836G Landfill Compactor and 834G Wheel Dozer Power Train Caterpillar

Assembly Procedure

Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned 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	g00674989

1. Install O-ring seals (96) and plugs (97).
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   Illustration 2	g00674987

2. Install block (95) and bolts (94).
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   Illustration 3	g06386014

3. Install seal (71) and (71A) onto piston (70).
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   Illustration 4	g00674790

4. Install piston (70).
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   Illustration 5	g00674788

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   Illustration 6	g00674750

5. Install two wear plates (68) and two friction discs (69).
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   Illustration 7	g00674748

6. Install plate (67). Install retaining ring (66) with the tab oriented up away from plate (67).
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   Illustration 8	g00674744

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   Illustration 9	g00674747

7. Install clutch adapter (65) and hub (63) to turbine (64).

8. Install bolts (62). Tighten bolts (62) to a torque of 105 ± 15 N·m (77 ± 11 lb ft).
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   Illustration 10	g06274224

9. Install retaining ring (65A) and seal ring (65B) on to hub (63).
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   Illustration 11	g00674727

10. Install bearing (61).
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    Illustration 12	g00674725

11. Install O-ring seal (59) and plugs (60).
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    Illustration 13	g00675696

12. Use the appropriate equipment to turn the housing assembly onto the opposite side, as shown.

13. Install turbine assembly (64) into the housing assembly.
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    Illustration 14	g00675769

14. Install the ring and the plate below bearing (58).

15. Install bearing (58).
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    Illustration 15	g00675437

16. Raise the temperature of bearing (57).

17. Install bearing (57) onto the outer shaft.

    Note: Allow bearing (57) and the shaft to reach a uniform temperature.

18. Use a suitable punch to reset the bearing around the inside race of the bearing. This will ensure that the bearing is seated correctly.

19. Raise the temperature of seal carrier (56).

20. Install seal carrier (56) onto the outer shaft.
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    Illustration 16	g00675571

21. Use a suitable punch to install pin (55).
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    Illustration 17	g00674523

22. Install seal (52).

23. Install seals (53).

24. Use Tooling (L) to install retaining ring (54).
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    Illustration 18	g03868881

25. Install orifice plug (51A).
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    Illustration 19	g00674522

26. Install seal (51) to sleeve (50).
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    Illustration 20	g00674521

27. Install sleeve (50) and bolts (49). Tighten bolts (49) to a torque of 30 ± 5 N·m (22 ± 4 lb ft).
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    Illustration 21	g00674520

28. Lower the temperature of race (48).

29. Install race (48) in drive gear (47).
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    Illustration 22	g00674519

30. Install drive gear (47) onto housing assembly (45).

31. Install bolts (46). Tighten bolts (46) to a torque of 105 ± 15 N·m (77 ± 11 lb ft).
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    Illustration 23	g00674514

32. Install Tooling (E) and a suitable lifting device to housing assembly (45).

33. Install housing assembly (45) to outer shaft assembly. The weight of housing assembly (45) is approximately 45 kg (100 lb).
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    Illustration 24	g00674516

34. Install seal (44) onto piston (43).
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    Illustration 25	g00674512

35. Install piston (43).
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    Illustration 26	g00674510

36. Install two friction discs (42) and one wear plate.
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    Illustration 27	g00674508

37. Install plate (41).

38. Install bolts (22) on the underside of plate (41).
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    Illustration 28	g00674506

39. Install bolts (38) and impeller (36) to adapter assembly (39). Tighten bolts (38) to a torque of 105 ± 15 N·m (77 ± 11 lb ft).
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    Illustration 29	g00674505

40. Lower the temperature of race (37).

41. Install race (37) in impeller (36).
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    Illustration 30	g00674507

42. Install the ring and the plate below bearing (40).

43. Install bearing (40).

44. Install the plate above bearing (40).
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    Illustration 31	g00674504

45. Use two people to install impeller (36) onto the shaft assembly. The weight of impeller (36) is approximately 29 kg (65 lb).
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    Illustration 32	g00674503

46. Install retaining ring (35).
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    Illustration 33	g00674501

47. Install the ring and the plate below bearing (34).

48. Install bearing (34).
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    Illustration 34	g00674499

49. Install spacer (33).
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    Illustration 35	g00674498

50. Install race (32). Use Tooling (L) to install retaining ring (31).

    Note: Inspect the splines on the stator. If the splines were damaged during disassembly, replace the stator with a new part.

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    Illustration 36	g00675434
    Typical Example

51. Raise the temperature of stator (24).

52. Install stator (24) onto cam (30).

53. Install retaining ring (29).
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    Illustration 37	g00675433

54. Install plate (28) and retaining ring (27) onto stator (24). Repeat this procedure for the opposite side.
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    Illustration 38	g00673889

55. Install springs (25) and rollers (26).

56. Install springs (25) in the deepest part of the groove. Assemble the springs so that the maximum number of loops face toward the outside of the cam.

57. Install rollers (26) in the narrowest part of the groove.
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    Illustration 39	g00673888

58. Install stator (24) to carrier assembly (23).
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    Illustration 40	g00673887

59. Carefully rotate carrier assembly (23) into the upright position. The springs and the rollers will hold the stator in place.

60. Install Tooling (D) and a suitable lifting device to carrier assembly (23). The weight of carrier assembly (23) is approximately 132 kg (290 lb).

61. Install carrier assembly (23) to the torque converter housing.
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    Illustration 41	g00673885

62. Install bolts (21). Tighten bolts (21) to a torque of 60 ± 7 N·m (45 ± 5 lb ft).
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    Illustration 42	g00675572

63. Raise the temperature of seal carrier (20).

64. Install seal carrier (20) onto inner shaft (18).

65. Raise the temperature of bearing (19). Install bearing (19) onto inner shaft (18).

    Note: Allow bearing (19) and the shaft to reach a uniform temperature.

66. Use a suitable punch to reset the bearing around the inside race of the bearing. This will ensure that the bearing is seated correctly.

67. Install the seal rings onto seal carrier (20).
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    Illustration 43	g00673883

68. Install Tooling (C) and a suitable lifting device to shaft assembly (18).

69. Install shaft assembly (18). The weight of shaft assembly (18) is approximately 17 kg (38 lb).
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    Illustration 44	g00673879

70. Carefully position the torque converter onto the side, as shown.
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    Illustration 45	g00673881

71. Install washer (17), retainer (16), and bolts (15). Tighten bolts (15) to a torque of 105 ± 15 N·m (77 ± 11 lb ft).
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    Illustration 46	g00673880

72. Install cover (14) and bolts (13). Tighten bolts (13) to a torque of 60 ± 7 N·m (44 ± 5 lb ft).
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    Illustration 47	g00660849

73. Position the torque converter upright.

74. Install gasket (10).

75. Install O-ring seals (11) and (12).
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    Illustration 48	g00660847

76. Use Tooling (M) to install seal (9) into retainer (8).
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    Illustration 49	g00660846

77. Install retainer (8) and bolts (7). Tighten bolts (7) to a torque of 60 ± 7 N·m (45 ± 5 lb ft).

    Note: It is necessary to install the torque converter into the torque converter housing prior to installation of the idler gear.

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    Illustration 50	g00665414

78. Install Tooling (A) and a suitable lifting device to the torque converter housing.

79. Install the torque converter housing to the torque converter. The weight of the torque converter housing is approximately 270 kg (600 lb).
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    Illustration 51	g00665412

80. Install bolts (6).
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    Illustration 52	g00665121

81. Install yoke (5).

82. Install O-ring seal (4).
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    Illustration 53	g00665406

83. Install bolt (2) and retainer (3). Tighten bolt (2) to a torque of 240 ± 25 N·m (175 ± 20 lb ft).
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    Illustration 54	g00674986

84. Install bearings (92) and ring (93) to idler gear assembly (91).
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    Illustration 55	g00675821

85. Install idler gear assembly (91).
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    Illustration 56	g00675822

86. Install idler gear shaft (90).

87. Install bolt (89).
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    Illustration 57	g00674982

88. Install O-ring seal (88) to cover (87).
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    Illustration 58	g00675823

89. Install bolts (86) and cover 87.
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    Illustration 59	g00675717

90. Lower the temperature of bearing cup (85).

91. Install bearing cup (85) into the housing.
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    Illustration 60	g00675718

92. Raise the temperature of bearing (83).

93. Install bearing (83) onto gear assembly (77).
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    Illustration 61	g00674959

94. Install plate (82) onto adapter (80).

95. Use Tooling (L) to install retaining ring (81).
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    Illustration 62	g00674957

96. Install adapter assembly (80) into gear assembly (77).

97. Install retaining ring (79).
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    Illustration 63	g00675719

98. Raise the temperature of bearing (78).

99. Install bearing (78) onto gear assembly (77).

    Note: Allow bearing (78) and gear assembly (77) to reach a uniform temperature.

100. Use a suitable punch to reset the bearing around the inside race of the bearing. This will ensure that the bearing is seated correctly.
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     Illustration 64	g00675721

101. Install gear assembly (77) and shim pack (84).

102. If both pump drives were removed, repeat Steps 90 through 101 for the remaining pump drive.
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     Illustration 65	g00716568

103. Lower the temperature of bearing cup (75). Install bearing cup (75) into adapter (73). Ensure that bearing cup (75) is seated.
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     Illustration 66	g00716572

     Note: DO NOT install the seals to the adapters at this time.

104. Use two people to install adapters (73) and (77) on the torque converter housing. The weight of adapter (73) is approximately 30 kg (65 lb).

105. Install bolts (72) and bolts (78). Tighten bolts (72) and (78) to a torque of 240 ± 40 N·m (177 ± 30 lb ft).

106. When possible, rotate either the torque converter or the outer housing to ensure that the bearings are properly seated.
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     Illustration 67	g01142905

107. Use Tooling (N) to check bearing end play. The bearing end play must be 0.15 ± 0.05 mm (.006 ± .002 inch). Remove shims (84) to attain the correct bearing end play.

108. Remove the pump adapters from the torque converter housing.
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     Illustration 68	g00674954

109. Use Tooling (B) to install seal (76) into adapter (73).

110. Lightly lubricate seal (76) with oil.
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     Illustration 69	g00674953

111. Install O-ring seals (74) on adapter (73).

112. Lubricate O-ring seals (74) prior to assembly.

113. Install two O-ring seals and one lip seal on the remaining adapter.
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     Illustration 70	g00716572

114. Install the correct amount of shims (84) to the torque converter housing. The correct shim thickness was determined in the above steps.

115. Use two people to install adapters (73) and (77) on the torque converter housing. The weight of adapters (73) and (77) is approximately 30 kg (65 lb).

116. Install bolts (72) and bolts (78). Tighten bolts (72) and (78) to a torque of 240 ± 40 N·m (177 ± 30 lb ft).

117. When possible, rotate either the torque converter or the outer housing to ensure that the bearings are properly seated.

118. Use Tooling (N) to recheck the bearing end play. If necessary, repeat the above procedure.
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     Illustration 71	g00660841

119. Install speed sensor (1).

End By:

1. Install the transmission oil pump. Refer to Disassembly and Assembly, "Transmission Oil Pump - Install".

2. Install the torque converter outlet relief valve. Refer to Disassembly and Assembly, "Relief Valve (Torque Converter Outlet) - Install".

3. Install the modulating valve for the torque converter impeller clutch. Refer to Disassembly and Assembly, "Modulating Valve (Torque Converter Impeller Clutch) - Install".

4. Install the modulating valve for the torque converter lockup clutch. Refer to Disassembly and Assembly, "Modulating Valve (Torque Converter Lockup Clutch) - Install".

5. Install the torque converter. Refer to Disassembly and Assembly, "Torque Converter - Install".