Caterpillar cat 324 d fm excavator (prefix jgk) service repair manual (jgk00001 and up)

Service Repair Manual
Models
324D FM EXCAVATOR

Shutdown SIS
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Product: EXCAVATOR
Model: 324D FM EXCAVATOR JGK
Configuration: CUSTOM SUPPORT LITERATURE FOR THE 324D FM LGP JGK00001-UP (MACHINE)
Disassembly and Assembly
324D and 325D Forest Machines Machine Systems
Media Number -KENR5986-02 Publication Date -01/02/2012 Date Updated -27/06/2017
i02568643
Final Drive - Disassemble
SMCS - 4050-015
Disassembly Procedure
Start By:
a. Remove the final drive. Refer to Disassembly and Assembly, "Final Drive - Remove".
Table 1
Required Tools
Tool Part Number Part Description Qty
A
3H-0468 Puller Plate 2
5F-7366 Forcing Screw 1
8B-7548 Push-Puller Tool Gp 1
8T-0070 Bolt 2
8T-3282 Hard Washer 2
B 1P-0520 Driver Gp 1
C 1P-2321 Combination Puller 1
D 138-7573 Link Bracket 3
E
156-7100 Slide Hammer Puller Gp 1
M5x0.8x1.5 Bolt 1
F 10mm Drill 1
G 138-7575 Link Bracket 3
H 199-6557 Spanner Socket 1
1/15CUSTOM SUPPORT LITERATURE FOR THE 324D FM LGP JGK00001-UP (MA...
2020/8/6https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw...

J 127-8458 Final Drive Bench Ar 1
K 127-8468 Reaction Bar As 1
L
3S-6224 Electric Hydraulic Pump Gp 1
8T-0820 Hydraulic Pressure Gauge 1
3B-7722 Pipe Bushing 2
1P-2376 Quick Connect Coupler 2
1P-2377 Dust Plug 2
8F-0024 Hose As 2
M 128-4075 Shaft As 1
N 194-3885 Adapter Plate 1
Illustration 1 g00903052
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.

1. Install Tooling (A) and Tooling (B). Apply slight pressure to plate (1). Remove retaining
ring (2).
2. Carefully remove Tooling (A) and Tooling (B).
3. Remove plate (1).
4. Remove O-ring seal (3).
5. Remove springs (4).
6. Remove piston (5).
a. Remove piston seals (6) from piston (5).

7. Remove coupler (7).
8. Remove brake discs (8).
9. Remove bottom brake plate (9).
10. Turn over the final drive.

11. Attach a suitable lifting device to sprocket (10). The weight of sprocket (10) is
approximately 41 kg (90 lb). Remove sprocket (10).
12. Remove cover (11).
13. Remove sun gear (12). Remove planetary gear set (13). Remove retaining rings (14).
a. Install Tooling (C). Remove gears (15).

b. Cut a notch in the bearing cup. Remove one row of bearing rollers through the notch.
After the bearing rollers are out, the remaining parts will drop out. Remove the
retaining ring from the bearing cup.
14. Remove planetary gear set (16).
a. Remove retaining rings (17).

b. Install Tooling (C). Remove gear (18).
15. Remove bolts (19).
16. Remove retainer ring (19A).

17. Install Tooling (D) and a suitable lifting device to planetary gear set (20). The weight of
planetary gear set (20) is approximately 36 kg (80 lb).
a. Install Tooling (C). Remove gear (21).
b. Remove retaining ring (22).

18. Rotate ring (23) for one notch.
19. Remove ring (23).
20. Install Tooling (E) into dowel pin (24). Remove dowel pin (24) from locknut (25).
Note: The threads for the nut will be damaged from the dowel pins.
21. Use Tooling (F) to drill the holes in order to remove the damaged threads.
127-8458 Final Drive Disassembly and Assembly Bench
Note: The following procedure is for the 127-8458 Final Drive Disassembly and Assembly
Bench.
Reference: Refer to the Tool Operating Manual, NEHS0673 for further procedures concerning
127-8458 Bench.
1. Remove the suitable lifting device from Tooling (G) and attach the suitable lifting device to
the upper half of Tooling (J).

2. Remove the upper half of Tooling (J). The weight of the upper half of Tooling (J) is
approximately 816 kg (1800 lb).
3. Install Tooling (N) onto the lower half of Tooling (J). The weight of Tooling (N) is
approximately 100 kg (221 lb).
4. Fasten Tooling (G) and a suitable lifting device to the final drive.
5. Fasten the final drive onto the lower half of Tooling (N).
6. Install bolts (27) in the final drive through adapter ring (26).
10/15CUSTOM SUPPORT LITERATURE FOR THE 324D FM LGP JGK00001-UP (M...

7. Fasten Tooling (G) and a suitable lifting device to Tooling (H). The weight of Tooling (H)
is approximately 45 kg (100 lb).
8. Lower Tooling (H) into the final drive. Make sure that the notches in nut (25) are aligned
with the keys on Tooling (H).
9. Remove Tooling (I) and the suitable lifting device.
10. Place Tooling (K) onto Tooling (H).
11. Fasten a suitable lifting device to the upper half of Tooling (J) and install the upper half of
Tooling (J) to the lower half of Tooling (J). Pin the two halves together.

12. Attach Tooling (L) to the pressure reducing valve manifold, as shown.
13. Set the torque level for the bench to 2000 psi (14500 lb ft). Do not exceed this pressure.
Reference: Refer to the Tool Operating Manual, NEHS0673 for setting the torque level.
14. Place Tooling (M) through the bench and into Tooling (K).
15. Remove locknut (25). The breakaway torque will vary. The nut will loosen usually at
1400 psi (10750 lb ft).
16. Fasten a suitable lifting device to the upper half of Tooling (J).
17. Remove the upper half of Tooling (J).
Disassembly Procedure for the Main Housing and the Motor Housing

1. Fasten Tooling (G) and a suitable lifting device to main housing (29), as shown.
2. Separate the main housing (29) from the motor housing (30). The weight of the main
housing is approximately 123 kg (270 lb).
Note: Two outer races and one roller bearing will be removed with the main housing. The
other roller bearing and the two Duo-cone seal kits will remain with the motor housing.
3. Disassemble motor housing (30), as follows:
a. Use two screwdrivers and remove bearing (31) from the motor housing.
b. Remove the Duo-cone seal kit (32) from the motor housing.

c. Remove the two backup rings and O-ring seal (33) from the motor housing.
4. Disassemble the main housing (29), as follows:
a. Remove bearing (34) from the main housing (29).

b. Turn main housing (29) over 180 degrees, as shown.
c. Remove seal (35).
d. Remove bearing (36).
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All Rights Reserved.
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Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: 324D FM EXCAVATOR JGK
Configuration: CUSTOM SUPPORT LITERATURE FOR THE 324D FM LGP JGK00001-UP (MACHINE)
Disassembly and Assembly
324D and 325D Forest Machines Machine Systems
Media Number -KENR5986-02 Publication Date -01/02/2012 Date Updated -27/06/2017
i07141171
Final Drive - Assemble
SMCS - 4050-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 126-3994 Duo-Cone Seal Installer As 1
B 138-7573 Link Bracket 3
C 127-8458 Final Drive Bench Ar 1
D 154-9315 Thread File Group 1
E 138-7575 Link Bracket 2
F 199-6557 Spanner Wrench As 1
G 127-8468 Reaction Bar As 1
H
3S-6224 Electric Hydraulic Pump Gp 1
8T-0820 Hydraulic Pressure Gauge 1
3B-7722 Pipe Bushing 2
1P-2376 Quick Connect Coupler 2
1P-2377 Dust Plug 2
8F-0024 Hose As 2
I 128-4075 Shaft As 1
K 1P-0520 Driver Gp 1

L 1U-8223 Lifting Sling 2
M
3H-0468 Puller Plate 2
5F-7366 Forcing Screw 1
8B-7548 Push-Puller Tool Gp 1
8T-0070 Bolt 2
8T-3282 Hard Washer 2
1P-0520 Driver Gp 1
Assembly Procedure for the Main Housing
1. Assemble main housing (3), as follows:
a. Install bearing race (2).
b. Install seal (1).
c. Turn main housing (3) over 180 degrees, as shown.

d. Install bearing (4).
2. Assemble motor housing (6), as follows:
a. Install the two backup rings and O-ring seal (7) in the motor housing.
b. Install bearing (8).
c. Use Tooling (A) to install Duo-cone seal kit (9).

3. Place main housing (3) on motor housing (6).
4. Remove Tooling (B) and the suitable lifting device.
5. Use Tooling (D) to clean the threads that are on locknut (10).
6. Install locknut (10).

7. Fasten Tooling (E) and a suitable lifting device to Tooling (F).
8. Lower Tooling (F) into the final drive. Make sure that the notches in locknut (10) are
aligned with the keys on Tooling (F). The weight of Tooling (F) is approximately 45 kg
(100 lb).
9. Place Tooling (G) onto Tooling (F).
10. Fasten a suitable lifting device to the upper half of Tooling (C) and install the upper half of
Tooling (C) to the lower half of Tooling (C). Pin the two halves together.
11. Attach Tooling (H) to the pressure reducing valve manifold, as shown.
12. Set the torque level for the bench to 4000 N�m (2950 lb ft). Do not exceed this pressure.
Reference: Refer to the Tool Operating Manual, NEHS0673 for setting the torque level.

13. Place Tooling (I) through the bench and into Tooling (G).
14. Install locknut (10). Tighten locknut (10) to a torque of 4000 N�m (2950 lb ft).
15. Fasten a hoist to the upper half of Tooling (C).
16. Remove the upper half of Tooling (C).

17. Install dowel pin (11) into locknut (10).
Note: Do not reuse the old holes for the dowel pins.
18. Rotate ring (12) for one notch until the ring locks in place.

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19. Install retaining ring (15).
20. Install gears (14).
21. Install retaining ring (13).
22. Install Tooling (B) and a suitable lifting device to planetary gear set (16). The weight of
planetary gear set (16) is approximately 36 kg (80 lb). Position the planetary gear set into
the housing.

23. Install bolts (17).
Typical Example
24. Install gears (18). Install sun gear (18A) and the retaining ring.

25. Install planetary gear set (19).
a. Install retaining ring (20).
26. Install gears (21). Install sun gear (21A) and the retaining ring.
a. Install retaining rings (24). Install planetary gear set (23). Install sun gear (22).

Caterpillar cat 324 d fm excavator (prefix jgk) service repair manual (jgk00001 and up)

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