926M, 930M and 938M Wheel Loaders Power Train Caterpillar

Assembly Procedure

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Illustration 1	g02798848

1. Install orifice (104) (not shown). Tighten orifice (104) to a torque of 8 ± 2 N·m (71 ± 18 lb in).
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   Illustration 2	g02798845

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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   Illustration 3	g02798842

5. Install breather (100).
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   Illustration 4	g02798839

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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   Illustration 5	g02798836

7. Install the O-ring seals and plugs (98).
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   Illustration 6	g02798828

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).
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   Illustration 7	g02798821

10. Install O-ring seals (93).
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    Illustration 8	g02798808

11. Install bearing cups (92).
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    Illustration 9	g02798873

12. Install gear (91) onto shaft (88).
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    Illustration 10	g02798916

13. Install spacer (90) onto shaft (88).
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    Illustration 11	g02798918

14. Install bearing cone (89) onto shaft (88). Be sure that bearing cone (89) is seated completely.
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    Illustration 12	g02798922

15. Raise the temperature of bearing cone (87). Install bearing cone (87).
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    Illustration 13	g02798793

16. Install shaft assembly (86).
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    Illustration 14	g02798781

17. Install bearing cone (85).
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    Illustration 15	g02798775

18. Install seal rings (84) and (83).
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    Illustration 16	g02798768

19. Install seal rings (82) onto piston (81). Lubricate seal rings (82) with the lubricant that is being sealed.
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    Illustration 17	g02798764

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    Illustration 18	g02798930

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    Illustration 19	g02798936

20. Install piston (81).

21. Position the shaft assembly and piston (81) onto a suitable press. Use Tooling (G) and the suitable press to seat piston (81) into place.
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    Illustration 20	g02798750

22. Install sleeve (80).
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    Illustration 21	g02798744

23. Install spring (77) and washer (79).
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    Illustration 22	g02798719

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    Illustration 23	g02798724

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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.

24. Position shaft assembly (62) onto a suitable press. Use Tooling (F) to compress spring (77). Install retaining ring (78). Use the suitable press and Tooling (F) to slowly release the compressed spring (77).
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    Illustration 24	g02798982

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    Illustration 25	g02798983

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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    Illustration 26	g02798984

27. Install thrust washer (71).
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    Illustration 27	g02798989

28. Install thrust bearing (70).
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    Illustration 28	g02798990

29. Install gear assembly (63) into shaft assembly (62). Install needle bearing (69).
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    Illustration 29	g02798991

30. Install spacer (68).
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    Illustration 30	g02798993

31. Install needle bearing (67). Be sure that needle bearing (67) is seated correctly.
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    Illustration 31	g02799012

32. Install retaining ring (72).
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    Illustration 32	g02799013

33. Use suitable compressed air to check the operation of the clutch.
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    Illustration 33	g02799014

34. Install thrust bearing (66).
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    Illustration 34	g02799015

35. Install thrust washer (65).
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    Illustration 35	g02799016

36. Install bearing cone (64).
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    Illustration 36	g02798529

37. Install shaft assembly (62).
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    Illustration 37	g02799017

38. Use Tooling (E) and a suitable press to install seal (61) (not shown) into seal assembly (60).
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    Illustration 38	g02798526

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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    Illustration 39	g02798524

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).
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    Illustration 40	g02798523

41. Install bearing cup (56).
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    Illustration 41	g02799144

42. Raise the temperature of bearing cone (54). Install bearing cone (54) onto shaft assembly (53).
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    Illustration 42	g02799150

43. Raise the temperature of bearing cone (55). Install bearing cone (55) onto shaft assembly (53).
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    Illustration 43	g02798520

44. Install shaft assembly (53).
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    Illustration 44	g02798519

45. Install bearing cup (52).
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    Illustration 45	g02799153

46. Raise the temperature of bearing cone (51). Install bearing cone (51) onto shaft assembly (49).
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    Illustration 46	g02799158

47. Raise the temperature of bearing cone (50). Install bearing cone (50) onto shaft assembly (49).
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    Illustration 47	g02798512

48. Install shaft assembly (49).
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    Illustration 48	g02798510

49. Install orifice (43). Tighten orifice (43) to a torque of 8 ± 2 N·m (71 ± 18 lb in).
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    Illustration 49	g02798509

50. Install orifice (42). Tighten orifice (42) to a torque of 16 ± 2 N·m (142 ± 18 lb in).
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    Illustration 50	g02798507

51. Install the O-ring seal and plug (41).
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    Illustration 51	g02799170

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 (124 ± 27 lb in).
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    Illustration 52	g02798506

54. Install orifice (40). Tighten orifice (40) to a torque of 16 ± 2 N·m (142 ± 18 lb in).
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    Illustration 53	g02799176

55. Install the O-ring seal and one plug (39).
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    Illustration 54	g02798501

56. Install the O-ring seal and plug (38) into housing (29).
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    Illustration 55	g02798499

57. Install O-ring seal (37) onto tube assembly (36).
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    Illustration 56	g02798498

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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    Illustration 57	g02799191

59. Install seal (34).
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    Illustration 58	g02798494

60. Install shims (33).
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    Illustration 59	g02798492

61. Lower the temperature of bearing cup (32). Install bearing cup (32).
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    Illustration 60	g02798487

62. Install shims (31).
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    Illustration 61	g02798485

63. Install bearing cups (30) into housing (29).
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    Illustration 62	g02798481

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 to position housing (29).
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    Illustration 63	g02799198

65. Install four bolts (27).
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    Illustration 64	g02799278

66. Steps 66.a through 66.d are for checking the end play of shaft assembly (62) (not shown).

    1. Position Tooling (J) through the hole and onto shaft assembly (62) (not shown). Position Tooling (K) directly beneath shaft assembly (62).

    2. Use Tooling (K) to push the shaft until the indicator on Tooling (J) stops. Record the reading as Reading (AA).

    3. 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.

    4. 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).

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    Illustration 65	g02799640

67. Steps 67.a through 67.d are for checking the end play of shaft assembly (86).

    1. Attach Tooling (J) to the transmission, as shown in Illustration 65, with the tip of Tooling (J) resting on shaft assembly (86).

    2. Attach Tooling (L) to shaft assembly (86). Use a suitable pry bar 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).

    3. Lower shaft assembly (86) and rotate the gears five or seven 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 67.a through 67.c again.

    4. When the indicator on Tooling (J) returns to zero, Reading (BB) is the end play.

       Note: The correct end play is 0.0254 - 0.0762 mm (0.00100 - 0.00300 inch).

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    Illustration 66	g02800078

68. Steps 68.a through 68.d are for checking the end play of shaft assembly (49).

    1. Attach Tooling (J) to the transmission, as shown in Illustration 66, with the tip of Tooling (J) resting on shaft assembly (49).

    2. Attach Tooling (M) to shaft assembly (49). Use a suitable pry bar 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).

    3. Lower shaft assembly (49) and rotate the gears five or seven 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 68.a through 68.c again.

    4. When the indicator on Tooling (J) returns to zero, Reading (CC) is the end play.

       Note: The correct end play is 0.0254 - 0.0762 mm (0.00100 - 0.00300 inch).

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    Illustration 67	g02800136

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    Illustration 68	g02800137

69. Steps 69.a through 69.d are for checking the end play of shaft assembly (53).

    1. Position Tooling (J) through the hole and onto shaft assembly (53) (not shown). Position Tooling (N) directly beneath shaft assembly (53).

    2. Use Tooling (N) to push shaft assembly (53) until the indicator on Tooling (J) stops. Record the reading as Reading (DD).

    3. Lower Tooling (N) 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 69.a through 69.c again.

    4. When the indicator on Tooling (J) returns to zero, Reading (DD) is the end play.

       Note: The correct end play is 0.0254 - 0.0762 mm (0.00100 - 0.00300 inch).

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    Illustration 69	g02799198

70. Remove bolts (27).
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    Illustration 70	g02798481

71. Attach Tooling (C) and a suitable lifting device to housing (29). The weight of housing (29) is approximately 45 kg (100 lb). Use Tooling (C) and the suitable lifting device to remove housing (29).
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    Illustration 71	g02800261

72. If necessary, remove bearing cups (30) and add or remove shims (31) 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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    Illustration 72	g02800356

73. Apply Tooling (R) to the mating surface of the housing.
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    Illustration 73	g02798481

74. 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 to position housing (29).
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    Illustration 74	g02800359

75. Install bolts (27).
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    Illustration 75	g02800360

76. Install the O-ring seals and plugs (48) and (39).
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    Illustration 76	g02798479

77. Install O-ring seal (28) into yoke (26).
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    Illustration 77	g02800366

78. Install yoke (26) and bolt (25). Tighten bolt (25) to a torque of 120 ± 20 N·m (89 ± 15 lb ft).
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    Illustration 78	g02798465

79. Attach Tooling (A) and a suitable lifting device to transmission (24). The weight of transmission (24) is approximately 122 kg (270 lb). Use Tooling (A) and the suitable lifting device to remove transmission (24) from Tooling (B) and set transmission (24) in the upright position. Remove Tooling (A).
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    Illustration 79	g02798461

80. Install O-ring seal (23) into yoke (21).
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    Illustration 80	g02798458

81. Install spacer (22).
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    Illustration 81	g02798457

82. Install yoke (21) and bolt (20). Tighten bolt (20) to a torque of 120 ± 20 N·m (89 ± 15 lb ft).
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    Illustration 82	g02798452

83. Install the O-ring seal, fitting (19), and the cap onto valve (2). Install the O-ring seals, fittings (18), and the caps. Install the O-ring seal and fitting (17).
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    Illustration 83	g02798449

84. Install O-ring seal (16) onto relief valve (11). Install O-ring seal (15) and backup rings (13). Install O-ring seal (14) and backup rings (12)
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    Illustration 84	g02798448

85. Install relief valve (11) into valve assembly (2).
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    Illustration 85	g02798445

86. Install O-ring seal (10) onto temperature sensor (9).
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    Illustration 86	g02798442

87. Install temperature sensor (9) into valve assembly (2). Tighten temperature sensor (9) to a torque of 20 ± 3 N·m (177 ± 27 lb in).
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    Illustration 87	g02798437

88. Install O-ring seals (8) onto valve (7).
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    Illustration 88	g02798429

89. Install valve (7). Tighten valve (7) to a torque of 50 ± 5 N·m (37 ± 4 lb ft).
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    Illustration 89	g02798427

90. Install coil (6) and nut (5). Tighten nut (5) to a torque of 13.0 ± 1.5 N·m (115.06 ± 13.28 lb in).
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    Illustration 90	g02798422

91. Install O-ring seals (4) onto valve assembly (2). Install gasket (3).
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    Illustration 91	g02798420

92. Install valve assembly (2). Tighten the bolts that secure valve assembly (2) to a torque of 60 ± 12 N·m (44 ± 9 lb ft).
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    Illustration 92	g02798341

93. Install harness assembly (1).

End By:

1. Install the transmission.