Caterpillar Cat 924G and 924Gz Wheel Loader (Prefix 3DZ) Service Repair Manual Instant Download.pdf

Service Repair Manual
Models
924G and 924Gz Wheel Loader

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 924G WHEEL LOADER 3DZ
Configuration: 924G 924Gz Wheel Loader 3DZ00001-01048 (MACHINE) POWERED BY 3056 Engine
Disassembly and Assembly
924G and 924GZ Wheel Loaders Power Train
Media Number -RENR3506-05 Publication Date -01/05/2004 Date Updated -09/10/2017
i01738796
Power Shift Transmission - Disassemble
SMCS - 3030-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-2420 Transmission Repair Stand 1
B 1U-9759 Jack Stand 1
C 6V-2156 Link Bracket 2
D 4C-6136 Lifting Bracket 1
E 4C-6399 Spring Compressor 1
F FT-2343 Plexiglass Cover 1
G 1P-2321 Puller 1
H 4C-3652 Spring Compressor 1
Start By:
a. Separate the engine, and the transmission. Refer to Disassembly and Assembly, RENR3503,
"Engine from Torque Converter and Transmission - Separate".
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This will help to prevent dirt from entering the internal
mechanism.
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https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

Illustration 1 g00653680
1. Use Tooling (C) and a suitable lifting device in order to place the transmission on Tooling
(A) and (B), as shown. The weight of the transmission is approximately 500 kg (1100 lb).
2. Remove torque converter (1).
3. Remove bolts (2) and the top transmission case. The weight of the top transmission case is
approximately 163 kg (360 lb).
Note: Remove the selector and pressure control valve. Install Tooling (F). Refer to
Disassembly and Assembly, "Selector And Pressure Control Valve (Transmission)- Remove
And Install".
4. Remove bolts (3) and flex plate (4) from torque converter (1).
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5. Remove bolts (5) and plate (6).
6. Remove lip type seal (7) and seal (8).
7. Remove bolts (9).
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8. Remove gear assembly (10).
9. Remove O-ring seals (11).
10. Remove bolts (12) and gear (13).
11. Remove bearings and race (14).
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12. Using Tooling (D) to remove the forward low and the forward high clutch group (15). The
weight of the clutch group is approximately 27 kg (60 lb).
Note: When the clutch groups are disassembled, remove the shaft plugs (16) in order to
clean the oil passages. Use a punch to drive the plug into the shaft . Drill the remainder of
the aluminum plug out of the bore. Be careful not to drill any portion of the walls of the
bore. Use shop air or a cleaning solution in order to clean the shafts.
13. Remove ring (17) and washer (18).
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14. Remove ring (19).
15. Use a suitable press in order to remove gear (20).
16. Remove ring (22). Remove hub (21). Remove plates and discs (23).
Note: Take note of the number and order of plates and discs for assembly purposes.
17. Remove washer (24).
Note: The retainer may stick to the inside of hub (22) when the hub is removed.
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18. Remove ring (26). Press bearing (25) from hub (22).
19. Put the forward low clutch group in a press. Use Tooling (H) in order to compress the
spring. Remove ring (27).
20. Remove retainer (28) and spring (29).
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21. Release piston (32) by blowing shop air into lube passage (31). Remove piston (32).
22. Remove seals (30).
24. Disassemble the forward high clutch group by removing ring (34). Remove washer (35).
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25. Remove ring (36). Remove gear (37).
26. Remove hub (38).
27. Remove ring (39). Use a suitable press in order to remove bearing (40).
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28. Remove washer (41). Remove ring (42). Remove the plate and discs (43).
Note: Take note of the number and order of plates and discs for assembly purposes.
29. Put the forward high clutch group in a suitable press. Use Tooling (H) in order to remove
ring (44).
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31. Blow shop air into lube passage (48) in order to remove piston (47).
32. Remove seals (49) and (50).
33. Use Tooling (D) in order to remove reverse second gear clutch group (51). The weight of
the clutch group is approximately 32 kg (70 lb).
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35. Remove ring (54) and gear (55).
36. Remove hub assembly (56).
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38. Remove ring (57). Remove plates and discs (59).
Note: Take note of the number and order of the plates and discs for assembly purposes.
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40. Put the reverse clutch group in a suitable press. Use Tooling (H) in order to remove ring
(62).
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45. Install a suitable puller under gear (72). Pull gear (72), spacer (70), and bearing (71).
46. Remove spacer (73). Remove washer (74) and (75).
Note: Use Steps 35 through 44 for the remaining disassembly of the second gear clutch
group. In Step 40, use Tooling (E) instead of Tooling (H).
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47. Use Tooling (D) in order to remove first third gear clutch group (76). The weight of the
clutch group is approximately 50 kg (110 lb).
49. Remove ring (79) and gear (80).
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53. Remove ring (85). Remove plates and discs (86).
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54. Put the third gear clutch group in a suitable press. Use Tooling (H) in order to remove ring
(87).
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59. Disassemble the first gear clutch by installing Tooling (G) through the holes in gear (95).
Pull gear (95), washer (96), and bearing (97) together.
60. Remove washer (98). Remove ring (99) and gear (100).
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62. Remove washers (102) and (104). Remove ring (103). Remove plates and discs (105).
63. Remove ring (106).
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64. Remove bearing assembly (107).
65. Put the clutch group in a suitable press. Use Tooling (H) in order to remove ring (108).
66. Remove the retainer and seal assembly (109).
67. Remove spring (110).
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68. Remove piston (111). Blow shop air into the lube passage in order to release the piston.
69. Remove seals (112), (113), and (114).
70. Remove input shaft assembly (115).
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71. Remove carrier (117) and seal (116). Remove bearing (121) and gear (120).
72. Remove bearing (118) and gear (119).
73. Remove bearing (122) and bearing cups (123).
74. Remove bolt (124), washer (125), and yoke (126).
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75. Remove the bolt and washer (127).
76. Remove seal (128). Remove yoke (129) and brake drum (130) together.
77. Remove bolts (131). Remove plate (132).
78. Remove parking brake assembly (133), and lever (134).
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79. Remove bolts (135).
80. Install bolts (136). Tighten bolts (136) in order to remove cage (137).
81. Remove shims (138).
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82. Remove seal (139). Remove bearing cup (140) and lip seal (141).
83. Remove nuts (142) and cover (143).
84. Remove the output shaft and gear (144).
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85. Remove bolts (145) and shield assembly (147).
86. Remove bearing cup (146) and lip seal (148).
87. Remove bearing (149) from the output shaft.
88. Remove bearing (150). Remove ring (151) and gear (152).
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Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 924G WHEEL LOADER 3DZ
Configuration: 924G 924Gz Wheel Loader 3DZ00001-01048 (MACHINE) POWERED BY 3056 Engine
Disassembly and Assembly
924G and 924GZ Wheel Loaders Power Train
Media Number -RENR3506-05 Publication Date -01/05/2004 Date Updated -09/10/2017
i02055589
Power Shift Transmission - Assemble
SMCS - 3030-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-2420 Transmission Repair Stand 1
B 1U-9759 Jack Stand 1
C 6V-2156 Link Bracket 2
D 4C-6136 Lifting Bracket 1
E 4C-6399 Spring Compressor 1
F FT-2343 Plexiglass Cover 1
G 4C-6143 Clutch Piston Installer 1
H 4C-3652 Spring Compressor 1
J
4C-6137 Bearing Installer 1
4C-6142 Spacer 1
1P-531 Handle 1
K 4C-6402 Plug Installer 1
L 5P-3413 Pipe Sealant 1
M 9S-3263 Thread Lock Compound 1
N 1U-8846 Gasket Sealant 1
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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.
1. Install gear (152) and ring (151). Heat bearing (150) to a temperature of 135 °C (275 °F).
Install bearing (150).
2. Heat bearing (149) to a temperature of 135 °C (275 °F). Install bearing (149).
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3. ApplyTooling (L) to the seal bore.
4. Install lip seal (148). Lubricate the sealing lip with the lubricant that is being used.
5. Lower the temperature of bearing cup (146). Install bearing cup (146).
6. Use bolts (145) in order to install shield assembly (147). The torque for bolts (145) is
55 ± 10 N·m (40 ± 10 lb ft).
7. Install the output shaft and gear (144).
8. Use nuts (142) in order to install cover (143). The torque for nuts (142) is 9 ± 1 N·m
(6 ± 1 lb ft).
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9. Install lip type seal (141). Lubricate the sealing lip with the lubricant that is being used.
10. Lower the temperature of bearing cup (140). Install bearing cup (140).
11. Install seal (139).
12. Install shims (138). Use the shims in order to get 0.06 mm (0.002 inch) to 0.13 mm
(0.005 inch) end play on the output shaft.
Note: Lubricate the bore of the housing with the lubricant that is being used.
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13. Use bolts (135) in order to install the cage. The torque for bolts (135) is 70 ± 10 N·m
(50 ± 10 lb ft).
14. Install parking brake assembly (133) and lever (134).
15. Use bolts (131) in order to install plate (132). The torque for bolts (131) is 120 ± 20 N·m
(90 ± 15 lb ft).
16. Install brake drum (130) and yoke (129) together. Install seal (128).
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Caterpillar Cat 924G and 924Gz Wheel Loader (Prefix 3DZ) Service Repair Manual Instant Download.pdf

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Caterpillar Cat 924G and 924Gz Wheel Loader (Prefix 3DZ) Service Repair Manual Instant Download.pdf