826K Landfill Compactor, 825K Soil Compactor and 824K Wheel Dozer Machine Systems Caterpillar

Removal Procedure

Start By:

1. Remove the center drive shaft.

2. Remove or lower the front guard, depending on which machine is being serviced.

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Illustration 1	g03682183

1. Apply the parking brake from the cab in order to release the hydraulic pressure at brake actuator (2).

2. Disconnect hose assembly (1) from parking brake actuator (2).
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   Illustration 2	g03682190

3. Connect Tooling (A) to parking brake actuator (2), as shown. Use Tooling (A) to release the parking brake.
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   Illustration 3	g03682865

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   Illustration 4	g03682876

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   Illustration 5	g03682880

4. Remove bolt (3) and the washer. Install Tooling (C) at the same location.

5. Remove bolt (4), the washer, and the O-ring seal from the splined end of front drive shaft (6) (not shown).

6. Install the bar stock from Tooling (B) over the top of the front loader frame, as shown. Connect the ratchet puller and the lifting strap to the bar stock and to Tooling (C), as shown.

7. Make sure that parking brake drum (5) is supported by Tooling (C) and Tooling (B). Slide parking brake drum (5) off the splined end of front drive shaft (6) (not shown). The weight of parking brake drum (5) is approximately 39 kg (85 lb).
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   Illustration 6	g03682902

8. Use Tooling (A) to retract the actuator piston.

9. Remove the cotter pin and pin (8). Disconnect lever (9) from yoke (7).

10. Mark the position of lever (9) on camshaft (11) for installation purposes. Loosen bolt (10). Remove lever (9) from camshaft (11).
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    Illustration 7	g00525148

11. Remove bolts (12) and the washers. Remove brake assembly (13) from the machine.
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    Illustration 8	g03682922

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    Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

12. Disassemble the brake assembly by the following steps:

    1. Remove springs (14) and (18).

    2. Remove socket (15) and nut (17).

    3. Remove adjustment screw (16) from nut (17).
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       Illustration 9	g03683133

    4. Remove retaining rings (24) and (27).

    5. Remove anchor pin brace (25).

    6. Remove brake shoes (19) and (22) from plate assembly (28).

    7. Remove nuts (20) and (21) and the washers.

    8. Remove camshaft (11) from plate assembly (28).

    9. Remove pins (23) and (26) from plate assembly (28).

Installation Procedure

1. Check the condition of the lining and the brake shoe assemblies. Use new parts for replacement if the components are worn or damaged.
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   Illustration 10	g03683133

2. Assemble the brake assembly by the following steps:

   1. Install pins (23) and (26) to plate assembly (28).

   2. Install camshaft (11) to plate assembly (28).

   3. Install nuts (20) and (21) and the washers. Tighten nuts (20) and (21) to a torque of 169 to 226 N·m (125 to 167 lb ft).

   4. Install brake shoes (19) and (22) to plate assembly (28).

   5. Install anchor pin brace (25).

   6. Install retaining rings (24) and (27).
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      Illustration 11	g03682922

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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.

   7. Install adjustment screw (16) to nut (17).

   8. Install socket (15) and nut (17).

   9. Install springs (14) and (18).

3. The following steps are for the pre-adjustment of the brake assembly in the parking brake drum.
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   Illustration 12	g03683296

   1. Position parking brake drum (5) on a flat surface, as shown. Insert brake assembly (13) into parking brake drum (5), as shown.

   2. Rotate adjustment screw (16) in order to expand brake shoes (19) and (22). Expand brake shoes (19) and (22) until the brake shoes are tight against parking brake drum (5).

      Note: It may be necessary to hold up brake assembly (13) in parking brake drum (5) in order for brake shoes (19) and (22) to expand without contacting the flange radius on parking brake drum (5).

      Note: Parking brake drum (5) should be tight enough to not slip off brake assembly (13).

   3. Back off adjustment screw (16) by 12 notches (clicks).
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   Illustration 13	g00525148

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   Illustration 14	g03683358

   Note: Contact surfaces must be clean and dry.

4. Apply Tooling (D) to the mating surface of plate assembly (28).

5. Install brake assembly (13).

6. Install bolts (12) and the washers. Tighten bolts (12) to a torque of 300 ± 40 N·m (221 ± 30 lb ft). Remove all excess Tooling (D).
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   Illustration 15	g03682880

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   Illustration 16	g03682876

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   Illustration 17	g03682865

7. Attach Tooling (C) to parking brake drum (5). The weight of parking brake drum (5) is approximately 39 kg (85 lb). Install the bar stock from Tooling (B) over the top of the front loader frame, as shown. Connect the ratchet puller and the lifting strap to the bar stock and to Tooling (C), as shown.

8. Use Tooling (B) and Tooling (C) in order to install parking brake drum (5) onto front drive shaft (6) (not shown).

9. Install the O-ring seal, the washer, and bolt (4). Tighten bolt (4) to a torque of 530 ± 70 N·m (391 ± 52 lb ft).

10. Remove Tooling (B) and Tooling (C). Install the washer and bolt (3). Tighten bolt (3) to a torque of 105 ± 20 N·m (77 ± 15 lb ft).
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    Illustration 18	g03682190

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    Illustration 19	g03682902

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    Illustration 20	g03683451

11. Use Tooling (A) in order to pressurize parking brake actuator (2) to 12500 to 15000 kPa (1800 to 2200 psi) in order to extend shaft (29).

    Note: Do not exceed the maximum pressure of 25000 kPa (3600 psi) for parking brake actuator (2).

12. Adjust yoke (7) in order to achieve Dimension (L). Dimension (L) is 145 mm (5.7 inch). Do not torque nut (30) at this time.

13. Position lever (9) onto camshaft (11). Rotate lever (9) toward parking brake actuator (2) in order to remove slack in the system. Do not extend the brake shoes out to the parking brake drum.

14. Align the holes for yoke (7) and lever (9) by turning shaft (29) and lightly pushing up on lever (9) toward parking brake actuator (2).

15. Secure lever (9) on camshaft (11) by tightening bolt (10).

16. Apply Tooling (E) to the bore in lever (9). Apply Tooling (E) to the bores in yoke (7). Apply Tooling (E) to pin (8).

17. Install pin (8) and the cotter pin.

18. Tighten nut (30) to yoke (7).

19. Apply the brake by releasing the pressure in parking brake actuator (2). Measure parking brake actuator (2) stroke between "brake released" and "brake applied", as represented in Dimension (M). Dimension (M) must be within 35 to 50 mm (1.4 to 2.0 inch). If the parking brake actuator (2) stroke is within these limits, the parking brake adjustment is complete.

20. If the parking brake actuator (2) stroke Dimension (M) is not within the limits of 35 to 50 mm (1.4 to 2.0 inch), further adjustment is required.

21. Use Tooling (A) in order to apply pressure to parking brake actuator (2) and release the brake.

22. Remove the cotter pin and pin (8). Push lever (9) lightly toward parking brake actuator (2) in order to verify that the holes in yoke (7) and lever (9) are aligned with the slack taken out. If the holes are not aligned, Repeat Steps 13 through 18.

23. Recheck parking brake actuator (2) stroke Dimension (M). If Dimension (M) is not within the limits of 35 to 50 mm (1.4 to 2.0 inch), Return to Step 3.a.

    Note: The parking brake must hold the machine stationary on level ground in second gear forward when the engine is slowly accelerated up to 1250 RPM.

24. Remove Tooling (A).
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    Illustration 21	g03682183

25. Connect hose assembly (1) to parking brake actuator (2).

End By:

1. Install or raise the front guard, depending on which machine is being serviced.

2. Install the center drive shaft.