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

Removal Procedure

Start By:

1. Release hydraulic system pressure.

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Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately.

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Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

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

2. Turn the fuel supply to the OFF position.
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   Illustration 1	g03647177

3. Open door (1).
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   Illustration 2	g03647482

4. Remove shield (2).
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   Illustration 3	g03647484

5. Loosen clamp (3). Cut cable strap (4).
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   Illustration 4	g03647485

6. Disconnect hose assemblies (5).

7. Disconnect temperature sensor (6).
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   Illustration 5	g03647488

8. Remove bolt (8). Disconnect wire assemblies (7).
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   Illustration 6	g03647490

9. Disconnect hose assemblies (9).

10. Remove screw (11) and clamp (10) in order to disconnect wire assembly (12).
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    Illustration 7	g03647494

11. Remove O-ring seals (13) and (14) from wire assembly (12).
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    Illustration 8	g03647496

12. Remove nuts (15). Remove combustion head (16) and tube assembly (17) as one.
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    Illustration 9	g03647500

13. Remove combustion tube (18) and gaskets (19). Gaskets (19) are not reusable. Discard gaskets (19).

14. Do not remove studs (20).
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    Illustration 10	g03647515

15. Remove tube assembly (17) and the gasket from combustion head (16).
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    Illustration 11	g03647532

16. Remove fittings (21) and fittings (23). Remove spark plug (22).

Installation Procedure

1. Install combustion head (16) in the reverse order of removal.

   1. Tighten spark plug (22) to a torque of 58 ± 4 N·m (43 ± 3 lb ft).

   2. Tighten fittings (21) to a torque of 60 ± 6 N·m (44 ± 4 lb ft).

   3. Tighten fittings (23) to a torque of 30 ± 2 N·m (22 ± 1 lb ft). The final torque must occur within 16°-43° of rotation from a pre-torque level of 10 N·m (89 lb in).

   4. Install new gaskets (19).

   5. Apply Tooling (A) to the threads of studs (20).
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      Illustration 12	g03645276
      Nut tightening sequence.

   6. Tighten nuts (15) in a crisscross pattern, as shown in Illustration 12, to a torque of 23 ± 3 N·m (204 ± 27 lb in). Tighten nuts (15) again in a crisscross pattern, as shown in Illustration 12 to a torque of 28 ± 3 N·m (21 ± 2 lb ft). Tighten nuts (15) again in a crisscross pattern, as shown in Illustration 12 to a torque of 28 ± 3 N·m (21 ± 2 lb ft).

   7. Be sure that wire assembly (12) is free of oil and lubricants during the assembly process.

   8. Apply Tooling (B) to the threads of temperature sensor (6). Tighten temperature sensor (6) to a torque of 45 ± 5 N·m (33 ± 4 lb ft).

   9. Refer to Troubleshooting Manual, "ARD Ignition - Test" and Special Instructions, REHS4824 , "Replacement of the ARD Combustion Head on Caterpillar Products with Clean Emissions Modules".