Caterpillar Cat 924G Wheel Loader (Prefix WMB) Service Repair Manual (WMB00001 and up).pdf

Service Repair Manual
Models
924G and 924Gz Wheel Loader

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Product: WHEEL LOADER
Model: 924G WHEEL LOADER WMB
Configuration: 924G 924Gz Wheel Loader WMB00001-UP (MACHINE) POWERED BY 3056E Engine
Disassembly and Assembly
IT28G Integrated Toolcarrier and 924G, 924GZ and 928G Wheel Loaders Power
Train
Media Number -RENR6422-07 Publication Date -01/10/2017 Date Updated -09/10/2017
i06103589
Transmission and Torque Converter - Assemble
SMCS - 3001-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-2420 Transmission Repair Stand 1
B 180-3033 Repair Stand Set 1
C 138-7574 Link Bracket 2
D 4C-6136 Lifting Bracket 1
E 4C-6399 Compressor Assembly (Clutch Spring) 1
F FT-2343 Plexiglass Cover 1
H 4C-3652 Compressor Assembly (Clutch Spring) 1
J 4C-6402 Expander Tool Gp 1
K
4C-6137 Bearing Installer 1
4C-6142 Spacer 1
1P-0531 Handle 1
L 5P-3413 Pipe Sealant 1
M 9S-3263 Thread Lock Compound 1
N 1U-8846 Gasket Sealant 1
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P 4C-6143 Clutch Piston Installer 1
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 g01005243
1. Install gear (149) and retaining ring (148) . Raise the temperature of bearing cone (147) .
Install bearing cone (147) .
2. Raise the temperature of bearing cone (146) . Install bearing cone (146) .
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3. Apply Tooling (L) to the seal bore.
4. Install lip seal (145) . Lubricate the sealing lip with the lubricant that is being used.
5. Lower the temperature of bearing cup (143) . Install bearing cup (143) .
6. Use bolts (142) in order to install shield assembly (144) . Tighten bolts (142) to a torque of
55 ± 10 N·m (40 ± 10 lb ft).
7. Install the output shaft and gear (141) .
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9. Lower the temperature of bearing cup (139) . Install bearing cup (139) .
10. Install seal (138) .
11. Install shims (137) . 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.
12. Use bolts (135) in order to install the cage. Tighten bolts (135) to a torque of 70 ± 10 N·m
(50 ± 10 lb ft).
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13. Install parking brake assembly (133) and lever (134) .
14. Use bolts (131) in order to install plate (132) . Tighten bolts (131) to a torque of 120 ± 20
N·m (90 ± 15 lb ft).
15. Install brake drum (130) and yoke (129) together. Install seal (128) .
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16. Install the bolt and washer (127) . Tighten bolt (127) to a torque of 120 ± 20 N·m (90 ± 15
lb ft).
17. Use washer (125) and bolt (124) in order to install yoke (126) . Tighten bolt (124) to a
torque of 120 ± 20 N·m (90 ± 15 lb ft).
18. Lower the temperature of bearing cups (123) . Install bearing cups (123) . Use Tooling (J) to
install bearing (122) .
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19. Install gear (119) . Raise the temperature of bearing cone (118) . Install bearing cone (118) .
20. Install gear (120) . Raise the temperature of bearing cone (121) . Install bearing cone (121) .
21. Install seal (116) on carrier (117) and install carrier (117) .
22. Install the input shaft assembly (115) .
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23. Install seals (112) , (113) , and (114) .
Note: Lubricate the piston, and the bore with clean transmission oil.
24. Use Tooling (P) in order to install piston (111) .
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.
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25. Install spring (110) .
26. Install the retainer and seal assembly (109) .
27. Put the clutch pack in a suitable press. Use Tooling (H) in order to install retaining ring
(108) .
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28. Lower the temperature of bearing assembly (107) . Install bearing assembly (107) .
29. Install ring (106) .
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924G 924Gz Wheel Loader WMB00001-UP (MACHINE) POWERED BY 3056E ...
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Note: Refer to Specifications, "Power Shift Transmission" for the specifications of the
clutch discs.
30. Install plates and discs (105) . Install retaining ring (103) . Install washers (104) and (102) .
31. Install hub assembly (101) .
32. Install gear (100) and retaining ring (99) . Install washer (98) .
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33. Install gear (95) and washer (96) . Raise the temperature of bearing (97) . Install bearing
(97) .
Note: This completes the assembly of the first gear clutch pack.
Note: Refer to Specifications, "Power Shift Transmission" for the procedure to measure
running clearance.
34. Install seals (94) and (93) .
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36. Install seals (92) on shaft (91) .
37. Install spring (89) and retainer (88) .
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injury.
38. Put the third gear clutch pack in a suitable press. Use Tooling (H) in order to install
retaining ring (87) .
clutch discs.
39. Install plates and discs (86) . Install retaining ring (85) .
40. Install washer (84) .
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41. Use a suitable press in order to install bearing (83) . Install retaining ring (82) .
43. Install gear (80) and retaining ring (79) .
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44. Install washer (78) and retaining ring (77) .
Note: This completes the assembly of the third gear clutch pack.
Note: Refer to Specifications, SENR3504, "Power Shift Transmission" for the procedure to
measure running clearance .
45. Use Tooling (D) in order to install third gear clutch pack (76) . The weight of third gear
clutch pack (76) is approximately 50 kg (110 lb).
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Note: Use Steps 46 through 49 for the assembly of the clutch of the second gear clutch
pack. Use Tooling (E) in step 49 instead of Tooling (H) .
46. Install washers (75) and (74) . Install spacer (73) .
47. Install gear (72) , spacer (70) , and bearing cone (71) .
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Note: Lubricate the piston and the bore with clean transmission oil.
49. Use Tooling (P) in order to install piston (65) . Install seals (66) on shaft (67) .
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injury.
51. Put the reverse clutch pack in a suitable press. Use Tooling (H) in order to install retaining
ring (62) .
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clutch discs.
53. Install plates and discs (59) . Install retaining ring (57) .
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56. Install gear (55) and retaining ring (54) .
Note: This completes the assembly of the reverse second gear clutch pack.
running clearance.
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58. Use Tooling (D) in order to install reverse second gear clutch pack (51) . The weight of
reverse second gear clutch pack (51) is approximately 32 kg (70 lb).
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injury.
62. Put the forward high clutch pack in a suitable press. Use Tooling (H) in order to install
retaining ring (44) .
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Note: Refer to Specifications, "Power Shift Transmission" for specifications of the clutch
discs.
63. Install plates and discs (43) . Install retaining ring (42) . Install washer (41) .
65. Install hub (38) .
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66. Raise the temperature of gear (37) . Install gear (37) . Install retaining ring (36) .
Note: This completes the assembly of the forward high gear clutch pack.
running clearance.
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68. Install O-ring seals (33) .
69. Use Tooling (P) in order to install piston (31) . Install seals (32) on shaft (30) .
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injury.
71. Put the forward low clutch pack in a suitable press. Use Tooling (H) in order to compress
the spring. Install retaining ring (27) .
72. Use a suitable press in order to install bearing (25) . Install retaining ring (26) in hub (22) .
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Note: Refer to Specifications, "Power Shift Transmission" for specifications of clutch discs.
74. Install plates and discs (23) . Install hub (21) . Install retaining ring (22) .
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75. Raise the temperature of gear (20) . Install gear (20) . Install retaining ring (19) .
Note: This completes the assembly of the forward low gear clutch pack.
running clearance.
77. Use Tooling (D) in order to install the forward low and the forward high clutch pack (15) .
The weight of forward high clutch pack (15) is approximately 27 kg (60 lb).
Note: Use Tooling (J) in order to install plugs (16) .
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78. Lower the temperature of bearing cups (14) . Use Tooling (K) in order to install bearing
cups (14) .
79. Use bolts (12) in order to install gear (13) . Tighten bolts (12) to a torque of 12 ± 3 N·m (10
± 2 lb ft).
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80. Install gear assembly (10) .
81. Install O-ring seals (11) .
82. Install bolts (9) . Tighten bolts (9) to a torque of 55 ± 10 N·m (40 ± 10 lb ft).
83. ApplyTooling (L) to the seal bore.
85. Install seal (8) .
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Caterpillar Cat 924G Wheel Loader (Prefix WMB) Service Repair Manual (WMB00001 and up).pdf

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Caterpillar Cat 924G Wheel Loader (Prefix WMB) Service Repair Manual (WMB00001 and up).pdf