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

Assemble Procedure

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

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Illustration 1	g00397059
The correct method for compressing the metal seal rings.

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Illustration 2	g00397061
The ends of the metal seal rings must contact the inner notches (bottom half of the above illustration).

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Illustration 3	g00397157
Do not use this method in order to make new metal seal rings ready for installation.

1. Use the correct method in order to make the new metal seal rings ready for installation. Place your hands on each end of the metal seal ring and expand the ends by each other. Keep the metal seal ring in a circular shape in order to ensure an even bend fully around the metal seal ring The notches in the ends of the metal seal rings must contact each other. The metal seal ring will damage the edge of the bore if the metal seal ring is not installed correctly. The notches must be fully engaged.
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   Illustration 4	g03656227

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   Illustration 5	g03656218

2. Install bearing (140) into planetary gear (141).

3. Install thrust disc (142), planetary gear (141), and thrust disc (139) to carrier assembly (133).

4. Install shaft (137). Use a suitable punch in order to install spring pin (138) that holds shaft (137) in carrier assembly (133).

5. Repeat Steps 2 through 4 for the remaining planetary gears (141).
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   Illustration 6	g03656207

6. Use Tooling (H) in order to install bearing (132) into carrier assembly (133). Install retaining ring (131).

7. Install lock ring (135).

8. Install metal seal rings (136), (134), and (130).
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   Illustration 7	g03656202

9. Use Tooling (H) in order to install bearing (127) to clutch housing (128). Be sure to install bearing (127) with the notch in the UPWARD position. Install retaining ring (129).
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   Illustration 8	g03669917

10. Position clutch housing (128) onto carrier assembly (133). Install retaining ring (126).
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    Illustration 9	g03656118

11. Install retaining ring (124) (not shown). Use a suitable screwdriver in order to compress retaining ring (124) as ring gear (125) is installed.

12. Install spacer (123) (not shown) and gear (122).
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    Illustration 10	g03655898

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    Illustration 11	g03655892

13. Install bearings (119) and (116) into planetary gears (120) and (115).

14. Install thrust discs (121) and (118) on each side of planetary gear (120). Position planetary gear (120) into carrier assembly (106). Install thrust discs (117) and (114) on each side of planetary gear (115). Position planetary gear (115) into carrier assembly (106). Install shaft (112).

15. Use a suitable punch in order to install spring pin (113) that holds shaft (112) to carrier assembly (106).

16. Repeat Steps 13 through 15 for the remaining planetary gears.
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    Illustration 12	g03658297

17. Use Tooling (H) in order to install bearing (109) into carrier assembly (106). Install bearing (109) with the notch in the UPWARD position. Install retaining ring (108).
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    Illustration 13	g03655704

18. Install seal ring (110). Apply clean transmission oil to seal ring (110).

19. Install retaining ring (111) (not shown). Use a suitable screw driver in order to compress retaining ring (111) (not shown) as ring gear (107) is installed.
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    Illustration 14	g03658520

20. Install gear (105).
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    Illustration 15	g03669965

21. Use two people in order to install carrier assembly (106) and ring gear (107) as one onto clutch housing (128). The combined weight of carrier assembly (106) and ring gear (107) is approximately 28 kg (61 lb).
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    Illustration 16	g03658196

22. Use Tooling (F) in order to install bearing (104) into output shaft (102).
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    Illustration 17	g03658210

23. Raise the temperature of seal carrier (103). Install seal carrier (103) onto output shaft (102).
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    Illustration 18	g03655483

24. Install bearing (99) onto input shaft (97). Install retaining ring (98).

25. Install O-ring seals (100) and (101) onto input shaft (97).
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    Illustration 19	g03658244

26. Use a suitable soft faced hammer in order to install input shaft (97) into output shaft (102).
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    Illustration 20	g03655450

27. Install retaining ring (96).
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    Illustration 21	g03655405

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    Illustration 22	g03655396

28. Attach Tooling (E) and a suitable lifting device to shaft assembly (95). Use Tooling (E) and the suitable lifting device in order to install shaft assembly (95).

29. Remove Tooling (E) and install speed adapter (94). Tighten speed adapter (94) to a torque of 290 ± 40 N·m (214 ± 30 lb ft).
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    Illustration 23	g03655389

30. Install retaining ring (93).
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    Illustration 24	g03655381

31. Install ring seals (92) to clutch piston (91).
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    Illustration 25	g03655369

32. Install clutch piston (91).
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    Illustration 26	g03655357

33. Start with a friction disc (89) and install friction discs (89) and clutch plates (90).
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    Illustration 27	g03655302

34. Install plate (88) and ring gear (87).
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    Illustration 28	g03655226

35. Start with a friction disc (85) and install friction discs (85) and clutch plates (86).
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    Illustration 29	g03655220

36. Install ring seals (84) to clutch piston (83). Install clutch piston (83) to clutch housing (79).
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    Illustration 30	g03655056

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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.

37. Install dowels (82) and springs (81).

38. Attach Tooling (B) to clutch housing (79) in order to secure the clutch piston to clutch housing ' (79). Turn clutch housing (79) over and attach Tooling (A) and a suitable lifting device to clutch housing (79). The weight of clutch housing (79) is approximately 44 kg (97 lb).

39. Use Tooling (A) and the suitable lifting device in order to install clutch housing (79).

40. Install bolts (80).
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    Illustration 31	g03655052

41. Install sun gear (78).
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    Illustration 32	g03655043

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    Illustration 33	g03655030

42. Install bearing (76) into planetary gear (75).

43. Install thrust disc (77), planetary gear (75), and thrust disc (74) to carrier assembly (65).

44. Install shaft (72) into carrier assembly (65). Use a suitable punch in order to install spring pin (73) in order to secure shaft (72).

45. Repeat Steps 42 through 44 for the remaining planetary gears (75).
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    Illustration 34	g03655027

46. Use Tooling (H) in order to install bearing (71) into carrier assembly (65). Install retaining ring (70).
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    Illustration 35	g03655018

47. Install retaining ring (68) (not shown). Use a suitable screw driver in order to compress retaining ring (68) (not shown) as ring gear (69) is installed to carrier assembly (65).
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    Illustration 36	g03655014

48. Install hub (67) into carrier assembly (65). Install retaining ring (68).
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    Illustration 37	g03655005

49. Attach Tooling (A) and a suitable lifting device to carrier assembly (65). The weight of carrier assembly (65) is approximately 26 kg (57 lb). Use Tooling (A) and the suitable lifting device in order to install carrier assembly (65).

50. Install retaining ring (64).
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    Illustration 38	g03654999

51. Install dowels (61) and springs (62).

52. Start with a friction disc (60) and install friction discs (60) and clutch plates (63).
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    Illustration 39	g03654865

53. Install ring seals (59) to clutch piston (58). Install clutch piston (58) to clutch housing (45).
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    Illustration 40	g03670140

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    Illustration 41	g03654886

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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.

54. Position clutch housing (45) onto a suitable press. Position disc spring (57), as shown in Illustration 40, with the outside edge of the first disc spring (57) in contact with clutch piston (58).

55. Install the next two disc springs (57) with the outside edges in contact with each other, as shown in Illustration 40.

56. Position retainer plate (55) over disc springs (57). Use Tooling (D) and the suitable press in order to apply force onto retainer plate (55) and install retaining ring (56).
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    Illustration 42	g03654853

57. Install rotating housing (54). Install dowels (53).
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    Illustration 43	g03654849

58. Install friction discs (51) and clutch plates (52).
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    Illustration 44	g03654815

59. Install ring gear (49). Install the washers and bolts (50).
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    Illustration 45	g03654799

60. If ring carrier (46) was removed from clutch housing (45), raise the temperature of ring carrier (46) to a maximum temperature of 149° C (300° F). Install ring carrier (46).

61. Install pin (48).

62. Install seal rings (47). Apply clean transmission oil to seal rings (47).
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    Illustration 46	g03654779

63. Attach Tooling (A) and a suitable lifting device to clutch housing (45). The weight of clutch (45) is approximately 45 kg (100 lb). Use Tooling (A) and the suitable lifting device in order to install clutch housing (45).
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    Illustration 47	g03654770

64. Install ring seals (44) onto clutch piston (43). Install clutch piston (43) into clutch housing (40).
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    Illustration 48	g03654717

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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.

65. Attach Tooling (A) and a suitable lifting device to clutch housing (40). The weight of clutch housing (40) is approximately 44 kg (97 lb).

66. Attach Tooling (C) (not shown) to clutch housing (40) in order to secure clutch piston (43) to clutch housing (40).

67. Use Tooling (A) and the suitable lifting device in order to install clutch housing (40).

68. Install bolts (42).

69. Install dowels (41).
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    Illustration 49	g03654713

70. Install ring seals (39) to clutch piston (38). Install clutch piston (38).
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    Illustration 50	g03654699

71. Install springs (37) and dowels (36). Install friction disc (35), clutch plate (34), and friction disc (33).
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    Illustration 51	g03654672

72. Install O-ring seal (32).

73. Use Tooling (H) in order to install bearing (31) into manifold (29). Install retaining ring (30).
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    Illustration 52	g03654658

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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.

74. Attach Tooling (A) and a suitable lifting device to manifold assembly (29). The weight of manifold assembly (29) is approximately 73 kg (160 lb). Use Tooling (A) and the suitable lifting device in order install manifold assembly (29).

75. Install bolts (28) and the washers.
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    Illustration 53	g03654651

76. Install sun gear (27) and retaining ring (26).

77. Install dowels (25).
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    Illustration 54	g03654633

78. Install bearings (22) to planetary gear (23).

79. Install thrust disc (24), planetary gear (23), and thrust disc (21) to carrier assembly (15).
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    Illustration 55	g03654253

80. Install shaft (19) into carrier assembly (15). Use a suitable punch in order to install spring pin (20) in order to secure shaft (19).

81. Repeat Steps 78 through 80 for the remaining planetary gears (23).
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    Illustration 56	g03654246

82. Install the gaskets with the rubber surface facing slinger (18). Install slinger (18) to carrier assembly (15). Install locks (17) and bolts (16). Bend the tabs on locks (17).
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    Illustration 57	g03654239

83. Install carrier assembly (15).

84. Install spacer (13) and retaining ring (14).
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    Illustration 58	g03654233

85. Install ring gear (12).
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    Illustration 59	g03654228

86. Install dowels (11).

87. Start with a friction disc and install friction discs (9) and clutch plates (10).
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    Illustration 60	g03654216

88. Install ring seals (6) to clutch piston (7).

89. Install clutch piston (7) to clutch housing (4).
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    Illustration 61	g03654155

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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.

90. Install springs (6).

91. Attach Tooling (B) to clutch housing (4) in order to secure the clutch piston.

92. Attach Tooling (A) and a suitable lifting device to clutch housing (4). The weight of clutch housing (4) is approximately 32 kg (70 lb). Use Tooling (A) and the suitable lifting device in order to install clutch housing (4).

93. Install the washers and bolts (5).
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    Illustration 62	g03654101

94. Attach Tooling (A) and a suitable lifting device to planetary assembly (1). The weight of planetary assembly (1) is approximately 565 kg (1246 lb). Use Tooling (A) and the suitable lifting device in order to install planetary assembly (1) to transmission housing (3).

95. Install the washers and bolts (2).