Caterpillar Cat 924G and 924Gz Wheel Loader (Prefix 3PZ) 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 3PZ
Configuration: 924G 924Gz Wheel Loader 3PZ00001-01552 (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.
Illustration 1 g00655451
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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17. Install the bolt and washer (127). The torque for bolt (127) is 120 ± 20 N·m (90 ± 15 lb ft).
18. Use washer (125), and bolt (124) in order to install yoke (126) . The torque for bolt (124) is
120 ± 20 N·m (90 ± 15 lb ft).
19. Lower the temperature of bearing cups (123). Install bearing cups (123). Use Tooling (J) to
install bearing (122).
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20. Install gear (119). Heat bearing (118) to a temperature of 135 °C (275 °F). Install bearing
(118).
21. Install gear (120). Heat bearing (121) to a temperature of 135 °C (275 °F). Install bearing
(121).
22. Install seal (116) on carrier (117), and install carrier (117).
23. Install the input shaft assembly (115).
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24. Install seals (112), (113), and (114).
Note: Lubricate the piston, and the bore with clean transmission oil.
25. Use Tooling (G) in order to install piston (111).
26. Install spring (110).
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27. Install the retainer and seal assembly (109).
28. Put the clutch pack in a suitable press. Use Tooling (H) in order to install ring (108).
29. Lower the temperature of bearing assembly (107). Install bearing assembly (107).
30. Install ring (106).
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Note: Refer to Specifications, SENR3504, "Power Shift Transmission" for the
specifications of the clutch discs.
31. Install plates and discs (105). Install ring (103). Install washers (104) and (102).
32. Install hub assembly (101).
33. Install gear (100) and ring (99). Install washer (98).
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924G 924Gz Wheel Loader 3PZ00001-01552 (MACHINE) POWERED BY 3056 E...
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34. Install gear (95) and washer (96). Heat bearing (97) to a temperature of 135 °C (275 °F).
Install bearing (97).
Note: This completes the assembly of the first gear clutch pack.
Note: Refer to Specifications, SENR3504, "Power Shift Transmission" for the procedure to
measure running clearance.
35. Install seals (94) and (93).
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37. Install seals (92) on shaft (91).
38. Install spring (89), and retainer (88).
39. Put the third gear clutch pack in a suitable press. Use Tooling (H) in order to install ring
(87).
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40. Install plates and discs (86). Install ring (85).
41. Install washer (84).
42. Use a suitable press in order to install bearing (83). Install ring (82).
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44. Install gear (80) and ring (79).
45. Install washer (78) and ring (77).
Note: This completes the assembly of the third gear clutch pack.
measure running clearance .
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46. Use Tooling (D) in order to install third gear clutch pack (76). The weight of the clutch pack
is approximately 50 kg (110 lb).
Note: Use steps 47 through 50 for the assembly of the clutch of the second gear clutch pack.
Use Tooling (E) in step 50 instead of Tooling (H).
47. Install washers (75) and (74). Install spacer (73).
48. Install gear (72), spacer (70), and bearing (71).
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Note: Lubricate the piston and the bore with clean transmission oil.
50. Use Tooling (G) in order to install piston (65). Install seals (66) on shaft (67).
51. Install spring (64) and retainer (63).
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52. Put the reverse clutch pack in a suitable press. Use Tooling (H) in order to install ring (62).
54. Install plates and discs (59). Install ring (57).
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57. Install gear (55) and ring (54).
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Note: This completes the assembly of the reverse second gear clutch pack.
59. Use Tooling (D) in order to install reverse second gear clutch pack (51). The weight of the
clutch pack is approximately 32 kg (70 lb).
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62. Install spring (46), and retainer (45).
63. Put the forward high clutch pack in a suitable press. Use Tooling (H) in order to install ring
(44).
Note: Refer to Specifications, SENR3504, "Power Shift Transmission" for specifications of
the clutch discs.
64. Install plates and discs (43). Install ring (42). Install washer (41).
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66. Install hub (38).
67. Heat gear (37) to a temperature of 135 °C (275 °F). Install gear (37). Install ring (36).
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Note: This completes the assembly of the forward high gear clutch pack.
69. Install O-ring seals (33).
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70. Use Tooling (G) in order to install piston (31). Install seals (32) on shaft (30).
71. Install spring (29) and retainer (28).
72. Put the forward low clutch pack in a press. Use Tooling (H) in order to compress the spring.
Install ring (27).
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73. Use a suitable press in order to install bearing (25). Install ring (26) in hub (22).
Note: Refer to Specifications, SENR3504, "Power Shift Transmission" for specifications of
clutch discs.
75. Install plates and discs (23). Install hub (21). Install ring (22).
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76. Heat gear (20) to a temperature of 135 °C (275 °F). Install gear (20). Install ring (19).
Note: This completes the assembly of the forward low gear clutch pack.
78. Use Tooling (D) in order to install the forward low and the forward high clutch pack (15).
The weight of the clutch pack is approximately 27 kg (60 lb).
Note: Use Tooling (K) in order to install plugs (16).
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79. Lower the temperature of bearings and race (14). Use Tooling (J) in order to install bearings
and race (14).
80. Use bolts (12) in order to install gear (13). The torque for bolts (12) is 12 ± 3 N·m
(10 ± 2 lb ft).
81. Install gear assembly (10).
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82. Install O-ring seals (11).
83. Install bolts (9). The torque for bolts (9) is 55 ± 10 N·m (40 ± 10 lb ft).
84. Apply Tooling (L) to the seal bore.
85. Install lip type seal (7). Lubricate the sealing lip with the lubricant that is being used.
86. Install seal (8).
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Note: Lubricate the bore with the lubricant that is being used.
87. Use bolts (5) in order to install plate (6). The torque for bolts (5) is 55 ± 10 N·m
(40 ± 10 lb ft).
Note: Apply Tooling (M) to the threads of bolts (3).
88. Use bolts (3) in order to install flex plate (4) on torque converter (1). The torque for bolts
(151) is 60 ± 7 N·m (45 ± 5 lb ft).
89. Clean both mating surfaces of the transmission housing. Apply a continuous bead of
Tooling (N) to the mating surface of the transmission housing.
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90. Use Tooling (C) and a suitable lifting device in order to install the top transmission case.
Install bolts (2). The torque for bolts (2) is 55 ± 10 N·m (40 ± 10 lb ft). The weight of the
top transmission case is approximately 163 kg (360 lb).
Note: Install the selector and pressure control valve. Remove Tooling (F). Refer to
Disassembly and Assembly, "Selector And Pressure Control Valve (Transmission) -
Remove And Install".
91. Install torque converter (1).
92. Remove the transmission from Tooling (A) and (B). The weight of the transmission is
approximately 500 kg (1100 lb).
End By:
a. Connect the engine, and the transmission. Refer to Disassembly and Assembly, RENR3503,
"Engine to Torque Converter and Transmission - Connect".
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Tue Feb 2 15:31:57 UTC+0800 2021
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Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 924G WHEEL LOADER 3PZ
Configuration: 924G 924Gz Wheel Loader 3PZ00001-01552 (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
i01740177
Flow Control Valve - Remove and Install
SMCS - 5137-010-T3
Removal Procedure
Start By:
a. Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame
Lock - Separate and Connect".
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-1853 Retaining Pliers 1
Hot oil and hot components can cause personal injury. Do not allow hot
oil or hot components to contact skin.
At operating temperature, the engine coolant is hot and under pressure.
Steam can cause personal injury.
Check the coolant level only after the engine has been stopped and the
cooling system pressure cap is cool enough to touch with your bare
hand.
Remove the cooling system pressure cap slowly to relieve pressure.
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Cooling system conditioner contains alkali. Avoid contact with the skin
and eyes to prevent personal injury.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to local regulations and mandates.
1. Drain the transmission oil.
2. Remove hose assembly (1).
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Caterpillar Cat 924G and 924Gz Wheel Loader (Prefix 3PZ) Service Repair Manual Instant Download.pdf

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