826K Landfill Compactor, 825K Soil Compactor and 824K Wheel Dozer Power Train Caterpillar

Assembly Procedure

Note: Cleanliness is an important factor. Thoroughly clean all parts before assembly in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.

Note: Apply oil to all of the bearings before assembly.

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Illustration 1	g03675966

1. Install seal rings (86) and seal metal ring (85) onto shaft assembly (68).
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   Illustration 2	g03675945

2. Install adapter (84), hub (83), thrust bearing race (82), and bolts (81) to impeller (67). Tighten bolts (81) to a torque of 105 ± 14 N·m (77 ± 10 lb ft).
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   Illustration 3	g03675918

3. Lower the temperature of bushing (80). Install bushing (80 ) into carrier assembly (77).
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   Illustration 4	g03675910

4. Install bearing (79) to carrier assembly (77).
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   Illustration 5	g03675891

5. Install carrier assembly (77) and retaining ring (78) onto impeller (67).
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   Illustration 6	g03676100

6. Raise the temperature of bearing (76). Install bearing (76) onto support carrier (72).

7. Install retaining ring (74).

8. Install O-ring seal (75) and seal ring (73) onto support carrier (72).
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   Illustration 7	g03675529

9. Install support carrier (72) and retaining ring (71).
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   Illustration 8	g03675526

10. Lower the temperature of bearing outer race (70).

11. Install bearing outer race (70) to drive gear (69).
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    Illustration 9	g03675484

12. Install drive gear (69). Install bolts (68) and the washers. Tighten bolts (68) to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
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    Illustration 10	g03675448

13. Attach Tooling (A) and a suitable lifting device to impeller (67). The weight of impeller (67) is approximately 35 kg (77 lb). Use Tooling (A) and the suitable lifting device in order to place impeller (67) onto shaft assembly (68).
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    Illustration 11	g03675275

14. Install thrust bearing (66).
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    Illustration 12	g03675239

15. Install freewheel cam (65), plate (64), and retaining ring (63) into stator (57).
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    Illustration 13	g03675234

    Note: Freewheel springs (61) must be installed with maximum number of loops to the outside.

16. Flip stator (57) over and install freewheel springs (61) and freewheel rollers (62). Install retaining ring (60).
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    Illustration 14	g03675225

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    Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

17. Install plate (59) and retaining ring (58) into stator (57).
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    Illustration 15	g03675217

18. Install stator (57).
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    Illustration 16	g03675185

19. Install thrust bearing (56) and thrust bearing race (55).
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    Illustration 17	g03675181

20. Install split pins (54) and retaining ring (53) into turbine hub (52).
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    Illustration 18	g03675174

21. Connect turbine (51) to turbine hub (52). Install two bolts (40).
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    Illustration 19	g03675130

22. Install turbine hub (52) and turbine (51) as one unit. Remove bolts (40).
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    Illustration 20	g03675105

23. Install plate (50) and retaining ring (49).
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    Illustration 21	g03675083

24. Install race (48), thrust bearing (47), and thrust bearing race (46).
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    Illustration 22	g03674946

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    Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

25. Install springs (45). Install cover (44) onto coupling assembly (41). Install bolts (43) and the nuts. Tighten bolts (43) to a torque of 50 ± 10 N·m (37 ± 7 lb ft).
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    Illustration 23	g03674917

26. Install dowels (42).

27. Install coupling assembly (41) and bolts (40). Tighten bolts (40) to a torque of 60 ± 7 N·m (44 ± 5 lb ft).
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    Illustration 24	g03674905

28. Install backing plate (39) and friction disc (38).
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    Illustration 25	g03674887

29. Install splined plated (37).
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    Illustration 26	g03674880

30. Install seal rings (36) onto piston (34).
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    Illustration 27	g03674854

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    Illustration 28	g03676233

31. Lower the temperature of bearing sleeve (35). Install bearing sleeve (35) into clutch housing assembly (30) to a Depth of (X). Depth (X) is equal to 3.60 ± 0.15 mm (0.142 ± 0.006 inch).

32. Install piston (34) into clutch housing assembly (30).
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    Illustration 29	g03674844

33. Install ring (32) onto clutch housing assembly (30).

34. Install plug (33). Install plug assemblies (31) into clutch housing assembly (30).
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    Illustration 30	g03674827

35. Use two people in order to install clutch housing assembly (30). The weight of clutch housing assembly (30) is approximately 26 kg (57 lb). Install bolts (29). Tighten bolts (29) to a torque of 60 ± 7 N·m (44 ± 5 lb ft).
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    Illustration 31	g03674545

36. Install retaining ring (27) in the groove of idler gear (16) .
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    Illustration 32	g03676349

37. Lower the temperature of bearing cup (26). Install bearing cup (26) in idler gear (16).
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    Illustration 33	g03676354

38. Flip idler gear (16) to the opposite side. Install bearing cup spacer (25) in idler gear (16). The notch in bearing cup spacer (25) must be aligned with retaining ring (16).
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    Illustration 34	g03676357

39. Lower the temperature of bearing cup (24). Install bearing cup (24) in idler gear (16).
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    Illustration 35	g03674512

40. Install bearing cone (23), bearing cone spacer (22), and bearing cone (21) into idler gear (16).
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    Illustration 36	g03674505

41. Install O-ring seal (20) onto shaft assembly (19).
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    Illustration 37	g03676571

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    Illustration 38	g03676572

42. Install Tooling (H) in shaft assembly (19).

43. Hold idler gear (16) in position in torque converter housing (3). Install shaft assembly (19).

44. Remove Tooling (H) from shaft assembly (19).

45. Install bolt (15) and the washer. Tighten bolt (15) to a torque of 120 ± 20 N·m (90 ± 15 lb ft).

46. Install spring pins (17).

47. Install O-ring seal (18).
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    Illustration 39	g03674417

48. Install relief valve body (14) and the two O-ring seals.
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    Illustration 40	g03674411

49. Install manifold (13) and the O-ring seal.
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    Illustration 41	g03674384

50. Lower the temperature of bearing cup (11). Install bearing cup (11) in torque converter housing (3).
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    Illustration 42	g03676761

51. Raise the temperature of bearing cones (12). Install bearing cones (12) on drive gear (10).
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    Illustration 43	g03674377

52. Install drive gear (10).
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    Illustration 44	g03674374

53. Install adapter (9) and the O-ring seal.
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    Illustration 45	g03674346

54. Apply the lubricant that is being sealed to O-ring seal (8). Install O-ring seal (8) and shims (7).

55. Lower the temperature of bearing cup (6). Install bearing cup (6) into pump adapter (5).
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    Illustration 46	g03676772

56. Install Tooling (J) in torque converter housing (3).

57. Install pump adapter (5) and the shims on torque converter housing (3).

58. Install bolts (6) and the washers.
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    Illustration 47	g03676880
    Typical Example

59. Use Tooling (K) in order to check bearing end play. The bearing end play must be 0.15 ± 0.05 mm (0.006 ± 0.002 inch). Add or remove shims in order to get the correct bearing end play.

    Note: If end play is less than 0.10 mm (0.004 inch), add additional shims. If end play is greater than 0.20 mm (0.008 inch), remove shims.

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    Illustration 48	g03677169

60. Apply the lubricant that is being sealed to O-ring seal (4). Install O-ring seal (4) on torque converter housing (3).
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    Illustration 49	g03677180

61. Install Tooling (L) in torque converter (28).
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    Illustration 50	g03677194

62. Use Tooling (A) and a suitable lifting devise in order to position torque converter housing (3) onto torque converter (28), as shown. The weight of torque converter housing (3) is approximately 120 kg (265 lb). Install two of bolts (2) and the washers.
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    Illustration 51	g03674083

63. Install the remaining bolts (2) and the washers. Tighten bolts (2) to a torque of 120 ± 20 N·m (90 ± 15 lb ft).

End By:

1. Connect the torque converter to the transmission and the output transfer gears.