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

Engine - Remove and Install
1.1. Removal Procedure
2.1. Installation Procedure

Removal Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
6V-6146  Load Leveler Gp 

Start By:

  1. Connect the steering frame lock.

  2. Remove the air cleaner.

  3. Remove the clean emissions module or the muffler.

------ WARNING! ------

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.

------ WARNING! ------

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.


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.

  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.

    Illustration 1g03720106

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

    Illustration 2g03720125

  5. Disconnect harness assembly (1).

    Illustration 3g03720127

  6. Disconnect clips (3).

    Illustration 4g03721014

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

    Illustration 5g03721016

  8. Open door assembly (6).

    Illustration 6g03721019

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

    Illustration 7g03721021

  10. Remove clamp (9) and remove duct assembly (10).

    Illustration 8g03721023

  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).

    Illustration 9g03721028

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

    Illustration 10g03721030

  14. Loosen clamp (16) and remove tube (17).

    Illustration 11g03720967

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

    Illustration 12g03721032

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

    Illustration 13g03721033

  17. Disconnect hose assemblies (20).

    Illustration 14g03721036

  18. Disconnect hose assemblies (21). Disconnect clip (22).

    Illustration 15g03721039

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

    Illustration 16g03721044

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

    Illustration 17g03721005

  21. Disconnect hose (28) and (30). Disconnect hose assembly (29).

    Illustration 18g03721840

  22. Remove elbow (31).

  23. Disconnect hose assembly (32).

    Illustration 19g03721844

  24. Disconnect hose assemblies (33).

    Illustration 20g03721897

  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).

    Illustration 21g03721902

  27. Cut cable strap (38).

  28. Disconnect harness assembly (40).

  29. Remove tube assembly (39).

    Illustration 22g03721924

  30. Disconnect hose assemblies (41).

  31. Remove tubes (42).

  32. Disconnect hose (43).

    Illustration 23g03721943

  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).

    Illustration 24g03721951

  34. Lower compactor guard (45).

    Illustration 25g03721957

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

    Illustration 26g03721964

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

    Illustration 27g03721943

  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).

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