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

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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

Transmission and Torque Converter - Assemble

SMCS - 3001-016

Assembly Procedure

Table 1 Required Tools

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

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1. Install gear (149) and retaining ring (148) . Raise the temperature of bearing cone (147) . Install bearing cone (147) .

Illustration 2

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2. Raise the temperature of bearing cone (146) . Install bearing cone (146) .

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).

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7. Install the output shaft and gear (141) .

Illustration 3 g01005239

Illustration 4

8. Install lip seal (140) . Lubricate the sealing lip with the lubricant that is being used.

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.

Illustration 5 g01005236

Illustration 6

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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).

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15. Install brake drum (130) and yoke (129) together. Install seal (128) .

Illustration 7

Illustration 8

Illustration 9 g00685060

16. Install the bolt and washer (127) . Tighten bolt (127) to a torque of 120 ± 20 N·m (90 ± 15 lb ft).

Illustration 10 g00655120

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).

Illustration 11 g00655110

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) .

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Illustration 12

Illustration 13

22. Install the input shaft assembly (115) .

Illustration 14

23. Install seals (112) , (113) , and (114) .

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Illustration 15 g00654966

Note: Lubricate the piston, and the bore with clean transmission oil.

24. Use Tooling (P) in order to install piston (111) .

Illustration 16

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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Install spring (110) .

Put the clutch pack in a suitable press. Use Tooling (H) in order to install retaining ring

Illustration 17

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26. Install the retainer and seal assembly (109) .

Illustration 18

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27.

(108) .

Illustration 19

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28. Lower the temperature of bearing assembly (107) . Install bearing assembly (107) .

Illustration 20

29. Install ring (106) .

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Illustration 21

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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) .

Illustration 22 g00654724

Illustration 23

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Illustration 24

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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.

Illustration 25

34. Install seals (94) and (93) .

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Illustration 26

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Note: Lubricate the piston, and the bore with clean transmission oil.

35. Use Tooling (P) in order to install piston (90) .

36. Install seals (92) on shaft (91) .

Illustration 27

37. Install spring (89) and retainer (88) .

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Illustration 28

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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.

38. Put the third gear clutch pack in a suitable press. Use Tooling (H) in order to install retaining ring (87) .

Illustration 29

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Note: Refer to Specifications, "Power Shift Transmission" for the specifications of the clutch discs.

39. Install plates and discs (86) . Install retaining ring (85) .

40. Install washer (84) .

Illustration 30 g00654517

41. Use a suitable press in order to install bearing (83) . Install retaining ring (82) .

Illustration 31 g00654512

42. Install hub assembly (81) .

Illustration 32 g00654507

43. Install gear (80) and retaining ring (79) .

Illustration 33

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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 .

Illustration 34

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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).

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) .

Illustration 35 g00890612

Illustration 36 g00654403

48. Install seals (69) and (68) .

Illustration 37 g00890841

Illustration 38 g00654372

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) .

Illustration 39 g00654364

50. Install spring (64) and retainer (63) .

Illustration 40

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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.

51. Put the reverse clutch pack in a suitable press. Use Tooling (H) in order to install retaining ring (62) .

Illustration 41

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52. Use a suitable press in order to install bearing (61) . Install retaining ring (60) .

Illustration 42

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Note: Refer to Specifications, "Power Shift Transmission" for the specifications of the clutch discs.

53. Install plates and discs (59) . Install retaining ring (57) .

54. Install washer (58) .

Illustration 43

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55. Install hub assembly (56) .

Illustration 44

56. Install gear (55) and retaining ring (54) .

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Illustration 45

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57. Install washer (53) and retaining ring (52) .

Note: This completes the assembly of the reverse second gear clutch pack.

Note: Refer to Specifications, "Power Shift Transmission" for the procedure to measure running clearance.

Illustration 46 g00654301

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).

Illustration 47 g00654292

59. Install seals (49) and (50) .

Illustration 48 g00654280

Note: Lubricate the piston, and the bore with clean transmission oil.

60. Use Tooling (P) in order to install piston (47) .

61. Install spring (46) and retainer (45) .

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.

62. Put the forward high clutch pack in a suitable press. Use Tooling (H) in order to install retaining ring (44) .

Illustration 49

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Illustration 50

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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) .

Illustration 51 g00654263

64. Use a suitable press in order to install bearing (40) . Install retaining ring (39) .

Illustration 52 g00654261

65. Install hub (38) .

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66. Raise the temperature of gear (37) . Install gear (37) . Install retaining ring (36) .

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67. Install washer (35) and retaining ring (34) .

Note: This completes the assembly of the forward high gear clutch pack.

Note: Refer to Specifications, "Power Shift Transmission" for the procedure to measure running clearance.

Illustration 53

Illustration 54

Illustration 55

68. Install O-ring seals (33) .

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Illustration 56

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Note: Lubricate the piston, and the bore with clean transmission oil.

69. Use Tooling (P) in order to install piston (31) . Install seals (32) on shaft (30) .

Illustration 57

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70. Install spring (29) and retainer (28) .

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.

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) .

Illustration 58 g00654018

Illustration 59 g00890608

Illustration 60

73. Install washer (24) .

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Illustration 61

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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) .

76. Install washer (18) and retaining ring (17) .

Note: This completes the assembly of the forward low gear clutch pack.

Note: Refer to Specifications, "Power Shift Transmission" for the procedure to measure 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) .

Illustration 62 g00653932

Illustration 63 g00653893

Illustration 64 g00653858

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78. Lower the temperature of bearing cups (14) . Use Tooling (K) in order to install bearing cups (14) .

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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).

Illustration 65

Illustration 66

Illustration 67 g00653808

80. Install gear assembly (10) .

81. Install O-ring seals (11) .

Illustration 68

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82. Install bolts (9) . Tighten bolts (9) to a torque of 55 ± 10 N·m (40 ± 10 lb ft).

Illustration 69

83. ApplyTooling (L) to the seal bore.

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84. Install lip seal (7) . Lubricate the sealing lip with the lubricant that is being used.

85. Install seal (8) .