Caterpillar Cat 924H Wheel Loader (Prefix KLN) Service Repair Manual (KLN00001 and up).pdf

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Product: WHEEL LOADER
Model: 924H WHEEL LOADER KLN
Configuration: 924H Wheel Loader KLN00001-UP (MACHINE) POWERED BY C6.6 Engine
Disassembly and Assembly
924H, 924HZ, 928HZ and 930H Wheel Loaders Power Train
Media Number -KENR7606-09 Publication Date -01/03/2015 Date Updated -09/10/2017
i07377005
Transmission and Torque Converter - Assemble
SMCS - 3001-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
1U-9200 Lever Puller Hoist 1
138-7575 Link Bracket 3
B
8T-0372
Bolt
M12 - 1.75 by 90mm
3
180-3033 Jack Stand Gp 2
180-3032 Jack Stand Gp 1
189-0410 Shackle As 2
D
1U-9200 Lever Puller Hoist 1
138-7575 Link Bracket 4
189-0409 Shackle As 1
F 136-1452 Retaining Ring Pliers As 1
H 1P-1863 Retaining Ring Pliers 1
J 4C-6136 Lifting Bracket 1
K 1P-1861 Retaining Ring Pliers 1
L 1P-0510 Driver Gp 1
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M 4C-3652 Compressor Assembly 1
N 1P-1857 Retaining Ring Pliers 1
R 4C-6399 Compressor Assembly 1
S 9S-3263 Thread Lock Compound -
T 1U-8846 Gasket Sealant -
U 4C-6402 Expander Tool Gp 1
V 8S-2328 Dial Indicator Gp 1
Note: Cleanliness is an important factor. Before assembly, thoroughly clean all parts in cleaning
fluid. Allow the parts to air dry. Do not use wiping cloths or rags to dry parts. Lint may be
deposited on the parts which may cause trouble. Inspect all parts. If any parts are worn or
damaged, use new parts for replacement. Dirt and other contaminants can damage the precision
component. Perform assembly procedures on a clean work surface. Keep components covered and
protected at all times.
Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the
components, if necessary.
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.
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Illustration 1 g01399408
1. Install gear (148) and retaining ring (147). Raise the temperature of bearing cone (146) to
install bearing cone (146).
2. Raise the temperature of bearing cone (145) to install bearing cone (145).
3. Lower the temperature of bearing cup (143) and install bearing cup (143). Install lip seal
(144).
Note: Lubricate the sealing lip with the lubricant that is being sealed.
4. Install shield assembly (142) and bolts (141). Tighten bolts (141) to a torque of 55 ± 10 N·m
(41 ± 7 lb ft).
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5. Install the output shaft and gear (140).
6. Install lip seal (137). Lower the temperature of bearing cup (136) and install bearing cup
(143). Install seal (135).
7. Install shims (134), cage (133), and bolts (132).
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8. Use shims as required to achieve 0.06 mm (0.002 inch) to 0.13 mm (0.005 inch) of end play
on the output shaft.
9. Tighten bolts (132) to a torque of 70 ± 10 N·m (52 ± 7 lb ft).
10. Install lever (131) and parking brake assembly (130).
11. Install plate (129). Install bolts (128).
12. Install brake drum (127) and yoke (126) together. Install seal (125).
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13. Install washer (124) and bolt (123). Tighten bolt (123) to a torque of 120 ± 20 N·m
(89 ± 15 lb ft).
14. Install yoke (122), washer (121), and bolt (120). Tighten bolt (120) to a torque of
120 ± 20 N·m (89 ± 15 lb ft).
15. Lower the temperature of bearing cup (117) and install bearing cup (117). Install bearings
(118) and (119).
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16. Install gear (114). Raise the temperature of bearing cone (113) and carrier (111). Install
bearing cone (113) and carrier (111). Install ring seal (112) onto carrier (111).
17. Raise the temperature of bearing cone (116). Install gear (115) and bearing cone (116).
18. Install input shaft assembly (110).
19. Install seals (109) onto the piston.
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Note: Lubricate the seals and the bore with the lubricant that is being sealed.
20. Position first gear and third gear clutch group (81), as shown. Install piston (108) and spring
(107).
21. Install seal assembly (105) and ring (106).
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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.
22. Position Tooling (R) onto seal assembly (105). Use Tooling (R) and a suitable press to
compress the clutch spring. Install retaining ring (104). Slowly release the spring tension.
23. Install retaining ring (102). Install clutch plates and discs (103).
24. Install plate (101) and retaining ring (100).
25. Install washer (99) and thrust disc (98).
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26. Lower the temperature of bearing (97) to install bearing (97) into hub (96). Install hub (96)
onto gear (94).
27. Use Tooling (H) to install retaining ring (95).
28. Install gear (94) and thrust disc (93).
29. Install gear (92) and spacer (91).
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30. Raise the temperature of bearing (90) to install bearing (90).
31. Refer to Step 58 through 65 for the assembly of the clutch pack.
32. Install thrust disc (89).
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33. Lower the temperature of bearing (88) to install bearing (88) into hub (85). Use Tooling (K)
to Install retaining ring (87).
34. Use Tooling (L) to install hub (85) into gear (84). Use Tooling (H) to install retaining ring
(86).
35. Install gear (84), thrust disc (83), and retaining ring (82).
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36. Attach Tooling (J) and a suitable lifting device to first gear and third gear clutch group (81).
The weight of clutch group (81) is approximately 45 kg (100 lb). Install clutch group (81).
37. Position the reverse and second clutch group (60), as shown.
to Install retaining ring (78).
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(77).
42. Install gear (75).
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43. Install thrust disc (74), thrust disc (73), spacer (72), gear (71), spacer (70), and bearing (69).
44. Raise the temperature of bearing (69) to install bearing cone (69).
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45. Reposition the reverse and second clutch group (60), as shown.
to install retaining ring (66).
(63).
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50. Install gear (63), thrust disc (62), and retaining ring (61).
51. Attach Tooling (J) and a suitable lifting device to the reverse and second clutch group (60).
The weight of clutch group (60) is approximately 32 kg (70 lb). Install clutch group (60).
52. Position the forward low and the forward high clutch group (26), as shown.
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Dimension (X) is 5.25 ± 0.25 mm (0.207 ± 0.010 inch).
55. Install bearing (58) into the hub at the depth of 5.25 ± 0.25 mm (0.207 ± 0.010 inch).
56. Use Tooling (K) to remove retaining ring (57) from hub (56).
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57. Install hub (56), thrust disc (55), and retaining ring (54).
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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.
58. Reposition the clutch group, as shown. If equipped, install ball (51), spring (50), retainer
(49), seal (48), and retaining ring (47) into body (52).
59. Lubricate the bore and seal (48) with the lubricant that is being sealed and install valve
assembly (53).
60. Install rings (46).
61. Install seals (45) onto piston (44).
Note: Lubricate the seals with the lubricant that is being sealed.
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62. Install piston (44).
63. Install spring (43) and retainer (42).
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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.
64. Install Tooling (M) onto retainer (42). Use Tooling (M) and a suitable press to compress the
clutch spring. Install retaining ring (41). Slowly release the spring tension.
65. Install discs (39) and plates (40). Install plate (38) and retaining ring (37).
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to install retaining ring (34).
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68. Use Tooling (L) to install hub (32) into gear assembly (31). Use Tooling (H) to install
retaining ring (33).
69. Install gear assembly (31).
70. Install thrust disc (30) and retaining ring (29).
Note: If the plugs in the shaft were removed during disassembly use Tooling (U) to install
the plugs.
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71. Use Tooling (J) and a suitable lifting device to remove the forward low and the forward
high clutch group (26). The weight of the clutch group is approximately 27 kg (60 lb).
Position shaft assembly (27) out of the way and install the forward low and the forward high
clutch group (26).
72. Install sensors (28). Tighten sensors (28) to a torque of 37 ± 7 N·m (27 ± 5 lb ft).
73. Lower the temperature of bearing cup (24) and install bearing cup (24). Lower the
temperature of bearings (25) and install bearings (25).
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74. Install bearing (22) into bearing support (21). Install bearing support (21) into the bearing.
Use Tooling (H) to install retaining ring (23).
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75. Use a suitable press to install bearing assembly (20) into gear (18). Use Tooling (F) to
install retaining ring (19).
76. Install gear (18) onto the stator support. Apply Tooling (S) to the threads of bolts (17).
Install bolts (17).
77. Tighten bolts (17) to a torque of 12 ± 3 N·m (106 ± 27 lb in).
78. Install gear assembly (16) and bolts (15). Tighten bolts (15) to a torque of 55 ± 10 N·m
(41 ± 7 lb ft).
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79. Apply a continuous bead of Tooling (T) to the mating surface of the transmission housings.
80. Attach Tooling (D) and a suitable lifting device to housing assembly (13). The weight of
housing assembly (13) is approximately 141 kg (310 lb). Position housing assembly (13)
and install bolts (14). Tighten bolts (14) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
81. Use Tooling (V) to check the end play. Make sure that the shafts are free. After checking
clearence, rotate shaft 7 times to ensure tapered roller bearing is seated. Use shims to obtain
0.05 mm (0.002 inch) to 0.15 mm (0.006 inch) of end play.
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Caterpillar Cat 924H Wheel Loader (Prefix KLN) Service Repair Manual (KLN00001 and up).pdf

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