Service Training SESV1717

Meeting Guide 717 November 1999

TECHNICAL PRESENTATION

924G/924Gz WHEEL LOADERS

INTRODUCTION
924G/924GZ WHEEL LOADERS
INTRODUCTION

MEETING GUIDE 717 SLIDES AND SCRIPT

AUDIENCE
Level II--Service personnel who understand the principles of machine systems operation, diagnostic
equipment, and procedures for testing and adjusting.

CONTENT
This presentation describes the significant changes from the 924F/IT24F in machine features and
systems. This presentation covers component locations, nomenclature and a brief description of
systems operation.

OBJECTIVES
After learning the information in this presentation, the serviceman will be able to:
1. identify the major changes in the machine features and systems;
2. explain the basic operation of each system;
3. locate and identify components; and
4. explain the function of the components and systems.

REFERENCES
924G/924Gz Wheel Loader Service Manual RENR3500
924G/924Gz Wheel Loader Parts Manual SEBP2974

PREREQUISITES
Interactive Video Course "Fundamentals of Mobile Hydraulics" (CD ROM) TEMV9001
STMG 546 "Graphic Fluid Power Symbols" SESV1546

SUPPLEMENTARY TRAINING MATERIAL

STMG 684 "928G Wheel Loader/IT28G Integrated Toolcarrier--Introduction" SESV1694
STMG 670 "914G Wheel Loader/IT14G Integrated Toolcarrier--Introduction" SESV1670
STMG 581 "910E/916F/IT12B/IT14B Power Shift Transmission" SESV1581
STMG 667 "Challenger 35/45/55 Agricultural Tractors--
Implement, Hitch and Steering Systems" SESV1667

Estimated Time: 1.5 Hours

Visuals: 61 (2 X 2) Slides
Serviceman Handouts: 3 Work Sheets
Form: SESV1717
Date: 10/99
© 1999 Caterpillar Inc.
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TABLE OF CONTENTS

INTRODUCTION ..................................................................................................................5

MACHINE CONFIGURATIONS ..........................................................................................6

924G..................................................................................................................................7
924Gz................................................................................................................................8

MACHINE APPEARANCE...................................................................................................9

OPERATORÕS STATION .....................................................................................................10

ENGINE AND ELECTRICAL SYSTEM............................................................................21

POWER TRAIN ...................................................................................................................28

Torque Converter and Transmission ...............................................................................29
Power Train Hydraulic System .......................................................................................31
Electronic Transmission Control System........................................................................36
Axles ...............................................................................................................................39

HYDRAULIC SYSTEMS ....................................................................................................42

Work Tool Hydraulic System..........................................................................................44
Steering System ..............................................................................................................65
Brake/Fan Drive System .................................................................................................70

CONCLUSION.....................................................................................................................75

SLIDE LIST..........................................................................................................................76

SERVICEMAN'S HANDOUTS...........................................................................................77
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INSTRUCTOR NOTES
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924G/924Gz WHEEL LOADERS

© 1999 Caterpillar Inc.

INTRODUCTION

¥ Explain coverage This presentation covers the 924G and the 924Gz Wheel Loaders. A
Caterpillar 3056T direct injection, turbocharged engine provides 87 kW
(116 hp) to the flywheel at 2300 rpm for the 924G and the 924Gz.

¥ Power train An electronically controlled, four-speed forward, three-speed reverse

autoshift transmission of countershaft design with a single stage torque
converter transfers the engine power to the axles. The power train is
similar to that on the 924F and the IT24F.

The 924G/924Gz use a parallel flow work tool hydraulic system with
¥ Work tool hydraulics closed center, pilot operated control valves and a load sensing, variable
flow, axial piston pump. The 924F/IT24F machines use an interrupted
series flow hydraulic system with open center, pilot operated control
valves and a fixed displacement pump.
¥ Steering system The 924G/924Gz load sensing steering system uses a variable
displacement pump, as did the 924G/IT24F.
¥ Brake/fan drive The brake and fan drive hydraulic system has been redesigned, however
system this system is similar to that on the 928G wheel loader and the IT28G
integrated tool carrier.

This presentation will cover machine orientation and the operation of the
power train and machine hydraulic systems for the 924G and the 924Gz.
STMG 717 -6-
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MACHINE CONFIGURATIONS

¥ Machine The 924G replaces both the 924F and the IT24F. The 924G combines the
Configurations versatility of an integrated toolcarrier with the production of a wheel
loader. Therefore, an integrated toolcarrier configuration is not necessary
for this G series update.

The 924Gz retains the Z-bar linkage to satisfy market needs for areas that
still require this configuration

Both the 924G and the 924Gz machines are wheel loaders.

The only systems that are different between the 924G and the 924Gz are
the work tool hydraulic systems and the machine structures.
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924G Configuration
1
BOOM Versa Link linkage with box boom
lift arm
COUPLER Hydraulically controlled coupler

WORK TOOL Regeneration and equalization of

HYDRAULICS pressure by tilt control valve

3
2

¥ 924G 924G Wheel Loader

1. Box boom lift arm
The 924G is equipped with Versa Link© linkage for controlling the tilt of
the bucket or tool. This linkage includes a box boom lift arm (1). The
box boom lift arm offers the operator better visibility to the bucket or tool.
A High Lift linkage option enhances the loading capability of the 924G by
allowing the machine to load taller trucks.

2. Hydraulically A hydraulically controlled work tool coupler (2) is an option on the 924G.
controlled coupler This coupler is the same interface as previous integrated toolcarriers and
will connect to existing Caterpillar work tools.

3. Tilt control valve
The main difference between the work tool hydraulic systems of the 924G
and the 924Gz is in the tilt control valve (3). The 924G tilt control valve
regenerates the return oil from the tilt cylinder during the dump cycle.
The tilt control valve equalizes the pressure on both sides of the piston in
the tilt control cylinder with the pressure in the lift circuit during the dump
operation. Hydraulic system operation will be discussed in greater detail
later in this presentation.
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924Gz Configuration
1
BOOM Z-Bar linkage

COUPLER Can be equipped with

Caterpillar work tool coupler

WORK TOOL Conventional tilt control valve

HYDRAULICS operation

¥ 924Gz 924Gz Wheel Loader

1. Lift arms The 924Gz is equipped with Z-bar linkage for controlling the tilt of the
bucket. This linkage includes a conventional slab-type lift arm (1).

2. Pin-on linkage The 924Gz can be equipped with a Caterpillar work tool coupler as an
aftermarket attachment. However, these machines will be delivered only
with pin-on linkage (2).

3. Tilt control valve The 924Gz tilt control valve (3) does not regenerate oil or equalize
pressure during the dump cycle.
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MACHINE APPEARANCE

¥ Redesigned cab The redesigned cab and sloped hood visually differentiate the
924G/924Gz from the 924F Wheel Loaders and the IT24F Integrated
Toolcarriers.

- Access doors The cab is equipped with two doors for easier access. Improved ladders,
- Handrails
handrails and platforms make entry and exit easier and offer room to
maneuver while servicing the machine.
¥ Sloping hood The sloping rear hood enhances the operator's view toward the rear of the
machine. The rear hood configuration allows the operator to see objects
close to the rear of the machine that cannot be seen with the rectangular
shaped hood found on the previous "F" Series Wheel Loaders.
¥ Larger The 924G/924Gz is also larger in size than the 924F Wheel Loaders and
the IT24F Integrated Toolcarriers. The 924G/924Gz is 14 mm (0.5 in.)
taller and it has a 100 mm (4 in.) longer wheel base than the 924F/IT24F.
STMG 717 - 10 -
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OPERATOR'S STATION

¥ Cab components: The 924G/924Gz cab is shared with the 928G and the IT28G. The two
door design provides access from the right or left side of the cab.
- Right side door

- Bonded glass The bonded glass in the front window eliminates distracting metal frames.
The increase in cab glass area enhances the view around the machine.
¥ Molded nonmetallic Molded nonmetallic materials inside the cab allow for easy installation of
materials
features such as a coat hook, lockable storage boxes, and cup, vacuum
bottle and cooler holders.

¥ Improved ventilation Improved ventilation provides better air flow to the operator and the
windows. The optional air conditioning keeps the cab temperature
comfortable for operation in warm environments.
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¥ Door latch release Both doors have latches that hold the doors fully open.
(arrow)
Push the button at the pivot point of the door in order to release this latch.
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1 5

4
2

¥ Cab components: The six-way adjustable suspension seat (1) adds to the overall comfort
1. Adjustable seat level by smoothing the ride over rough ground.

The seat cushion angle lever (2) raises the front of the seat cushion to the
2. Seat cushion angle
lever desired position.

The front/rear lever (3) allows forward and rearward adjustment.

3. Front/rear lever
The suspension adjustment knob (4) adjusts the stiffness of the seat
4. Suspension
suspension.
adjustment knob
The backrest adjustment (not shown) allows the backrest centerline to
5. Retractable seat conform to the operator's spinal curve and provides the proper support to
belt
the back's lumbar region.

A retractable seat belt (5) is also included with the seat.

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3 2

¥ Left front console A left front console has been added to the 924G/924Gz operatorÕs station.
1. Five position Some controls have been moved here for easy access by the operator.
headlamp switch
The headlamp switch (1) has the following positions: OFF, PARK
2. Rotating beacon (panel/tail lamps), ROADING (front headlamps), WORK 1 (front cab
switch floodlamps) and WORK 2 (rear cab floodlamps). Each position of the
switch illuminates more lamps than the previous positions.
3. Thermal start aid
switch The three switches below the headlamp switch include: rotating beacon
(2), thermal starting aid (3) and the transmission neutralizer override (4).
4. Transmission
neutralizer override
During normal operation, the transmission is neutralized when the brakes
are applied. Use the transmission neutralizer override switch to override
this feature.

Warning lamps are located on the left front console, including the brake
pressure indicator lamp, engine oil pressure indicator lamp, coolant
temperature indicator lamp, transmission oil temperature indicator lamp
and differential lockup indicator lamp.

NOTE: Throughout the cab, some of the switches are for optional
attachments, so not every machine will have all the switches that are
shown in this presentation.
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3 5

4
6

2
1

10

¥ Front console In the center console, individual gauges with dial faces show the
conditions of the various machine systems. The group includes the
1. Horn button
following gauges: engine coolant temperature (3), hydraulic oil
temperature (4), fuel level (5), and transmission oil temperature (6). An
2. Lamps
optional speedometer (not shown) is available. This gauge group is
3. Engine coolant similar to the gauge group in the cab of the 928G/IT28G.
temperature gauge
The horn button (1) is located in the center of the steering wheel.
4. Hydraulic oil
temperature gauge The four lamps (2) spaced around the steering column are the turn signal
indicators (left and right), the high beam indicator (optional) and the
5. Fuel level gauge trailer light indicator (optional). The F-N-R indicator is located directly
above the steering column.
6. Transmission oil
temperature gauge
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1
2 3 9

9
5
4
6

11

¥ Right front console Shown in this view is the right side of the front console.
components:
The optional turn signal lever (1) is on the right side of the steering
1. Turn signal
column. Pulling the turn signal switch away from the console operates
(optional)
the hazard lights.
2. Engine start switch
The engine start switch (2) is located on the right side of the front
console.
3. Dimmer switch
location (optional) A switch for dimming the roading lights (3) is optional.
4. Lighter (24V) A cigarette lighter (4) on the right front console provides a 24V power
source for electrical components. An optional 12V power source is
5. Secondary steering
located on the lower left side of the seat.
test switch
(optional) The switch to activate the secondary steering system test (5) is located
next to the indicator lamps.
6. Indicator lamps
Indicator lamps (6) include: alternator, park brake, cab floodlamps, and
7. Steering wheel tilt (if equipped) secondary steering motor ON lamp and a primary steering
latch
pressure fault lamp.
8. Front windshield The steering wheel tilt latch (7) allows the operator to adjust the steering
wiper switch
wheel to the desired angle.
9. Rear windshield Two switches are used to control the windshield wipers. One switch (8)
wiper switch
controls the front windshield wiper and another switch (9) controls the
rear windshield wiper.
STMG 717 - 16 -
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3 4
1

12

¥ Lever functions: Reduced lever efforts and shorter lever throws are achieved by using pilot
1. Joystick control operated work tool controls resulting in decreased operator fatigue.

2. Transmission
The 924G/924Gz will have one of several different work tool hydraulic
control switch control arrangements depending on the machine configuration. The
standard configuration has a joystick pilot valve control lever (1). The
3. Third function joystick pilot valve control lever controls the bucket LIFT and DUMP
control functions. Additional control levers are used to control the third (3) and
fourth (4) functions if the machine is so equipped. Some machines may
4. Fourth function
control
be equipped with as many as four single function levers. However, the
High Lift option will only allow for three functions.

¥ Solenoids perform
detent
¥ Hydraulic control lock
The pilot valves contain normally energized solenoids which hold the
lever in detent for the loader FLOAT position, the bucket kickout circuit,
the loader lift kickout circuit, or the third function lever "rearward
position."
A hydraulic control lock (pilot shutoff) lever is located between the seat
and the right console. The lever controls a valve which interrupts the
flow of oil to the pilot valves and also deactivates the control lever
solenoid detents if moved out of the unlocked position. Fully raise the
lever in order to shut off the pilot system. The lever should be all the way
on or off, do not leave the lever in the middle position.
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The hydraulic control lock lever can be used to prevent a work tool from
moving accidentally when maintenance is being performed or to prevent
accidental movement of the work tools during roading.

A transmission control (F-N-R) switch (2) can be incorporated into the

joystick pilot valve control lever. This switch allows the operator to shift
from forward to reverse without releasing the steering wheel.

An optional downshift switch (not shown) is located at the front of the

joystick pilot valve control lever.
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3
8 4 1

5 2

13

¥ Right console Shown in this view is the right side console. Switches mounted on the
switches console are used to control certain machine functions. The icon on the
1. Fan speed switch switch indicates the function that the switch performs. This location
provides better accessibility to these controls. Controls that are located on
2. Temperature the right console are autoshift on/off (3), ride control on/off/auto (4),
control knob
kickout on/off (5), defrost on/off (6), air conditioning (7), temperature
control (2) and fan speed switch (1).
3. Autoshift ON/OFF
A switch (8) controls the engagement and disengagement of the coupler
4. Ride control
on the 924G. Two actions are required to activate the switch. First, the
ON/OFF/AUTO
slide on the switch must be moved forward, then the switch can be
5. Kickout ON/OFF activated. This prevents inadvertent decoupling of the work tool. The
steering system supplies oil to the control valve for the coupler.
6. Defrost ON/OFF
The fan speed switch controls the heating and air conditioning fan speed.
7. Air conditioning The temperature control knob allows the operator to vary the air
ON/OFF temperature from the heating and air conditioning systems.

8. Coupler control
switch
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14

¥ Pedals The brake pedals have changed to a suspended pedal from a clip pedal on
1. Accelerator the 924F/IT24F.

The pedal (1) on the right is the accelerator. The center pedal and the
2. Service brake
pedals pedal on the left (2) are both service brake pedals. Linkage connects the
brake pedals. Depressing either pedal ENGAGES the service brakes and
NEUTRALIZES the transmission unless the transmission neutralizer
override switch is activated.

The transmission neutralizer is controlled by two pressure switches on the

brake control valve.
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15

¥ Side console All the fuses (1) are located in the operatorÕs station inside the right side
door. This helps protect the fuses from outside elements and provides
1. Fuses
easier access to the fuses.
2. ET Connector A diagnostic indicator lamp is located at the bottom of the fuse
compartment. The diagnostic indicator lamp can be used to identify
3. Relays
active and logged faults.

The diagnostic port connector (2) for electronic technician is located just
inside the right door of the cab.

Several relays (3) are located on this panel: Alarm "A" relay, Alarm "B"
relay, Park brake light/Seat alarm relay, Park brake alarm relay, Ride
control/Load check relay, and the backup alarm relay.
STMG 717 - 21 -
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1 2

8
5

4 6

16

ENGINE AND ELECTRICAL SYSTEM

¥ 3056 Engine The engine is mounted in the rear frame. Doors on each side of the
machine allow access to the engine compartment.
1. Engine oil filters
The engine in the 924G/924Gz is a Caterpillar 3056T, producing 87 kW
2. Tool box
(116 hp) to the flywheel, which is a 10% increase in power over the
924F/IT24F. The 3056T will meet the vehicular emissions regulations
3. Fuel tank
through the year 2002.
4. Fuel fill tube
The engine oil filters (1), which have internal check valves to prevent oil
5. Battery disconnect
leakage during filter changes, are located on the left side of the engine.
switch
The fuel tank (3) is located at the rear of the machine below the cooling
system. The non-metallic tank prevents fabrication debris and corrosion
6. Engine oil S¥O¥S
port and is more resistant to leakage. A tool box (2) is located directly above
the fuel tank.
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7. Fuel injection The fuel fill tube (4) can be accessed with the radiator closed and the right
pump side door open.
8. Fuel-water The battery disconnect switch (5) is also located on the right side of the
separator machine. The engine oil S¥O¥S port (6) is located on the right side of the
engine.

The fuel-water separator (8) is located on the right side of the machine.
The 924F/IT24F did not have a fuel-water separator.

The 3056T engine has a different fuel injection pump (7) and different
injectors than the 3114 engine. The fuel system configuration in the
924G/924Gz is similar to the current fuel system configuration on the
914G/IT14G.

INSTRUCTOR NOTE: For additional information about the fuel

system, see STMG 670 "914G Wheel Loader/IT14G Integrated
Toolcarrier" (Form SESV1670).
STMG 717 - 23 -
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2 5

17

¥ Cooling system The 924G/924Gz cooling system is different from that on the 924F/IT24F.
The standard cooling system can be used in a wider variety of applications
1. Fan drive motor like waste handling, agricultural applications and landfill operations.
2. Fan and fan shroud The non-metallic fan pulls the air through the radiator. The incoming air
flows through the screens in the engine compartment access doors. These
3. Air conditioning
screens have a vertical weave in order to allow foreign material to drop
condenser
off the screen when the machine is not operating.
4. Hydraulic oil cooler The fan is driven by a hydraulic motor (1), allowing the fan and the fan
shroud (2) to be swung away from the radiator. A gear pump, which is
5. Radiator
shared with the brake system, provides the oil flow which drives the fan
drive motor.

The hydraulic oil cooler (4) and the air conditioning condenser (3) are at
the front of the radiator and can be swung forward to clean the radiator.

The standard hydraulic oil cooler is included in the package with an

optional heavy duty hydraulic oil cooler.
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924G STARTING AND CHARGING SYSTEM

304-WH
ALT. BREAKER
TO SERVICE METER AND
G S 101-RD 60 109-RD 109-RD B+ SECONDARY STEERING CONTROL
D+ R
MTR BAT AUX. BREAKER LAMP BREAKER B-

MOTOR 30 115-RD 102-RD

15 ALTERNATOR

STARTER 115-RD 10 A 105-RD

MAIN BREAKER

60 109-RD
RD-00
R
308-YL

NEG POS NEG POS C OFF

DISCONNECT S ON
307-OR B ST
SWITCH FIRST GEAR
SECOND GEAR
(OPTIONAL) THIRD GEAR
FOURTH GEAR
START RELAY
NEUTRAL
REVERSE KEY START
FORWARD
SWITCH
+ BATTERY
GROUND
EXTERNAL FWD
EXTERNAL REV RESISTOR
BACKUP REALY
FUEL
112-PU 117-RD
KEY SWITCH IN
SHUTOFF 396-PK-18
CST SHIFTER SOLENOID
MAIN START
RELAY RELAY
306-GN START AID
SWITCH
15 A
109-RD
310-PU

188-WH
FROM
RESISTOR
399-OR LAMP
SWITCH
T° 377-OR
COOLANT
COLD SWITCH COLD START
MOTOR
START HEATER 373-GN
ADVANCE
MOTOR

18

This slide shows the wiring schematic for the starting and charging system
in the RUN condition.
¥ Starting system The red colored wires have battery voltage when the key start switch is in
the OFF position. When the key is moved to the "ON" or "START"
positions, power flows from the batteries through the auxiliary breaker to
the "B"terminal of the key start switch.

Power flows from the "R" terminal on the key start switch through the
fuel shutoff resistor to the fuel shutoff solenoid. When the solenoid is
energized, the fuel is allowed to enter the fuel injection pump. If the key
is moved to the "OFF" position or if there is a loss of electrical power, the
solenoid becomes de-energized and the flow of fuel to the pump is
interrupted.
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Power also flows from the key start switch, to the transmission control
lever (CST shifter). If the lever is in the neutral position, power will flow
through the shifter to the start relay.

When the start relay is energized, power flows from the batteries, through
the alternator breaker and the start relay, to the starter.

¥ Optional start aid The optional start aid system includes the following components: the
system fifteen amp fuse, start aid switch, cold start resistor, cold start heater,
coolant switch and the cold start advance motor. When the key is in the
"ON" position, the main relay is energized which connects the cold start
system to the batteries.

¥ Charging system The charging system includes the following components: the batteries,
alternator breaker, alternator and the key start switch.

The "R" terminal on the key start switch provides the "exciting" current to
the alternator in order to energize the electro-magnets in the alternator.
As the alternator turns, power flows through the alternator breaker to
charge the batteries. Power from the alternator also flows through the
main breaker and the main relay to the accessories.
STMG 717 - 26 -
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1 6
2

4 4

3 5

19

1. Start relay Shown in this slide are the major electronic components on the left side of
the machine.
2. Cold start resistor
The breaker/relay panel is attached to the left side of the hydraulic tank.
3. Fuel shutoff Included on this panel are the start relay (1), the cold start resistor (2), the
resistor fuel shutoff resistor (3), the main breaker (4), the alternator breaker (5),
and the auxiliary breaker(6).
4. Main breaker
The starter (7) is located at the front of the engine compartment on the left
5. Alternator breaker side.
6. Auxiliary breaker The alternator (9) is located at the rear of the engine compartment on the
left side. There is a standard alternator and an optional high output
7. Starter
alternator.
8. Cold start heater The cold start heater (8) is also located at the rear of the engine.

9. Alternator
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20

1. Transmission Shown in this slide are the major elecrical components in the cab and on
control lever the right side of the machine.

2. Main relay The transmission control lever (CST shifter) (1) is located on the steering
column.
3. Fuel shutoff
solenoid The main relay (2) is located below the fuse panel inside the cab right
door.
4. Battery
The fuel shutoff solenoid (3) is on the top of the fuel injection pump.

One battery (4) is located on each side of the machine in an enclosed

battery box.
STMG 717 - 28 -
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21

POWER TRAIN

The power train for the 924G/924Gz is very similar to that of the
924F/IT24F.
¥ Transmission The transmission is the same transmission that is used in the 924F/IT24F.

¥ Axles The axles use a larger casting. A new mounting of the front axle to the
front frame provides a more rigid structure to the machine. An integrated
lip was added to the casting to protect the Duo Cone seals in waste
handling applications.

¥ Differential The differential and the inboard final drives are the same as those on the
924F/IT24F.
¥ Final drives
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22

¥ Torque converter Torque Converter and Transmission

- Automotive style
One of the changes in the power train is the torque converter.
- Flex plate
The torque converter on this machine is a automotive type torque
converter, similar to those used on other small Caterpillar machines.

A flex plate is used on the 924G/924Gz to connect the engine and the
torque converter.
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PUMP
TORQUE 924G/924Gz TRANSMISSION
CONVERTER

INPUT SHAFT

LOW AND HIGH

CLUTCH SHAFT

REVERSE AND SECOND

CLUTCH SHAFT

THIRD AND FIRST

CLUTCH SHAFT

OUTPUT SHAFT

PARKING BRAKE

23

¥ Same transmission as The power shift transmission (countershaft design) provides four
924F/IT24F
FORWARD speeds and three REVERSE speeds. This is the same
- Torque converter transmission that is used in the 924F and the IT24F.
- Power train pump The gear-type transmission pump provides oil flow to the transmission
- Input shaft control valve and transmission speed and directional clutches.
- FORWARD The transmission has five shafts. The input shaft is driven by the turbine
HIGH/LOW shaft
of the torque converter. The FORWARD LOW and FORWARD HIGH
- REVERSE and clutch shaft and the REVERSE and SECOND clutch shaft are then driven
SECOND shaft by the input shaft. The third clutch shaft contains the THIRD and FIRST
- THIRD and FIRST gear speed clutches. The output shaft directs power to the front and rear
shaft axles. The shoe-type parking brake is mounted on the transmission output
- Output shaft shaft.
- Parking brake INSTRUCTOR NOTE: For additional information about the
transmission, see STMG 581 "910E/916F/IT12B/IT14B Power Shift
Transmission" (Form SESV1581).
STMG 717 - 31 -
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924G/924Gz POWER TRAIN HYDRAULIC SYSTEM

FLOW 1
CONTROL
1 2 3
VALVE 2
3
DIFFERENTIAL
VALVE
CONTROL
VALVE

4 6
CHECK 5
FILTER VALVE 4 5
6 DUMP
PUMP VALVE
TORQUE
CONVERTER

RELIEF
VALVE

SUCTION
SCREEN COOLER

TRANSMISSION
LUBE

24

Power Train Hydraulic System

¥ Identify components The power train hydraulic system on the 924G/924Gz is the same as the
and trace oil flow power train hydraulic system on the 924F/IT24F.

The gear pump is driven by the torque converter impeller through a

transfer gear. The filter is externally mounted.

The flow control valve is mounted in the transmission case. The flow
control valve sends oil to the transmission control valve and supplies the
torque converter with the remainder of the oil.
¥ Transmission control The transmission control valve controls three directional clutches and
valve controls: three speed clutches. The differential valve, check valve and dump valve
- Three speed are part of the transmission control valve.
clutches
The torque converter inlet relief valve is located in the transmission case
- Three directional
below the control valve.
clutches
STMG 717 - 32 -
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The oil-to-water cooler is located in the bottom tank of the radiator.

NOTE: The colors in the sectional views and hydraulic schematics

throughout this presentation denote various pressures within the
system. The legend of color codes is as follows:

Red - Pump supply and P1 pressure

Red and White Stripes - Reduced and P2 pressure

Red Dots - Second reduction of supply pressure

Pink - Third reduction of supply pressure

Orange - Signal, pilot or torque converter oil

Green - Open to tank

Blue - Blocked oil

Yellow - Activated valve envelopes or

moving parts

Brown - Lube oil

STMG 717 - 33 -
11/99

2
1

3 4

25

1. Transmission fill The transmission fill tube (1) is on the left side of the machine near the
tube articulation joint. The fill tube contains a dipstick.

2. Transmission oil The transmission oil filter (2) is on the inside of the frame on the left side
filter of the machine. The filter housing contains a pressure tap to check
transmission supply pressure and an S¥O¥S tap for taking transmission oil
3. Transmission sight
samples.
gauge
The transmission sight gauge (3) and the transmission filter are accessed
4. Side cover
through the opening behind the steps on the left side of the machine.

The transmission sight gauge is on the left side of the machine behind the
steps. Maintain the transmission oil level between the LOW mark and the
HIGH mark on the sight gauge when the transmission is warm and to the
top of the sight gauge when the transmission is cool.

Access to the transmission control valve and pressure taps can be obtained
by removing the side cover (4) on the right side of machine.
STMG 717 - 34 -
11/99

2
5

4
3

26

¥ Identify components: Shown in this view is the transmission control valve mounted on the
1. Dump valve transmission. A dump valve (1) is mounted to the control valve.

Three pressure taps are provided on the transmission control valve for
¥ Identify pressure tap
locations: checking P1 speed clutch pressure (2), P2 directional clutch pressure (4)
and P3 torque converter inlet pressure (5).
2. Torque converter
outlet Use pressure tap (2) to check torque converter outlet pressure.

3. P1

4. P2

5. P3
STMG 717 - 35 -
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TRANSMISSION CONTROL VALVE

NEUTRAL

1 2 3
FWD FWD
HIGH REV LOW

DIFFERENTIAL
VALVE
ORIFICE
CHECK
VALVE
3
FWD HI FWD LO REV
LOAD
PISTON 2

1
PUMP
SUPPLY SLUG

4 SELECTOR
6 1ST SPD 2ND SPD
SPOOL
3RD SPD

MODULATING DUMP
5 RELIEF VALVE SPOOL

1ST 2ND
4 SPEED SPEED 5
ORIFICE

BACK FLOW
CHECK VALVE PISTON
3RD
SPEED 6

27

¥ Valve components The 4F/3R transmission control valve has six solenoids which control
three directional clutches and three speed clutches. The transmission
control valve also contains the following components: speed and
directional spools, dump valve, backflow check valve, differential valve,
modulating relief valve and load piston, and orifice check valve.

- Loss of electrical Loss of electrical power to any speed or directional solenoid will prevent
power prevents that particular clutch from engaging.
shifting
The transmission control valve for the 924G/924Gz is very similar to the
transmission control valve that was used on the 924F/IT24F.

INSTRUCTOR NOTE: For more detailed information about the

operation of the transmission control valve, Technical Instruction
Module "Electronically Controlled Power Shift Transmission Control
Valve" (Form SEGV2572).
STMG 717 - 36 -
11/99

ELECTRONIC TRANSMISSION CONTROL SYSTEM

TRANSMISSION NEUTRALIZER
OVERRIDE SWITCH

SHIFT SPEEDOMETER
LEVER
TRANSMISSION
TRANSMISSION
NEUTRALIZER SWITCH SOLENOID

SERVICE
CONNECTOR SOLENOID

AUTO/MANUAL
SWITCH SOLENOID

HARNESS CODE ELECTRONIC

CONNECTOR SOLENOID
CONTROL
MODULE
DOWNSHIFT
SWITCH SOLENOID

ENGINE SPEED
SENSOR SOLENOID

TRANSMISSION
SPEED SENSOR
DIAGNOSTIC
RIDE CONTROL/LOAD INDICATOR
CHECK SWITCH

PARK BRAKE PARK BRAKE

SWITCH ALARM RELAY

RIDE CONTROL
F-N-R SWITCH LOAD CHECK RELAY

28

Electronic Transmission Control System

¥ Electronic transmission This graphic shows a block diagram for the electronic transmission
control system control system. The electronic control module (ECM) receives inputs
components from the operational controls, harness code, and sensors. Based on the
inputs that it receives, the ECM shifts the machine, activates relays or
sends signals to the diagnostic indicator .

The electronic transmission control system inputs consist of the following

components:
Shift lever - allows the operator to choose
transmission speed and direction

Downshift switch - allows the operator to manually

downshift the transmission
Neutralizer switch - neutralizes the transmission when the
operator ENGAGES the service
brakes
STMG 717 - 37 -
11/99

Neutralizer override switch - overrides the transmission neutralizer

switch

Auto/Manual switch - ON/OFF switch for the electronic

transmission control system

Transmission speed sensor - indicates transmission speed

Engine speed sensor - indicates engine speed

Ride control/load check - OFF/ON/AUTO switch for ride

switch control
Park brake switch - neutralizes the transmission when the
parking brake is ENGAGED

F-N-R switch - allows the operator to change the

transmission direction

The electronic control system outputs consist of the following

components:
Transmission solenoids - control transmission speed and
direction

Diagnostic indicator - flashes fault codes

Park brake alarm relay - alerts the operator if the park brake is
on during operation

Ride control/load check relay - activates/deactivates the ride control

system

Speedometer - indicates machine speed to the

operator

INSTRUCTOR NOTE: This electronic control system is similar to

that on the 928G/IT28G. For more information, refer to STMG 694
"928G Wheel Loader/IT28G Integrated Toolcarrier" (Form
SESV1694).
STMG 717 - 38 -
11/99

29

¥ Operational inputs Shown in these views are the main operational input mechanisms and the
and ECM ECM.
1. Transmission
The transmission control lever (1) is identical to the lever that is used in
control lever
the 928G/IT28G.
2. Transmission
A transmission control (F-N-R) switch (2) is an option. This switch is
control (F-N-R)
switch integrated into the joystick control lever if the machine is equipped with
this option. The downshift button (3) is on the front of the joystick
3. Downshift button control lever.

4. Pressure switches The transmission neutralizer on the 924G/924Gz uses two pressure
switches (4) located on the brake valve instead of one mechanical switch
5. Electronic control which was used on the 924F/IT24F. Using two pressure switches
module (ECM) provides smoother neutralization of the transmission when the brakes are
applied and smoother engagement of the transmission when the brakes are
released.
The ECM (5) is located under the cab on the right side.
STMG 717 - 39 -
11/99

30

Axles

¥ Axle contains inboard The axles contain inboard planetary final drives. The front axle is fixed to
planetary final drives the frame, but the pinned rear axle allows 15¡ oscillation in each direction
with 15.5 or 17.5-25 tires.

The axles are an oversize casting to allow for future brake improvements.
A new mounting of the front axle to the front frame gives a more rigid
structure to the machine. An integrated lip was added to the casting to
protect the Duo Cone seals in waste handling applications.
STMG 717 - 40 -
11/99

FRONT / REAR AXLE DIFFERENTIAL

AXLE SUN GEAR

SHAFT
INBOARD
PLANETARY
BEVEL GEAR
AND PINION

31

¥ Axle similar to other The axle is similar to the axles on other Caterpillar Wheel Loaders. The
wheel loaders standard axle contains a conventional differential and fully enclosed wet
- Optional limited slip
disc brakes with a single disc for each wheel. The axle can be ordered
differential
- NoSPIN differential
with a limited slip differential. A NoSPIN differential is available for
available special orders.

¥ Power flow: The transmission output shaft transmits power to the bevel pinion shaft
- Drive shaft
and bevel gear and pinion assembly in the front and rear axles. The bevel
- Bevel pinion shaft gear and pinion assembly transfers power to the differential. The
- Differential differential transmits power to the sun gear shafts. The sun gear shafts
- Sun gear shaft transmit power to the inboard planetaries. The motion of the planet
- Planet gears
carriers causes the axle shafts to rotate.
- Planet carriers
- Axle shaft
STMG 717 - 41 -
11/99

32

¥ Parking Brake The transmission is neutralized when the parking brake is applied. This
neutralizer is a mechanical switch and can be overridden. The parking
brake transmission neutralizer switch is the same as that used on the
928G/IT28G.
STMG 717 - 42 -
11/99

33

HYDRAULIC SYSTEMS

¥ Three hydraulic There are three major hydraulic systems on the 924G/924Gz: the steering
systems system, the brake system/fan drive system, and the work tool hydraulic
- Steering system system. All three systems share a common hydraulic tank.

- Brake/fan drive The steering system and the brake/fan drive hydraulic system on the
- Work tool hydraulic 924G/924Gz are very similar to those on the 928G/IT28G. The work tool
system hydraulic system, however, is different.
STMG 717 - 43 -
11/99

34

¥ Vented hydraulic tank All three hydraulic systems share a common tank which is located behind
1. Clean-out hole the cab. The tank has changed from a pressurized tank to a vented tank.
Also, a large clean-out hole (1) in the tank allows for easier flushing and
2. Sight glass cleaning for service.

3. Hydraulic oil filter The sight glass (2) on the hydraulic tank has been moved to the left side of
the tank on the outside of the machine. This makes the sight glass easier
4. Ecology drain to check during maintenance.

The hydraulic oil filter (3) on the 924G/924Gz is plumbed into the fan
drive system and is located in front of the cooling package. The S¥O¥S
port is part of the filter base. This filtration system is similar to the
928G/IT28G.

The ecology drain (4) function is now provided by a manual shut-off

valve. This valve is located on the left side of the machine at the front of
the engine access door.
STMG 717 - 44 -
11/99

35

Work Tool Hydraulic System

¥ Work tool hydraulic The pilot operated work tool hydraulic system on the 924G/924Gz is very
system different from the previous hydraulic system. The 924F/IT24F machines
- Closed center valves use an interrupted series flow hydraulic system with open center, pilot
in parallel operated control valves and a fixed displacement pump. The
- Variable flow axial 924G/924Gz machines use a parallel flow hydraulic system with closed
piston pump center, pilot operated control valves and a load sensing, variable flow
axial piston pump. The improvements have been made to the hydraulic
system in order to increase the versatility of the 924G.
¥ 924G tilt circuit The tilt circuit of the 924G is different from the tilt circuit of the 924Gz.
With the Versa Link© linkage on the 924G, extending the cylinder will tilt
the work tool forward and retracting the cylinder will rack the work tool
back.
STMG 717 - 45 -
11/99

36

¥ 924Gz tilt circuit On the 924Gz, the tilt cylinder must extend in order to tilt the bucket back
and retract to dump the bucket.

The 924Gz and the 924G both benefit from the improved hydraulic
system. The load sensing system only consumes horsepower from the
engine when needed. The load check poppets in each bank valve allow
almost zero drift and there is almost zero voiding in the cylinders.
STMG 717 - 46 -
11/99

TILT OPTIONAL RIDE LIFT TO AUXILIARY

COMBINATION VALVE CYLINDER CONTROL SYSTEM CYLINDERS FUNCTION
TO AUXILIARY
FUNCTION

BACK
PRESS. TILT LIFT AUXILIARY AUXILIARY
VALVE CONTROL CONTROL CONTROL CONTROL
VALVE VALVE VALVE VALVE
SINK
VALVE

SIGNAL FROM
STEERING
SYSTEM PRESSURE
REDUCING
VALVE
COUPLER
CONTROL
VALVE
TO STEERING
SYSTEM
PILOT CONTROL VALVES

MANIFOLD
WORK TOOL STEERING
PUMP TO SECONDARY
PUMP
STEERING
PRESSURE
SWITCH
924G WORK TOOL
FROM
BRAKE
PISTONS
FROM
BRAKE/FAN
HYDRAULIC SYSTEM
DRIVE SYSTEM

37

¥ Work tool hydraulic The work tool hydraulic system on the 924G and the 924Gz consist of the
system for 924G following components:

Work tool pump - Provides flow to the bank valves

Steering pump - Provides flow to the pressure reducing

valve and the steering system
Pressure reducing valve - Limits the maximum pressure of the
pilot oil
Pilot control valves - Control the flow of pilot oil to the bank
valves
Bank valves - Control the flow of supply oil to the
cylinders or the work tools
Ride control system - Functions as a shock absorber by
cushioning the ride at high speeds
Sink valve - Drains the oil from the signal network
when none of the bank valves are
activated
STMG 717 - 47 -
11/99
Back pressure valve
The following components are on the 924G only:
Coupler control valve
Coupler engagement cylinders -
Combination valve
- Maintains a small amount of pressure
in the return galley of the valve bank in
order to assist in the opening of the
makeup valves
- Controls the flow of oil to the coupler
engagement cylinders
Move the engagement pins on the work
tool coupler
- Performs the relief function on the
head end of the tilt cylinder
STMG 717 - 48 -
11/99

OPTIONAL RIDE LIFT

TILT CYLINDER TO AUXILIARY
CONTROL SYSTEM CYLINDERS
FUNCTION

TO AUXILIARY
FUNCTION

BACK
PRESS. TILT LIFT AUXILIARY AUXILIARY
VALVE CONTROL CONTROL CONTROL CONTROL
VALVE VALVE VALVE VALVE
SINK
VALVE

FROM TO STEERING
STEERING SYSTEM
SYSTEM PRESSURE
REDUCING
MANIFOLD VALVE

WORK TOOL STEERING

PUMP PUMP TO SECONDARY
STEERING
PRESSURE
SWITCH PILOT CONTROL VALVES
FROM BRAKE FROM
PISTONS BRAKE/
FAN DRIVE
SYSTEM

924Gz WORK TOOL

HYDRAULIC SYSTEM

38

¥ Work tool hydraulic This view shows a block diagram of the 924Gz work tool hydraulic
system for 924Gz system. The machine is not equipped with a coupler control valve,
coupler engagement cylinders or a combination valve.

Since the 924Gz tilt circuit is configured differently, the combination

valve is not necessary.
STMG 717 - 49 -
11/99

4 2
1

39

¥ Hydraulic pumps The work tool hydraulic pump (2) has changed from a vane pump to a
1. Steering pump variable displacement axial piston pump. The steering (1) and work tool
pumps are located under the left side of the cab, which is in the same area
2. Work tool pump as the pumps on the 924F/IT24F. The steering pump is mounted onto the
work tool pump.
3. Signal pressure tap
for steering pump The signal pressure taps (3) and (4) are located on the compensator valves
for the steering and work tool pumps.
4. Signal pressure tap
for work tool pump There are separate suction lines for the work tool and steering pumps.

- Separate suction
lines
STMG 717 - 50 -
11/99

MARGIN SIGNAL MARGIN SPOOL

SPRING

CUTOFF SPOOL

PUMP OPERATION
CUTOFF CONSTANT FLOW
SPRING

ACTUATOR PISTON

BIAS SPRING

PUMP OUTPUT

SWASHPLATE

40

¥ Load sensing work This view shows a cross sectional view of the work tool pump or the
tool hydraulic system steering pump. These pumps are variable displacement axial piston
and steering system
pumps and are similar to the variable displacement pumps on other
use variable
displacement pumps
Caterpillar machines.

The pump has one swashplate actuator piston which adjusts the angle of
the swashplate.

The compensator valve controls the flow of oil to the swashplate control
piston and thereby controls the pump output. Inside the compensator
valve are the margin spool and the cutoff spool.

The margin spring maintains the pump supply pressure higher than the
signal pressure. The cutoff spring controls the maximum system pressure.

- Steering pump The work tool pump provides flow for only the bank valves. The steering
provides pilot oil pump provides flow for the pilot system and the steering system.
flow
STMG 717 - 51 -
11/99

NOTE: Depending on the adjustments made to the margin spool and

the amount of pump leakage, LOW PRESSURE STANDBY and
margin pressure can be equal. However, margin pressure can never
be higher than LOW PRESSURE STANDBY.

INSTRUCTOR NOTE: This pump is similar to the implement

hydraulic pump on the Challenger 35/45/55 Agricultural Tractors.
For information on the operation of this pump, see STMG 667-01
"Challenger 35/45/55 Agricultural Tractors--Implement, Hitch and
Steering Systems" (Form SESV1667-01).
STMG 717 - 52 -
11/99

3
6
4

2
1

41

1. Pressure reducing The pressure reducing valve is located on the right side of the machine
valve under the cab. Oil flows from the steering pump to the pressure reducing
valve (1). The reduced pressure oil is the pilot oil.
2. Combination valve
The pressure reducing valve limits the maximum pressure in the pilot
3. Pilot oil pressure system. This is the same pressure reducing valve as that used in the
tap
924F/IT24F.
4. Steering system The pilot oil pressure tap (3) and the steering system pressure tap (4) are
pressure tap
located on the pressure reducing valve.
5. Tilt head end The combination valve (2) is located next to the pressure reducing valve.
pressure tap
The combination valve is only on the 924G and consists of both a diverter
valve and a relief valve. This valve performs the relief function for the
6. Tilt rod end
pressure tap head end of the tilt cylinder on the 924G.

The tilt head end pressure tap (5) and the tilt rod end pressure tap (6) are
located on the combination valve.
STMG 717 - 53 -
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42

¥ Pilot Control Valves From the pressure reducing valve, pilot oil flows through a screen to the
pilot control valves. This screen was not used on the 924F/IT24F.
- Location The pilot control valves are located in the right side console inside the
cab.
- Operation The pilot control valves have been designed to allow for less lever effort.
They operate in the same manner as the pilot control valves on the
924F/IT24F. The pilot control valves control the flow of pilot oil to the
bank valves.

NOTE: There is no longer a mechanical lock on the pilot valve for

the third function of the hydraulic system. The lock was used to
prevent accidental uncoupling of the work tool. But, since this lever
does not control the work tool coupler, the lock on this lever is not
necessary. The work tool coupler is controlled by a switch on the
right console.
STMG 717 - 54 -
11/99

924G TILT CONTROL VALVE

TILT BACK

TO TANK

INLET COMBINATION VALVE TILT CONTROL

MANIFOLD CALVE
AREA CONTROL AREA CONTROL
SPOOL SPOOL

POPPET POPPET

RESOLVER

MAKEUP RELIEF
VALVE VALVE

CHECK VALVE
TO TANK
RETURN GALLEY

SINK MAIN CONTROL

VALVE SPOOL
SIGNAL TO
COMPENSATOR VALVE
SIGNAL NETWORK
SUPPLY GALLEY
FROM DRAIN PASSAGE
PUMP

FROM PILOT TO PILOT

CONTROL VALVE CONTROL VALVE

43

¥ Bank valves From the work tool pump, the oil flows to the closed center, pilot operated
bank valves. Shown here is an individual bank valve.

- Control flow to the The bank valves control the flow of hydraulic oil from the implement
cylinders pump to the cylinders. The valves also send signal oil back to the work
tool pump.

¥ Common components Each bank valve operates differently, but all of the valves share the same
basic components.

- Pressure galley A common galley carries pressure oil from the work tool pump to all the
bank valves. Also, a common galley carries return oil away from the bank
- Return galley valves to the tank.

- Resolvers Resolvers determine which function in all of the valves has the highest
demand. Then, the signal for the highest demand is sent to the pump.
The resolvers are double check valves containing two balls.
STMG 717 - 55 -
11/99

- Poppets Each valve has two poppets which act as a lock valve. The poppets close
off the ports so that there is almost zero drift of the work tools when the
bank valve is in the HOLD position. Passages in the poppet allow a
restricted amount of oil to flow from the port in the valve to the back side
of the poppet.

- Area control spools Every poppet is controlled by an area control spool that is located directly
behind the poppet. Pilot oil opens these spools by forcing the spool
upward. Moving the spool upward opens the back side of the poppet to
the tank. The poppet is opened by the area control spool in order to allow
return oil to flow from the port to the main control spool.

- Main control spool The main control spool is controlled by pilot oil from the pilot control
valves. The spool is machined differently for each bank valve.
STMG 717 - 56 -
11/99

RESOLVER POPPET AREA

CONTROL
SPOOL

MAIN CONTROL PRESSURE RETURN

SPOOL GALLEY GALLEY

44

¥ Bank valve This view shows the components of the tilt control valve for the 924G.
components
STMG 717 - 57 -
11/99

924G TILT CONTROL VALVE

DUMP
HEAD END ROD END POPPET
PORT RESOLVER PORT
AREA CONTROL
SPOOL

ORIFICE

MAIN CONTROL SUPPLY RETURN

SPOOL GALLEY GALLEY

45

¥ Tilt control valve for During the dump cycle, the tilt control valve on the 924G regenerates
924G return oil from the rod end of the cylinder and sends it to the head end of
- Regeneration of the cylinder. This regenerated oil flows through the pressure galley and is
return oil equal to pump output pressure. The result is that the pressure on both
sides of the piston is equal to the pressure in the pressure galley.
- Pressure
equalization in Pressure equalization prevents the head end of the tilt cylinder from
cylinder with voiding, resulting in a powered dump rather than the bucket dumping due
pressure galley
to the force of gravity. During simultaneous lift and dump operations, this
action also provides additional supply oil so both the tilt and lift circuits
operate smoothly. Without pressure equalization, the pump would not be
able to mee the flow needs of both circuits, resulting in the lift function to
be slower than desired.

The tilt control valve for the 924G is the only valve that regenerates oil
and equalizes pressure.
STMG 717 - 58 -
11/99

¥ Dump Operation To begin the dump cycle, pilot oil flows into the right end of the spool.
- Spool The spool starts to shift to the left, connecting the pressure oil passage to
the left poppet and the right poppet.

- Area control spool Pilot oil also flows through an orifice to the bottom side of the right area
control spool and the area control spool shifts upward. The oil from the
back side of the right poppet begins to flow to the return passage in the
valve to be regenerated.

- Resolver At the same time, supply oil flows past the spool and encounters the
resolver which is next to the poppet. If the pressure oil in the valve is at a
higher pressure than the pressure in the signal passage, the ball unseats
and the oil signals the pump to upstroke to meet the flow demand. If the
pressure oil in the valve is at a lower pressure than the signal passage, the
pump will already be upstroked by another circuit, but the pump will
upstroke more to meet the additional flow demand of the tilt circuit.

- Left poppet The left poppet is opened by the supply oil and oil flows out to the head
end of the cylinder.

- Right poppet As supply oil flows out to the cylinder, the pressure of the return oil
increases. Return oil flowing through the right poppet causes a pressure
drop across the poppet and it opens.

- Pressure Now, system pressure is open to both the rod end and the head end of the
equalization tilt cylinder. The bucket dumps because of two factors: the effective area
of the head side of the piston is greater than the effective area of the rod
side of the piston and the weight of the load and the bucket. These two
forces cause the cylinder to extend and the bucket dumps.

- Regeneration of oil Pressure oil flows out to the head end of the cylinder. Return oil flows
back from the rod end of the cylinder and is sent through the pressure oil
passage to the head end of the cylinder. Oil from the back side of the
right poppet also flows into the passage that is between the right poppet
and the spool. In this manner, nearly all of the return oil is regenerated.
STMG 717 - 59 -
11/99

924G TILT CONTROL VALVE

TILT BACK
AREA CONTROL HEAD END ROD END
SPOOL POPPET RESOLVER
PORT PORT

ORIFICE

MAIN CONTROL SUPPLY RETURN

SPOOL GALLEY GALLEY

46

¥ Tilt back operation During tilt back, the valve does not regenerate return oil, nor are the
pressures equalized on each side of the piston in the cylinder.

- Spool Pilot oil flows into the left end of the spool. The spool starts to shift to the
right. This connects the pressure oil passage to the right poppet and the
return passage to the left poppet.

- Area control spool Pilot oil also flows through the orifice to the bottom side of the left area
control spool and the area control spool shifts upward. The oil from the
back side of the left poppet to begins to return to tank.

- Resolver The pressure oil flows past the spool and encounters the resolver which is
next to the poppet. The resolver senses the oil pressure and sends the
appropriate signal to the pump. The pump upstrokes because of the
increase in the flow demand.
STMG 717 - 60 -
11/99

- Right poppet The right poppet is opened by the supply oil and oil flows out to the rod
end of the cylinder.

- Left poppet As supply oil flows out to the cylinder, the pressure of the return oil
increases. Return oil flowing through the left poppet causes a pressure
drop across the poppet and it opens. Return oil flows from the head end
of the cylinder to tank.

Supply oil continues to flow past the right poppet and out to the cylinder.
Return oil flows past the left poppet. The cylinder retracts and the bucket
tilts back.
STMG 717 - 61 -
11/99

MAKEUP VALVE RELIEF VALVE

47

¥ Pressure relief and The tilt control valve on the 924G also includes a pressure relief valve and
makeup valves a makeup valve.

- Pressure relief The direct acting pressure relief valve is connected to the rod end of the
tilt control cylinder. It is in parallel to the shoulder of the rod end poppet
in the valve.

- Makeup The makeup valve is connected to the head end of the tilt control cylinder.
This valve is in parallel to the shoulder of the head end poppet in the
valve. The makeup valveÕs purpose is to provide oil to the head end of the
cylinder during dumping operations when extra supply oil is needed.
STMG 717 - 62 -
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COMBINATION DIVERTER/RELIEF VALVE

BACK DRAG OPERATION

TILT
CYLINDER

48

¥ Combination valve Plumbed into the tilt control cylinder on the 924G is a combination valve
with a diverter valve and a relief valve. The combination valve performs
the relief function on the head end of the cylinder during backdragging.

This slide shows the combination valve during a back drag operation. The
bucket is forcing the cylinder piston in, thus causing a void on the rod end
and pressure on the head end of the cylinder.

The spool in the diverter valve is connected to each end of the tilt
cylinder. The function of the diverter is to sense the pressure differential
between the head end and the rod end of the cylinder. If the pressure
differential exceeds 3000 KPa (435 psi), the diverter opens and oil from
the head end of the cylinder flows to the relief valve. If the pressure on
the relief valve exceeds 12,300 KPa (1780 psi), the relief valve opens and
the oil is returned to tank.

The reason for the diverter valve is to keep the relief valve setting low and
yet allow for the high pressures needed for the pressure equalization of the
tilt circuit during the dump operation.
STMG 717 - 63 -
11/99

49

¥ Ride control system Shown here is the ride control valve. This valve is located at the bottom
of the frame on the left side of the machine.

The optional ride control system on the 924G/924Gz is very similar to the
ride control system on the 924F/IT24F. However, the new auto ride
control system is factory set to activate at 8 km/h (5 mph).

The auto ride activation speed is now programmable. The Electronic

Technician (ET) service tool can be used to select an activation speed
between 5 and 15 km/h (3 and 9 mph). This customizes the ride control
activation to the job site and allows the operator to concentrate more on
operating the machine rather than turning ON or OFF the ride control
system.
STMG 717 - 64 -
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50

¥ Ride control The ride control system uses one accumulator (arrow). This accumulator
accumulator is located on the left side of the machine.

A floating piston in the ride control accumulator separates the oil from the
nitrogen gas. Since nitrogen gas is compressible, the gas serves as a
spring. Any downforce on the lift arms is transferred through the oil at
the head end of the lift cylinders to the accumulator. The force in the oil
is transmitted to the accumulator piston, which compresses the nitrogen
gas. Compressing the nitrogen gas absorbs the pressure spike and the oil
displacement caused by the downward force on the lift arms. This
operation results in less ground induced shocks on structures and
components, reduced tire flexing and a greater payload retention.
STMG 717 - 65 -
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LEFT
STEERING
CYLINDER

METERING
SECTION

CROSSOVER RIGHT
RELIEF LINE RELIEF STEERING
VALVE VALVES CYLINDER
SUPP.
STEERING CONTROL
PUMP VALVE
SECTION
M STEERING
METERING PUMP
IMPLEMENT
PUMP TO IMPLEMENT VALVES

TO PILOT SYSTEM

STEERING
FROM PUMP
BRAKES LOAD SENSING STEERING SYSTEM
RIGHT TURN

51

Steering System

¥ Steering system The hydraulic steering system steers the machine by changing the
components machineÕs angle of the articulation.
- Steering pump
The steering system consists of the following components: steering
- Steering metering pump, steering metering pump and steering cylinders. A secondary
pump
steering system is an option on this machine.
- Steering cylinders
The basic operation of the steering system has not changed from the
- Secondary steering 924F/IT24F. However, some modifications to the components of the
system
system have improved the steering performance of the 924G/924Gz.

INSTRUCTOR NOTE: The steering system is similar to that on the

928G/IT28G. For more information, refer to STMG 694 "928G
Wheel Loader/IT28G Integrated Toolcarrier" (Form SESV1694).
STMG 717 - 66 -
11/99

52

¥ Steering pump The steering pump (1) provides flow to the steering cylinders. The
1. Variable steering pump is a variable displacement axial piston pump. The steering
displacement axial metering pump sends a signal to the pump and the pump upstrokes or
piston pump destrokes to meet the flow demand.

2. Signal pressure tap The steering pump is located on the left side of the machine under the cab
and is driven by the implement pump.

Signal pressure tap (2) is located on the compensator valve. The steering
pump output pressure tap is located on the pressure reducing valve.

This is the same style of variable displacement piston-type pump as the

work tool hydraulic pump.
STMG 717 - 67 -
11/99

53

¥ Steering metering The steering metering pump (arrow) controls the flow of oil from the
pump components: steering pump to the steering cylinders. The steering metering pump is
- Control valve located under the front of the cab.
section
The steering metering pump consists of a control valve section, a
- Metering section
metering section, crossover line relief and makeup valves, and a check
- Crossover line relief valve. A mechanical linkage connects the steering wheel to the control
and makeup valves valve and metering sections of the steering metering pump.
- Check valves
The new steering metering pump allows for a wider range of modulation.
This provides smoother steering and better control of the machine.
STMG 717 - 68 -
11/99

54

¥ Steering cylinders The steering cylinders change the machineÕs angle of articulation.

- Located on each A steering cylinder is located on each side of the articulation joint of the
side of the machine machine.
- Pins and bores The pins and bores on the steering cylinders have been made longer on
longer the 924G/924Gz than on the 924F/IT24F. Also, the bosses for the
steering cylinders are thicker. These changes will decrease the contact
stresses in the cylinders and increase the pin bore life.
STMG 717 - 69 -
11/99

2 1

55

¥ Supplemental steering A secondary steering system is an option on the 924G/924Gz which

system allows the operator to continue to steer the machine if the engine fails or
1. Hydraulic pump the steering pump stops. The system consists of a hydraulic pump (1) that
is driven by an electric motor (2), which are located below the cooling
2. Electric motor package in front of the fuel tank. The ECM controls the motor through a
relay.

- Operation If the steering pressure drops, a signal from the control module closes a
contact and the secondary steering pump starts. The secondary steering
motor, relay and pump are located at the rear of the machine in front of
the fuel tank.

- Retrofittable The secondary steering system is retrofittable onto a 924G/924Gz.

- Manual test and auto The secondary steering system has a manual test and an auto test to
test ensure correct operation. The auto test consists of a three second test
when the start key is in the ON position, prior to turning over the engine.
During the test, the operator should steer the machine and confirm that the
system works properly.
STMG 717 - 70 -
11/99

BRAKE SYSTEM
CUT-IN/BRAKES RELEASED
TANDEM ACCUMULATOR CHARGING
BRAKE VALVE
VALVE

REAR AXLE SHUTTLE

BRAKES REAR VALVE
BRAKE
ACCUMULATOR
CHECK
VALVE

FRONT AXLE
BRAKES CUT IN/CUT OUT
VALVE
PRIORITY
VALVE
FRONT
BRAKE
ACCUMULATOR

RELIEF
VALVE
ENGINE FAN
BRAKE AND
FAN PUMP

MOTOR GROUP
COOLER

FILTER

56

Brake/Fan Drive System

¥ Brake hydraulic
system
- Identify components
- Drives cooling fan
The brake hydraulic system maintains the hydraulic pressure necessary to
apply the service brakes. The major components of this system are: the
pump, the brake accumulator charging valve group, the accumulators, the
brake control valve and the brake pistons (located in the axle).
This hydraulic system also powers the cooling fan. Therefore, it will be
referred to as the brake/fan drive system.

The brake/fan drive system is a new design feature on the 924G/924Gz.

However, this system is similar to the brake/fan drive system that is used
on the 928G/IT28G.

INSTRUCTOR NOTE: The brake/fan drive system is similar to that

on the 928G/IT28G. For more information, refer to STMG 694
"928G Wheel Loader/IT28G Integrated Toolcarrier" (Form
SESV1694).
STMG 717 - 71 -
11/99

4
1

2 3

57

¥ Brake/fan drive pump The brake hydraulic pump (1) has changed from a vane pump on the
1. Gear pump 924F/IT24F to a gear pump on the 924G/924Gz. This is the same pump
that powers the cooling fan. The pump has also changed location. It is no
2. Brake accumulator longer mounted onto the other pumps, but is now located on the right side
charging valve at the rear of the engine.
group
The accumulator charging valve (2) is attached to the brake/fan drive
3. Brake accumulator pump. This valve group directs the oil flow from the pump to either the
pressure tap
accumulators or the fan drive system depending on the pressure in the
accumulators.
4. Pressure switch
The accumulator charging valve creates priority for charging the brake
accumulators over the cooling fan drive. The operation of the
accumulator charging valve is different from that on the 924F/IT24F, but
it is similar to that used on the 928G/IT28G.

The pressure switch (4) activates the brake pressure warning lamp and
alarm on the left front console when pressure in the brake system is low.

Use the pressure tap (3) to check the CUT-IN and CUT-OUT pressures.
There are no adjustments for CUT-IN and CUT-OUT pressures, so if the
pressures are not correct, replace the accumulator charging valve.
STMG 717 - 72 -
11/99

58

¥ Brake accumulators The brake accumulators (arrow) have changed location from the
924F/IT24F and are now mounted vertically onto the right side of the
hydraulic tank support. The precharge pressure in the accumulators has
been reduced.

The accumulators store fluid energy for quick response of the brakes.
STMG 717 - 73 -
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59

¥ Brake control valve The brake control valve is located under the front of the cab. The valve is
manually actuated by foot. The brake control valve directs oil from the
accumulators to the brake pistons.

Pressing the brake pedal directs oil from the system to the brake pistons
and releasing the brake pedal allows oil from the brake pistons to return to
tank.

- Maximum pressure The maximum pressure has been reduced in order to accommodate for the
decreased change to the seals on the brake pistons.

The valve linkage has also changed from the 924F/IT24F to accommodate
the use of the suspended brake pedal. However, the operation of the
brake control valve has not changed.
STMG 717 - 74 -
11/99

REACTION BRAKE
PLATE PISTON

DISC
BRAKES

SUN GEAR
SHAFT

BRAKE
DISC

60

¥ Disc brakes Each brake disc rotates with the sun gear shaft. The brakes are
hydraulically engaged. When the brake pressure is drained, the piston
seals and retraction springs retract the piston to RELEASE the brakes.

- Brake pistons The seals on the brake pistons are a D-ring design which are easier to
service and install than the seals used on the 924F/IT24F. Because of the
lower pressure in the brake system, the piston size has increased. The
increase in effective area allows the pistons to apply the same brake force
with lower pressure. The brake piston and the reaction plate are heavier,
providing better dissipation of heat.

- Brake discs The discs have increased in surface area in order to improve service life
and performance. There is now one disc per wheel and the disc is
designed with a cross-hatch pattern for better oil flow.
STMG 717 - 75 -
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61

CONCLUSION

This concludes the introduction presentation on the 924G and the 924Gz
Wheel Loaders.

This presentation discussed the component locations and systems

operation of the power train and hydraulics systems on these wheel
loaders. When used in conjunction with the service manual, the
information in this package should permit the serviceman to do a
thorough job of troubleshooting these systems and diagnosing problems
on the machines.
STMG 717 - 76 -
11/99

SLIDE LIST
1. 924G machine cutaway 40. Hydraulic pump cutaway
2. 924F model view 41. Pressure reducing valve and combination
3. 924G configuration valve
4. 924Gz configuration 42. Pilot control valves
5. Hood and cab 43. Schematic of 924G tilt control valve
6. Front of cab 44. Bank valve components
7. Door latch release 45. 924G tilt control valve dump operation
8. Seat 46. 924G tilt control valve tilt back operation
9. Left front console 47. 924G tilt control valve makeup valve and
10. Center front console relief valve
11. Right front console 48. Combination valve schematic
12. Work tool control levers 49. Ride control valve
13. Right console 50. Ride control accumulator
14. Pedals 51. Steering system schematic
15. Fuse box 52. Steering pump
16. Engine and fuel tank 53. Hand metering unit
17. Cooling system 54. Steering cylinder
18. Starting and charging system 55. Secondary steering pump
19. Electrical components -- Left side 56. Brake system schematic
20. Electrical components -- Right side 57. Brake pump
21. 924G powertrain cutaway 58. Brake accumulators
22. Torque converter 59. Brake control valve
23. Transmission cutaway 60. Brakes cutaway
24. Powertrain hydraulic system 61. 924G machine cutaway
25. Transmission service points
26. Transmission control valve
27. Transmission control valve schematic
28. Electronic transmission control system
block diagram
29. Transmission controls
30. Front axle
31. Axle cutaway
32. Parking brake
33. 924G hydraulic cutaway
34. Hydraulic tank
35. 924G hydraulic cutaway
36. 924Gz hydraulic cutaway
37. 924G work tool hydraulics block diagram
38. 924Gz work tool hydraulics block diagram
39. Hydraulic pumps
 11/99
STMG 717
Startintg and Charging System
Components

Directions: Fill in the blank next to the

letters with the correct component name.

A.
924G STARTING AND CHARGING SYSTEM
304-WH

B. E TO SERVICE METER AND

G S 101-RD 109-RD 109-RD
60 B+ SECONDARY STEERING CONTROL
MTR BAT
I LAMP BREAKER
D+
B-
R

C. B 30 115-RD 15 102-RD
G

D.
A 115-RD 10 A 105-RD

J RD-00
60 109-RD

R
308-YL

E. NEG POS NEG POS C OFF

S ON
307-OR
FIRST GEAR B ST

SECOND GEAR
THIRD GEAR

- 77 -
FOURTH GEAR

F. START RELAY

K
NEUTRAL
REVERSE
FORWARD

+ BATTERY
GROUND
EXTERNAL FWD
EXTERNAL REV
RESISTOR
G. 112-PU 117-RD
BACKUP REALY
KEY SWITCH IN

H 396-PK-18

F D
H. 15 A
306-GN

109-RD
L
M 310-PU

I. 188-WH
FROM
RESISTOR
399-OR LAMP
SWITCH
T° 377-OR
J. COOLANT
MOTOR SWITCH
N

Serviceman's Handout No. 1

373-GN

C
K.

L.

M.

N.
STMG 717 - 78 - Serviceman's Handout No. 2
11/99

Work Tool Hydraulic Component Checklist

Directions: Use this sheet to take notes during the slide presentation. During a lab exercies, use this
sheet as a checklist when identifying and locating components.

Work Tool Pump

Steering Pump

Pressure Reducing Valve

Pilot Control Valves

Sink Valve

Tilt Control Valve

Lift Control Valve

Auxiliary Control Valve

Back Pressure Valve

Tilt Cylinder

Lift Cylinders

Coupler Control Valve (924G only)

Coupler Engagement Cylinders (924G only)

Combination Valve (924G only)

 11/99
STMG 717
Work Tool Hydraulic Components

Directions: Fill in the blank next to the

letters with the correct component name.

A.
J N I M
B.

C. X

D. A
C F K

E. H

F.

- 79 -
SIGNAL FROM
STEERING
SYSTEM

G. E

L
H.
TO STEERING
SYSTEM
B
I.

J. G D
MANIFOLD

TO SECONDARY
STEERING
PRESSURE

Serviceman's Handout No. 3

FROM SWITCH

K. BRAKE
PISTONS FROM
BRAKE/FAN
DRIVE SYSTEM

L.

M.

N.
SESV1717 Printed in U.S.A.
11/99