21	g03721902

27. Cut cable strap (38).

28. Disconnect harness assembly (40).

29. Remove tube assembly (39).
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    Illustration 22	g03721924

30. Disconnect hose assemblies (41).

31. Remove tubes (42).

32. Disconnect hose (43).
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    Illustration 23	g03721943

33. Attach Tooling (A) and a suitable lifting device to the lifting points on engine (44). The weight of engine (44) is approximately 1815 kg (4001 lb).
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    Illustration 24	g03721951

34. Lower compactor guard (45).
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    Illustration 25	g03721957

35. Remove bolts (46) (not shown) and the washers.
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    Illustration 26	g03721964

36. Remove bolts (47) and the washers that hold the torque converter to engine (44).
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    Illustration 27	g03721943

37. Use Tooling (A) and the suitable lifting device in order to remove engine (44) from the machine.

Installation Procedure

1. Install engine (44) in the reverse order of removal.

   1. Tighten nut (19) to a torque of 6.0 + 1.5 - 1.0 N·m (53.10 +13.28 - 8.85 lb in).