Caterpillar Cat 924K Wheel Loader (Prefix PWR) Service Repair Manual Instant Download.pdf

Service Repair Manual
Models
924K Wheel Loader

Illustration 94 g02798848
1. Install orifice (104) (not shown). Tighten orifice (104) to a torque of 16 ± 2 N·m (142 ± 18
lb in).
2. Install the O-ring seal and plate (103) .
3. Install the O-ring seal plug (102) .
4. Install the O-ring seal and sight glass (101) . Tighten sight glass (101) to a torque of 40 ± 5
N·m (30 ± 4 lb ft).
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924K Wheel Loader PWR00001-UP (MACHINE) POWERED BY C6.6 Engine(SE...
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5. Install breather (100) .
6. Install orifices (99) (not shown). Tighten orifices (99) to a torque of 16 ± 2 N·m (142 ± 18
lb in).
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7. Install the O-ring seals and plugs (98) .
8. Install the O-ring seal, sensor (96) , and bolt (97) . Tighten bolt (97) to a torque of 14 ± 3
N·m (124 ± 27 lb in).
9. Install the O-ring seal, sensor (94) , and bolt (95) . Tighten bolt (95) to a torque of 14 ± 3
N·m (124 ± 27 lb in).
10. Install O-ring seals (93) .
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11. Install bearing cups (92) .
12. Install gear (91) onto shaft (88) .
13. Install spacer (90) onto shaft (88) .
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14. Install bearing cone (89) onto shaft (88) . Be sure that bearing cone (89) is seated
completely.
15. Raise the temperature of bearing cone (87) . Install bearing cone (87) .
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16. Install shaft assembly (86) .
17. Install bearing cone (85) .
18. Install seal rings (84) and (83) .
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19. Install seal rings (82) onto piston (81) . Lubricate seal rings (82) with the lubricant that is
being sealed.
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20. Install piston (81) .
21. Position the shaft assembly and piston (81) onto a suitable press. Use Tooling (G) and the
suitable press in order to seat piston (81) into place.
22. Install sleeve (80) .
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23. Install spring (77) and washer (79) .
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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24. Position shaft assembly (62) onto a suitable press. Use Tooling (F) in order to compress
spring (77) . Install retaining ring (78) . Use the suitable press and Tooling (F) in order to
slowly release the compressed spring (77) .
25. Install end plate (76) onto gear assembly (63) .
26. Install friction disks (74) and plates (75) , ending with a plate (75) .
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27. Install thrust washer (71) .
28. Install thrust bearing (70) .
29. Install gear assembly (63) into shaft assembly (62) . Install needle bearing (69) .
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30. Install spacer (68) .
31. Install needle bearing (67) . Be sure that needle bearing (67) is seated correctly.
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32. Install retaining ring (72) .
33. Use suitable compressed air in order to check the operation of the clutch.
34. Install thrust bearing (66) .
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35. Install thrust washer (65) .
36. Install bearing cone (64) .
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38. Use Tooling (E) and a suitable press in order to install seal (61) (not shown) into seal
assembly (60) .
39. Apply Tooling (H) to bolts (59) . Install seal assembly (60) and bolts (59) to plate (58) .
Tighten bolts (59) to a torque of 13 ± 3 N·m (115 ± 27 lb in).
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40. Apply Tooling (H) to bolts (57) . Install plate (58) and bolts (57) . Tighten bolts (57) to a
torque of 13 ± 3 N·m (115 ± 27 lb in).
41. Install bearing cup (56) .
42. Raise the temperature of bearing cone (54) . Install bearing cone (54) onto shaft assembly
(53) .
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(53) .
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45. Install bearing cup (52) .
(49) .
(49) .
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49. Install orifice (43) . Tighten orifice (43) to a torque of 16 ± 2 N·m (142 ± 18 lb in).
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51. Install the O-ring seal and plug (41) .
52. Install the O-ring seal and sensor (47) . Install bolt (46) . Tighten bolt (46) to a torque of 14
± 3 N·m (1240 ± 27 lb in).
53. Install the O-ring seal and sensor (44) . Install bolt (45) . Tighten bolt (45) to a torque of 14
± 3 N·m (1240 ± 27 lb in).
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55. Install the O-ring seal and one plug (39) .
56. Install the O-ring seal and plug (38) into housing (29) .
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57. Install O-ring seal (37) onto tube assembly (36) .
58. Apply Tooling (H) to bolts (35) . Install tube assembly (36) and bolts (35) . Tighten bolts
(35) to a torque of 13 ± 3 N·m (115 ± 27 lb in).
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59. Install seal (34) .
60. Install shims (33) .
61. Lower the temperature of bearing cup (32) . Install bearing cup (32) .
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62. Install shims (31) .
63. Install bearing cups (30) into housing (29) .
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64. Attach Tooling (C) and a suitable lifting device to housing (29) . The weight of housing (29)
is approximately 45 kg (100 lb). Use the Tooling (C) and the suitable lifting device in order
to position housing (29) .
65. Install four bolts (27) .
66. Steps 66.a through 66.d are for checking the end play of shaft assembly (62) (not shown).
a. Position Tooling (J) through the hole and onto shaft assembly (62) (not shown).
Position Tooling (K) directly beneath shaft assembly (62) .
b. Use Tooling (K) in order to push the shaft until the indicator on Tooling (J) stops.
Record the reading as Reading (AA) .
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c. Lower Tooling (K) and rotate the gears 5 to 7 times, or until the indicator on Tooling
(J) reads zero.
Note: If the indicator on Tooling (J) does not read zero, the reading is faulty . Perform
Steps 66.a through 66.c again.
d. When the indicator on Tooling (J) returns to zero, Reading (AA) is the end play.
Note: The correct end play is 0.0254 - 0.0762 mm (0.00100 - 0.00300 inch).
67. Steps 67.a through 67.d are for checking the end play of shaft assembly (86) .
a. Attach Tooling (J) to the transmission, as shown in Illustration 158, with the tip of
Tooling (J) resting on shaft assembly (86) .
b. Attach Tooling (L) to shaft assembly (86) . Use a suitable pry bar in order to pry up
on Tooling (L) and shaft assembly (86) . Pry up shaft assembly (86) until the indicator
on Tooling (J) stops. Record this reading as Reading (BB) .
c. Lower shaft assembly (86) and rotate the gears five or seven times or until the
indicator on Tooling (J) reads zero.
d. When the indicator on Tooling (J) returns to zero, Reading (BB) is the end play.
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a. Attach Tooling (J) to the transmission, as shown in Illustration 159, with the tip of
Tooling (J) resting on shaft assembly (49) .
b. Attach Tooling (M) to shaft assembly (49) . Use a suitable pry bar in order to pry up
on Tooling (M) and shaft assembly (49) . Pry up shaft assembly (49) until the
indicator on Tooling (J) stops. Record this reading as Reading (CC) .
c. Lower shaft assembly (49) and rotate the gears five or seven times or until the
indicator on Tooling (J) reads zero.
d. When the indicator on Tooling (J) returns to zero, Reading (CC) is the end play.
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a. Position Tooling (J) through the hole and onto shaft assembly (53) (not shown).
Position Tooling (N) directly beneath shaft assembly (53) .
b. Use Tooling (N) in order to push shaft assembly (53) until the indicator on Tooling
(J) stops. Record the reading as Reading (DD) .
c. Lower Tooling (N) and rotate the gears 5 to 7 times, or until the indicator on Tooling
(J) reads zero.
d. When the indicator on Tooling (J) returns to zero, Reading (DD) is the end play.
70. Remove bolts (27) .
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is approximately 45 kg (100 lb). Use Tooling (C) and the suitable lifting device in order to
remove housing (29) .
72. If necessary, remove bearing cups (30) and add or remove shims (31) in order to set the end
play for each shaft assembly. After the shim (31) have been added, the end play must be
rechecked using Steps 64 through 69.d.
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73. Apply Tooling (R) to the mating surface of the housing.
is approximately 45 kg (100 lb). Use the Tooling (C) and the suitable lifting device in order
to position housing (29) .
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75. Install bolts (27) .
76. Install the O-ring seals and plugs (48) and (39) .
77. Install O-ring seal (28) into yoke (26) .
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Caterpillar Cat 924K Wheel Loader (Prefix PWR) Service Repair Manual Instant Download.pdf

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