1 Test 924G, 1 General Information

924G 924Gz Wheel Loader 3PZ00001-UP (MACHINE) POWERED BY 3056 Eng...
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Producto: WHEEL LOADER
Modelo: 924G WHEEL LOADER 3PZ
Configuracin: 924G 924Gz Wheel Loader 3PZ00001-UP (MACHINE)
POWERED BY 3056 Engine
Pruebas y Ajustes
924G and 924GZ Wheel Loaders Hydraulic System
Nmero de medio -RENR3511-03
Fecha de publicacin -01/03/2007
Fecha de actualizacin -09/03/2007

i02297251
Pilot System Pressure - Test

SMCS - 5050-032-PS
Table 1
Required Tools
Quantity
Part Number
Description
8T-0856
6000 kPa (870 psi) Pressure Gauge
177-7860
Hose Assembly
6V-4143
Coupler Assembly
6V-3989
Nipple
NOTICE
Care must be taken to ensure that fluids are contained during

performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop
Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
https://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 09/09/2011
924G 924Gz Wheel Loader 3PZ00001-UP (MACHINE) POWERED BY 3056 Eng... Pgina 2 de 3
Illustration 1
g00623972
1. Remove the access panel on the right side of the machine.
Illustration 2
Pressure reducing valve
g00623709
(1) Test port for the pilot oil pressure in the pressure reducing valve. (2) Test port for the steering pressure in the
pressure reducing valve. (3) Relief valve.
1. Install a 8T-0856 Pressure Gauge on a 177-7860 Hose Assembly . Install the other end of the
hose to the test port (2) for the steering pressure in the pressure reducing valve.
Note: Prior to testing the pilot system pressure, make sure that the standby pressure of the
steering pump is within the specification. The maximum standby pressure of the steering pump
is 4300 170 kPa (625 25 psi).
2. Install a 8T-0856 Pressure Gauge on a 177-7860 Hose Assembly .
3. Install the other end of the hose assembly on the test port for the pilot pressure (1) .
4. Start the engine and run the engine at high idle. With the oil at normal operating temperature,
the pressure reading must be 2600 170 kPa (375.0 25.0 psi).
5. If the pressure reading is correct, stop the engine and remove the test equipment from pressure
tap (1) .
If the pressure reading is not correct, stop the engine. Perform the following procedure:
a. Loosen the locknut on the relief valve (3) . Turn the stem on the relief valve clockwise
in order to increase the pressure. Turn the stem on the relief valve counterclockwise in
order to decrease the pressure.
6. If the pressure reading is correct, stop the engine and remove the test equipment from the
pressure tap (1) .
Copyright 1993 - 2011 Caterpillar Inc.

Todos los derechos reservados.
Red privada para licenciados del SIS.
Fri Sep 9 21:56:24 EST 2011
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Pruebas y Ajustes

i01670316
Hydraulic System Pressure - Release

SMCS - 4250-553-PX ; 4300-553-PX ; 5050-553-PX
Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the
engine has been stopped. Serious injury can be caused if this pressure is
not released before any service is done on the hydraulic system.
Make sure all of the work tools have been lowered to the ground, and
the oil is cool before removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the filler cap is cool
enough to touch with your bare hand.
NOTICE

containing fluids.
1. Lower the work tool to the ground.
2. Stop the engine. Engage the parking brake.
3. Move the control levers through the full range of travel. Repeat the movement of the levers
several times in order to discharge the accumulator for the pilot system. This will relieve any
pressure that may be present in the work tool hydraulic system.
4. Depress the brake pedal repeatedly. This will relieve any pressure that may be present in the
brake hydraulic system.

Fri Sep 9 22:12:31 EST 2011
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Pruebas y Ajustes

i01851150
General Testing and Adjusting Information

SMCS - 5050-025; 5050-081
Sudden movement of the machine or release of oil under pressure can

cause injury to persons on or near the machine.
To prevent possible injury, perform the procedure that follows before
testing and adjusting the hydraulic system.
NOTICE

containing fluids.
Note: Permit only one operator on the machine. Keep other personnel away from the machine or in
the operator's sight.
1. Park the machine on a smooth, level surface. Move away from other operating machines and
away from personnel.
2. Lower the work tools to the ground. Stop the engine.
3. Engage the parking brake. Place blocks in front of the wheels and behind the wheels.
4. When the work tool is raised for testing or for adjusting, make sure that the work tool is
supported correctly. Also, make sure that the work tool is fully in the DUMP position. The lift
circuit has high oil pressure when the lift arms raise the front of the machine.
Note: When you stop the machine, make sure that the front of the machine is not off the
ground. Unless raising the machine off the ground is required for a test, lower the machine to
the ground and stop the engine.
5. Install the steering frame lock so that the machine cannot articulate.
6. Turn the key to the ON position without starting the engine. Cycle the hydraulic control levers
through all positions in order to release the pressure in the hydraulic system. Place the tilt
control lever in the FLOAT position. Place the lift control lever in the HOLD position.
When any test is performed on the hydraulic system, the hydraulic oil must be at the normal
operating temperature.
During a diagnosis of the hydraulic system, remember that correct oil flow and correct pressure are
necessary for correct machine operation. The pump output increases as the engine speed increases
and vice versa.

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Operacin de Sistemas

i01220255
General Information
SMCS - 5050
S/N - 9SW1-2026
S/N - AAN1-UP
S/N - 3PZ1-1342
Illustration 1
g00606849
Schematic for the Work Tool System for the 924G Wheel Loader with the VersaLink front end
(1) Coupler
(2) Accumulator for the ride control
(3) Solenoid for the ride control
(4) Combination valve
(5) Tilt cylinder
(6) Lift cylinder
(7) Lines to the third function
(8) Lines to the fourth function
(9) Bank valves
(10) Pilot valves
(11) Connector with an orifice
(12) Accumulator for the pilot valves
(13) Pressure reducing valve
(14) Screen
(15) Shutoff for the pilot valve
(16) Back pressure valve
(17 ) Manifold
(18) Piston pump
(19) Hydraulic tank
(20) Coupler control valve
(A) Test port for the signal pressure of the piston pump for the work tool
(B) Test port for the signal pressure of the piston pump for the steering system
(C) Test port for the piston pump for the work tools
(D) Test port for the steering system
(E) Test port at the pressure reducing valve
(F) Line to the pressure switch for the secondary steering
(G) Lines to the steering system
(H) Lines from the relief valve in the steering system
(J) Line from the coupler to the load sensing pressure for the steering system
(K) Test port for the pressure for float detent
(L) Rackback position
(M) Dump
(N) Raise
(P) Lower
(Q) Auxiliary
(R) Auxiliary
(S) Auxiliary
(T) Auxiliary
The 924G Wheel Loader hydraulic system is made up of three systems: Work Tool Hydraulic System, Brake
And Fan Drive System and Steering System.
All three systems share a common hydraulic tank. The hydraulic tank is vented.
Illustration 2
g00652402
The location for the hydraulic tank is behind the cab.
Illustration 3
g00610704
The location for the sight glass for the hydraulic oil is on the left side of the machine.
Work Tool Hydraulic System

The work tool hydraulic system is composed of the following components: (1) Coupler cylinder, (2)
Accumulator for the ride control, (3) Ride control solenoid valve, (4) Combination valve, (5) Tilt cylinder, (6)
Lift cylinders, (9) Bank valve, (10) Pilot valve, (12) Accumulator for pilot oil, (13) Pressure reducing valve,
(14) Screen, (15) Shutoff valve for the pilot control valves, (16) Back pressure valve, (17) Manifold, (18)
Piston pump, (19) Hydraulic tank and (20) Coupler control valve.
Illustration 4
Left side of the machine
g00652406
(1) Coupler. (2) Accumulator for the ride control. (3) Ride control solenoid valve. (5) Tilt cylinder. (6) Lift cylinders. (18) Piston
pump. (19) Hydraulic tank. (20) Coupler control valve.
Access to the piston pump (18) is achieved by removing panels under the platform. The lift cylinders (6) are
mounted under the box boom in the front frame. The ride control solenoid valve (3) is mounted on the left side
of the machine.
Illustration 5
Right side view of the machine
g00652411
(4) Combination valve. (9) Bank valves. (10) Pilot valves. (12) Accumulator for the pilot valves. (13) Pressure reducing valve. (14)
Screen. (15) Shutoff for the pilot valves. (16) Back pressure valve. (17) Manifold.
Access to the pilot accumulator (12) is achieved by opening the door to the engine compartment. Access to the
bank valves (9) is achieved by removing an access panel. Access to the pressure reducing valve (13) and
access to the combination valve (4) is achieved by removing the access panels under the platform. The
manifold (17) is mounted in the center of the machine on the piston pump.
Illustration 6
Control levers
g00611051
(15) Shutoff for the pilot valve. (21) Lift lever and tilt lever. (22) Auxiliary lever for the third function control. (23) Auxiliary lever
for the fourth function control.
The work tool hydraulic system features control valves that are pilot operated. The control valves are closed
center valves. The system is load sensing with a variable displacement pump. The work tool hydraulic system
is load sensing and the system has pressure compensation. The control valves are parallel to each other.
The system only consumes horsepower for the engine as the system requirements are needed.
The 924G uses a box boom construction. Because of the box boom design, the orientation of the tilt cylinder is
different from the 924Gz machine.
Brake And Fan Drive System

The brake and fan drive system circulates the oil to the cooler in order to cool the oil in the hydraulic system.
Also, the brake and fan drive system provides supply oil to the brake system.
For more information about the specifications for the brake and fan drive system, refer to Service Manual
module, RENR3510, "Hydraulic System Specifications".
For more information about the brake and fan drive system, refer to Service Manual module, RENR3509,
"Brake and Fan Drive System, Systems Operation Testing and Adjusting".
Steering System
The steering system steers the machine by changing the angle of the articulation of the machine.
For more information about the specifications for the steering systems, refer to Service Manual module,
RENR3510, "Hydraulic System Specifications".
For more information about the steering system, refer to Service Manual module, RENR3508, "Steering
System, Systems Operation Testing and Adjusting".

Fri Sep 9 22:23:48 EST 2011

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924G 924Gz Wheel Loader 3PZ00001-UP (MACHINE) POWERED BY 3056 Eng...

924G and 924GZ Wheel Loaders Hydraulic System

Nmero de medio -RENR3511-03

Fecha de publicacin -01/03/2007

Fecha de actualizacin -09/03/2007

Pilot System Pressure - Test

6000 kPa (870 psi) Pressure Gauge

Care must be taken to ensure that fluids are contained during

1. Remove the access panel on the right side of the machine.

Copyright 1993 - 2011 Caterpillar Inc.

Fri Sep 9 21:56:24 EST 2011

924G and 924GZ Wheel Loaders Hydraulic System

Nmero de medio -RENR3511-03

Fecha de publicacin -01/03/2007

Fecha de actualizacin -09/03/2007

Hydraulic System Pressure - Release

Care must be taken to ensure that fluids are contained during

Copyright 1993 - 2011 Caterpillar Inc.

Fri Sep 9 22:12:31 EST 2011

924G and 924GZ Wheel Loaders Hydraulic System

Nmero de medio -RENR3511-03

Fecha de publicacin -01/03/2007

Fecha de actualizacin -09/03/2007

General Testing and Adjusting Information

Sudden movement of the machine or release of oil under pressure can

Care must be taken to ensure that fluids are contained during

Copyright 1993 - 2011 Caterpillar Inc.

Fri Sep 9 22:19:43 EST 2011

924G and 924GZ Wheel Loaders Hydraulic System

Nmero de medio -RENR3511-03

Fecha de publicacin -01/03/2007

Fecha de actualizacin -09/03/2007

The location for the hydraulic tank is behind the cab.

Work Tool Hydraulic System

Brake And Fan Drive System

Copyright 1993 - 2011 Caterpillar Inc.

Fri Sep 9 22:23:48 EST 2011

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