936 transmision desarmado y armado

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Producto: WHEEL LOADER

Modelo: 936 WHEEL LOADER 33Z00971

Configuración: 936 WHEEL LOADER 33Z00001-03090 (MACHINE) POWERED BY 3304 ENGINE

Desarmado y Armado 936 WHEEL LOADER POWER TRAIN Número de medio -SENR2911-01 Fecha de publicación -01/10/2004 Fecha de actualización -13/06/2005

SENR29110031

Transmission

SMCS - 3150-015; 3150-016

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Disassemble Transmission

START BY:

a. separation of transfer gears from transmission *

b. separation of torque converter from transmission

*See Disassemble Transfer Gears.

1. Fasten tooling (B) and a hoist to transmission housing (1) as shown.

2. Install the transmission assembly on tooling (A). The weight of the transmission and case is 340 kg (750 lb.).



3. Fasten tooling (C) and a hoist to housing (2) as shown.

4. Remove two bolts (3), and make a separation of the transmission planetary group from case (4). The weight of the transmission planetary group is 263 kg (580 lb.).

5. Remove O-rings (5) and O-ring seal (6) from transmission case (4).

6. Fasten tooling (C) and a hoist to transmission planetary group (7) as shown.

7. Carefully turn the transmission planetary group over, and install it on tooling (A) as shown.

8. Use tool (D), and remove retaining ring (8) from the shaft.

9. Remove carrier (9) from the shaft.



10. Remove O-ring seal (10) from carrier (9).

11. Use a hammer and punch to push the pins through carrier (9) into shafts (11).

12. Use a hammer and punch, and remove shafts (11) from the carrier.

13. Remove discs (14), bearing assemblies (12) and gears (13) from the carrier. Remove pins (15) from shafts (11).



14. Remove bolts (16) that hold No. 6 (first speed) clutch housing (17) to the transmission planetary group.

15. Install tooling (E) to hold plate (18) and the piston in the No. 6 clutch housing as shown.

16. Remove No. 6 clutch housing (17) from the planetary group.

17. Remove plate (18) from the No. 6 clutch housing.

18. Remove piston (19) and three pins (20) from the No. 6 clutch housing.

19. Remove seal rings (21) and (22) from the piston.



20. Remove springs (24), three discs (25) and three remaining plates (26) (first speed).

21. Remove gear (23).

22. Use tool (F) to remove retaining ring (27) from the shaft.

23. Use tool (D), and remove retaining ring (28) from the housing.

24. Remove bolts (30) that hold housing (29) to the planetary group.



25. Install tooling (C) and a hoist, and remove housing (29) from the planetary group. The weight of the housing is 31 kg (68 lb.).

26. Use tool (F), and remove retaining ring (31) from the housing.

27. Use tool (H) to remove the bearing from the housing.

28. Use tool (G) to compress retaining ring (33), and remove housing assembly (32). Remove retaining ring (33) from the housing assembly.



29. Use plate (34) which is approximately 152 mm (6.00 in.) long x 25.4 mm (1.00 in.) wide x 10 mm (3.93 in.) thick, two 1/2 in. nuts and a press to put plate (36) and the bevel springs under compression. Remove retaining ring (35) from the gear.

30. Remove plate (36) from the gear.

31. Remove four springs (37) from the piston.

32. Remove piston (38) from housing assembly (39).



33. Remove seal rings (40) from piston (38).

34. Remove housing (39) from shaft (41).

35. Remove seal rings (43) from housing (39).

36. Do not remove seal carrier (42) from the housing unless it is worn or damaged. Use a hammer and chisel to break the carrier and remove it. After carrier (42) is removed, remove the pin that holds the carrier in position on the housing.

37. Remove springs (45).

38. Remove two discs (44) and two plates (46) (third speed).

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39. Use tool (F), and remove retaining ring (47).

40. Remove gear assembly (48) from the shaft.

41. Remove gear (49) from the housing.

42. Remove three discs (50) and two plates (second speed) from gear (49).



43. Use a screwdriver, and remove ring (51) and plate (52) from the gear.

44. Remove piston (53) from the No. 3 and No. 4 clutch housing.

45. Remove seal rings (54) from piston (55).

46. Install tooling (J) to hold plate (56) and the piston in No. 3 and No. 4 clutch housing.



47. Install tooling (K) and a hoist, and remove No. 3 and No. 4 clutch housing (57). The weight of the clutch housing is 26 kg (58 lb.).

48. Remove plate (56) from the No. 3 and No. 4 clutch housing.

49. Remove piston (58) from the No. 3 and No. 4 clutch housing.

50. Remove seal rings (59) and (60) from piston (58).



51. Remove springs (63) and rods (62) from the housings.

52. Remove three discs (61) and two plates (64) (fourth speed).

53. Remove carrier (65) and gear (66) as a unit from the clutch housing.

54. Use 3.18 mm (.125 in.) diameter rods (67) with a point ground on one end to put the retaining ring under compression that holds carrier (65) and gear (66) together. Install rods (67) between the retaining ring and gear (66) to compress the retaining ring into carrier (65).

55. Remove carrier (65) from gear (66).

56. Remove retaining ring (68) from carrier (65).



57. Use a hammer and a punch to push the pins through carrier (65) and into shafts (69).

58. Use a hammer and a punch, and remove shafts (69) from carrier (65).


60. Remove ring (74) that holds bearing (76) in the carrier.

61. Remove shaft (75) and bearing (76) as a unit from the carrier.

62. Use tool (F), and remove ring (78) from shaft (75).

63. Remove gear (77) from shaft (75).



64. Use tooling (L) and a press, and push shaft (75) out of bearing (79) as shown.

65. If necessary, remove bearing (80) from both ends of shaft (75).

66. Remove three bolts (82) that hold housing (81) to the planetary group.

67. Use tooling (E) to hold plate (84) and the piston in the No. 2 clutch housing.

68. Install tooling (C) and a hoist, and remove No. 2 clutch housing (83). The weight of the clutch housing is approximately 18 kg (40 lb.).



69. Remove plate (84) from the No. 2 clutch housing.

70. Remove piston (85) from the No. 2 clutch housing.


72. Remove springs (91) and (92) from the housing.

73. Remove three discs (88) and two plates (90) (forward).

74. Remove gear (89) from the housing.



75. Use tool (F), and remove retaining ring (93)

76. Remove carrier (94) and gear (95) as a unit from the clutch housing.

77. Use 3.18 mm (.125 in.) diameter rods (96) with a point ground on one end to put the retaining ring under compression that holds carrier (94) and the gear together. Install rods (96) between the retaining ring and gear (95) to compress the retaining ring into carrier (94).

78. Remove carrier (94) from gear (95).




80. Use a hammer and a punch to push the pins through carrier (94) and into shafts (98).

81. Use a hammer and punch, and remove shafts (98) from carrier (94).


83. Use tool (F) to expand ring (104) into carrier (94). Use tooling (H) to remove bearing (103) and gear as a unit from the carrier.

84. Use a press, and remove bearing (103) from gear (105).




86. Remove plate (107) from No. 1 clutch housing.

87. Remove three discs (109) and three plates (110) (reverse) from the No. 1 clutch housing.

88. Remove carrier (108) from the gear.

89. Remove carrier (111) from carrier (108).



90. Remove seal ring (112) from carrier (111).

91. Remove rings (113) and (114) from carrier (108).

92. Use a hammer and a punch to push the pins through carrier (108) and into the shafts.

93. Use a hammer and a punch, and remove the shafts from carrier (108).

94. Remove disc (118), gears (115) and bearing assemblies (116) from the carrier. Remove pins (119) from shafts (117).



95. Remove gear (121) from the No. 1 clutch housing.

96. Remove gear (120) from the shaft.

97. Remove piston (122) from the No. 1 clutch housing.


99. Remove seal ring (126) from shaft (125).

100. Remove the shaft and No. 1 clutch housing as a unit from tooling (A). The weight of the shaft and housing is 52 kg (115 lb.).



101. Remove bolt (127), retainer (129) and gear (128) from the end of shaft ((125).

102. Remove retaining ring (130) that holds the bearing and support in position in the No. 1 clutch housing.

103. Use a soft hammer, and remove shaft (125) and the bearing as a unit from the No. 1 clutch housing.

104. Remove seal rings (131) from shaft (125).



105. Use a press and tool (M) to remove bearing (132) from the shaft.

106. Remove dowels (133) from the No. 1 clutch housing.

Assemble Transmission

NOTE: Inspect all parts for wear or damage, and make replacements if needed. Put clean transmission oil on the parts at assembly.



1. Install a dowel (2) in each side of No. 1 clutch housing (1). The dowels must be installed until they are 10.5 ± .5 mm (.41 ± .02 in.) above outside surface (X).

2. Heat bearing (4) to a maximum temperature of 135°C (275°F), and install it on shaft (3) as shown.

3. Install seal rings (5) and (6) on shaft (3). Make sure the hooked ends of the rings are engaged after the rings are installed.

NOTICE

Align shaft (3) so that the hooked ends of seal (6) are not in alignment with the oil cavity in the No. 1 clutch housing. Make sure seals (5) and

(6) are not damaged when the shaft is installed in the bore of the housing.



4. Carefully install shaft (3) in the No. 1 clutch housing.

5. Install retaining ring (7) in the No. 1 clutch housing to hold the shaft and bearing in place.

6. Put gear (8) in position on the end of shaft (3) as shown.

7. Install retainer (9) and bolt (10) to hold the gear in place. Tighten the bolt to a torque of 110 ± 10 N·m (80 ± 7 lb.ft.).

8. Install the shaft and No. 1 clutch housing as a unit on tooling (A) as shown. The weight of the shaft and housing is 52 kg (115 lb.).

9. Install seal ring (11) on shaft (3). Make sure the hooked ends of the rings are engaged after the rings are installed.



10. Install seal rings (12) and (14) on piston (13). Make sure the seal rings are installed with the lip of the seals up as shown.

11. Install piston (13) in the No. 1 clutch housing. Make sure the lip of the seals is down.

12. Install gear (16) on the shaft.

13. Install gear (15) in the No. 1 clutch housing.



14. Install bearing (18) in gear (17).

15. Install discs (20) and gears (17) in carrier (22).

16. Install shafts (19) that hold the discs, gears and bearing assemblies in carrier (22).

NOTE: If pins (21) are damaged, a replacement will be necessary.

17. Use a hammer and a punch to install pins (21) that hold the shafts in the carrier. Make sure the pins are installed even with the counterbore in the carrier.

18. Install seal rings (23) on carrier (22). Make sure the hooked ends of the ring are engaged after the ring is installed.

19. Install seal ring (25) on carrier (24). Make sure the hooked ends of the ring are engaged after the ring is installed.

20. Install carrier (24) in carrier (22).



21. Make an alignment of carrier (22) with gear (16) on the shaft and carrier (22) with gear (15). Install carrier (22) in the No. 1 clutch housing.

22. Install plate (28) in the No. 1 clutch housing so the small holes in the plate are in alignment with small holes in the housing.

23. Install three discs (26) and two remaining plates (27) (reverse) in the No. 1 clutch housing. Start and stop with a disc.

24. Put plate (29) in position on the No. 1 clutch housing as shown.

25. Heat bearing (30) to a maximum temperature of 135°C (275°F), and install it on gear (31). Make sure the bearing is installed so the groove is toward the top as shown.



26. Install retaining ring (32) in the groove of carrier (33) as shown.

27. Use tool (B) to expand retaining ring (32). Use tool (C) and a press to install bearing (30) and gear (31) as a unit in carrier (33). Ring (32) must engage in the groove of bearing (30).

28. Install bearings (37) in gears (35).

29. Install discs (34) and gears (35) in the bottom and top of carrier (33).





31. Use a hammer and a punch to install pins (38) that hold the shafts in carrier (33). Make sure the pins are installed even with the counterbore in the carrier.

32. Install retaining ring (39) in the groove of carrier (33).

33. Compress retaining ring (39), and install carrier (33) in gear (40) until the retaining ring engages into the groove in gear (40).

34. Put carrier (33) and gear (40) as a unit in position on carrier (22) in the No. 1 clutch housing. Turn shaft (3) to make sure gear (40) is correctly engaged with the gears in carrier (22).



35. Use tool (B) to install retaining ring (41) that holds the carrier in place.

36. Install gear (42) on carrier (33). Make sure the gear is correctly engaged with the gears in carrier (33).

37. Install three discs (43) and two plates (44) on plate (29). Start and stop with a disc.

38. Install springs (45) in the housing assembly as shown.



39. Install seal rings (46) and (47) on piston (48). Make sure the seal rings are installed with the lips of the seals up as shown.

40. Install piston (48) in No. 2 clutch housing (49). Make sure the lip of the seals is down.

41. Install plate (50) in the No. 2 clutch housing so the small holes in the plate are in alignment with the small holes in the housing.

42. Install tooling (D) to hold the piston and plate in the No. 2 clutch housing.

43. Put No. 2 clutch housing (49) in position on plate (29) as shown. The weight of the clutch housing is 18 kg (40 lb.).



44. Install three bolts (51) that hold the two housings and plate together. Install the bolts until they are approximately 1.588 to 3.18 mm (.0625 to .1250 in.) from the surface of clutch housing (49).

45. If bearings (52) were removed, lower the temperature of the two bearings, and put them in position in both ends of shaft (53). Use tool (F) to install the bearings until they are 12.0 ± 0.5 (.47 ± .02 in.) from the end of the shaft. The inside diameter of the bearings must be 34.988 ± .039 mm (1.3775 ± .0015 in.) after assembly.

46. Heat bearings (54) to a maximum temperaturr of 135° C (275° F), and install it on the shaft as shown. Make sure ball (55) in the shaft fits into the notch in the bearing, and the groove (slot) in the bearing is toward the top of the shaft.

47. Install gear (56) on shaft (53) as shown.



48. Use tool (B) to install retaining ring (57) on the end of the shaft.

49. Install shaft (53) over shaft (3) as shown.

50. Install retaining ring (58) in the carrier to hold shaft (53) in place.



51. Install bearing (59) in gear (60).

52. Install discs (62) and gears (60) in carrier (64).


54. Use a hammer and a punch to install pins (63) that hold the shafts in the carrier. Make sure the pins are installed even with the counterbore in carrier (64).

55. Install seal ring (65) in the groove of carrier (64) as shown. Make sure the hooked ends of the ring are engaged after the ring is installed.

56. Compress retaining ring (65), and install carrier (64) in gear (66) until the retaining ring engages into the groove in gear (66).



57. Put carrier (64) and gear (66) as a unit in position on carrier (33) in the No. 1 clutch housing. Turn shaft (53) to make sure gear (66) is correctly engaged with the gears in carrier (33).

58. Install three discs (67) and two plates (68) (fourth speed) on the No. 2 clutch housing. Start and stop with a disc as shown.

59. Put rods (69) in position through the housing assemblies and springs (45) as shown.

60. Install springs (70) on rods (69).


62. Install piston (71) in the No. 3 and No. 4 clutch housing. Make sure the lip of the seals is down.



63. Install plate (74) on the No. 3 and No. 4 clutch housing as shown. Make sure the larger holes in the plate are in alignment with the larger holes in the clutch housing.

64. Install tooling (G) to hold the piston and plate in the No. 3 and No. 4 clutch housing as shown.

65. Fasten tooling (H) and a hoist to No. 3 and No. 4 clutch housing, and install it on the No. 2 clutch housing as shown. The weight of the clutch housing is 26 kg (58 lb.).




67. Install piston (75) in the No. 3 and No. 4 clutch housing. Make sure the lip of the seals is down.

68. Install plate (78) in gear (79).

69. Install retaining ring (80) in the groove of gear (79) that holds plate (78) in place.

70. Install three discs (81) and two plates (82) (second speed) in the gear.



71. Put gear (79) in position on the carrier in the No. 3 and No. 4 clutch housing. Make sure the gear is correctly engaged with the gears in the carrier.

72. Install gear (83) in the clutch housing as shown.

73. Use tool (B) to install retaining ring (84) in the groove of the shaft as shown.

74. Install two plates (85) and two discs (86) (third speed) on the No. 3 and No. 4 clutch housing as shown. Make sure the small hole in plate (87) is installed on rods (69). Start with a plate and end with a disc.



75. Install springs (88) on the rods.

76. If carrier (89) was removed from housing (90), heat the new carrier to a temperature of 127° to 166°C (260° to 330°F) for a maximum of ten minutes, and install it on housing (90) so the part number can be seen after it is installed. Also, install the carrier with one of the grooves (slots) in the carrier in alignment with the pin hole in the housing.

Figure 1. Correct Method To Make (Non-Metal) New Seal Rings Ready For Installation.

Figure 2. Wrong Method To Make (Non-Metal) New Seal Rings Ready For Installation.

NOTICE

New seal rings must be preloaded before they are installed to prevent them from being damaged or broken when the clutch housing is



installed. There is a correct method to preload new seal rings prior to installation. Place your hands on each end of the seal ring, and pull (wind) the ends several inches past each other or until they almost make contact. See Figure 1. Use care to keep the ring shaped like a

circle. This will make an even bend (or ring "set") all around the ring. When the seal ring is in the groove of carrier (90) the ends must but together lightly. Do not bend the seal ring as shown in Figure 2. This

does not make an even bend all the way around the ring.

Do not attempt to use this method to preload a used seal ring. Also, do not use this procedure for cast iron seal rings. This will cause used or

cast iron seal rings to break.

77. Install seal rings (91) on carrier (89) as shown.

78. Put housing (89) in position on gear (92) as shown.

79. Install seal ring (93) on piston (95). Make sure the seal ring is installed with the lip of the seal down as shown.

80. Install seal ring (94) on piston (95). Make sure the seal ring is installed with the lip of the seal up as shown.



81. Install piston (95) in the housing assembly.

82. Install four springs (96) on the housing assembly as follows:

a. Install the first two springs with the outside diameter of the springs in contact with each other.

b. Install the next two springs with the outside diameter of the springs in contact with each other.

83. Install plate (97) on the housing assembly.

84. Use plate (99) which is approximately 152 mm (6.00 in.) long x 25.4 mm (1.00 in.) wide x 10 mm (3.93 in.) thick, two 1/2 in. nuts and a press to put plate (97) and bevel springs under compression. Install retaining ring (98) on gear (92).



85. Install retaining ring (101) on housing assembly (100).

86. Put the housing assembly and gear in position in gear (79) as shown.

87. Use tool (J) to make a compression of retaining ring (101), and install the housing assembly until the retaining ring engages in the groove in gear (79).

88. Use tooling (C), and install the bearing in housing (102).

89. Use tool (J) to install retaining ring (103) in the housing.



NOTE: Make sure the dowel in gear (92) and the notch in bearing (105) are in alignment. If necessary, turn gear (92) to make the alignment.

90. Install tool (E) and a hoist to housing (104), and put it in position on No. 3 and No. 4 clutch housing. The weight of the housing is 31 kg (68 lb.).

91. Install the six bolts that hold housing (104) in place.

92. Tighten lower three bolts (51) that were installed in Step 44 to a torque of 110 ± 10 N·m (80 ± 7 lb.ft.).

93. Tighten upper bolts (106) that were installed in Step 91 to a torque of 110 ± 10 N·m (80 ± 7 lb.ft.).

94. Use tool (K) to install retaining ring (107) on the housing assembly. If necessary, use a block of wood and a pry bar to lift up on gear (92) while installing retaining ring (107) as shown.



95. Use tool (B) to install retaining ring (108) on the shaft.

96. Install gear (109) on the housing as shown.

97. Install three discs (112) and three plates (110) (first speed) on the housing. Start with a plate and stop with a disc.

98. Install springs (111) in the housing.

99. Install seal rings (113) and (114) on piston (115). Make sure the rings are installed with the lip of the seals up as shown.



100. Install piston (115) in No. 6 clutch housing (116). Make sure the lip of the seals is down.

101. Install pins (117) in No. 6 clutch housing (116).

102. Install plate (118) on pins (117) in the No. 6 clutch housing.

103. Install tooling (D) to hold the piston and plate in the No. 6 clutch housing.

104. Put No. 6 clutch housing (116) in position on the housing as shown.



105. Install bolts (119) that hold the No. 6 clutch housing to the housing. Tighten the bolts to a torque of 110 ± 10 N·m (81 ± 7 lb.ft.).

106. Install bearings (120) in gears (121).

107. Install discs (123) and gears (121) in the bottom and top of carrier (125).



109. Use a hammer and a punch to install pins (124) that hold the shafts in the carrier. Make sure the pins are installed even with the counterbore in the carrier.



110. Install seal ring (126) on carrier (125). Make sure the hooked ends of the rings are engaged after the seal rings are installed.

111. Place carrier (125) in position over the shaft, and carefully install the carrier in the bore of housing (116).

112. Use tool (K) to install retaining ring (127) on the shaft.

113. Check to make sure the pistons are free in their clutch housings with tool (L) as follows:

a. Put air free of water under a pressure of 690 to 1030 kPa (100 to 150 psi) into each of the six oil passages.



b. If the pistons do not move, put a small amount of clean SAE 30 oil in each passage. Check for movement again. If the pistons still do not move, the transmission must be disassembled and the pistons and seal rings checked.

114. Fasten tooling (E) and a hoist to the transmission planetary as shown.

115. Remove the transmission planetary group from tooling (A). The weight of the transmission planetary group is 263 kg (580 lb.).

116. Fasten tooling (E) and a hoist to the transmission case.

117. Install the transmission case on tooling (A) as shown. The weight of the transmission case is 79 kg (175 lb.).

118. Install seals (128) and (129) on the transmission case.

119. Fasten tooling (E) and a hoist to the transmission planetary group as shown.

120. Put transmission planetary (130) in position in transmission case (131).



121. Install two bolts (132) that hold the transmission planetary group and case together.

122. Fasten tooling (M) and a hoist to the transmission assembly as shown.

123. Remove the transmission assembly from tooling (A). The weight of the transmission assembly is 340 kg (750 lb.).

END BY:

a. connection of torque converter to transmission

b. connection of transfer gears to transmission *

*See Assemble Transfer Gears.

Copyright 1993 - 2011 Caterpillar Inc.

Todos los derechos reservados.

Red privada para licenciados del SIS.

Mon Apr 25 12:13:55 CDT 2011



936 transmision desarmado y armado

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