CAT 924G Wheel Loader Parts Manual Catalog
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TM 5-3805-290-23P
TECHNICAL MANUAL
FIELD MAINTENANCE MANUAL
REPAIR PARTS AND SPECIAL TOOLS LISTS (RPSTL)
FOR
LOADER, LIGHT, SCOOP:
2.5 CUBIC YARD MULTIPURPOSE (MP) CLAMSHELL BUCKET,
DIESEL ENGINE DRIVEN (DED), 4-WHEEL DRIVE
NSN 3805-01-533-1768
MODEL 924G
DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.
HEADQUARTERS, DEPARTMENT OF THE ARMY
NOVEMBER 2007
TM 5-3805-290-23P
A/(B Blank)
LIST OF EFFECTIVE PAGES/WORK PACKAGES
Date of issue for original manual is:
Original 30 November 2007
TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 24 AND TOTAL NUMBER OF WORK PACK-
AGES IS 4 CONSISTING OF THE FOLLOWING:
Page/WP *Change
No. No.
Front Cover (2 pp.) 0
TOC (10 pp.) 0
WP 0001 00 (6 pp.) 0
WP 0002 00 (406 pp.) 0
WP 0003 00 (12 pp.) 0
WP 0004 00 (96 pp.) 0
Back Cover (2 pp). 0
* Zero in this column indicates an original page or work package.
TM 5-3805-290-23P
i
TECHNICAL MANUAL HEADQUARTERS
TM 5-3805-290-23P DEPARTMENT OF THE ARMY
Washington, D.C. 30 November 2007
TECHNICAL MANUAL
FIELD MAINTENANCE MANUAL
REPAIR PARTS AND SPECIAL TOOLS LISTS (RPSTL)
FOR
LOADER, LIGHT, SCOOP:
2.5 CUBIC YARD MULTIPURPOSE (MP) CLAMSHELL BUCKET,
DIESEL ENGINE DRIVEN (DED), 4-WHEEL DRIVE
NSN 3805-01-533-1768
MODEL 924G
DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this publication. If you find any mistakes or if you know of a way to improve the pro-
cedures, please let us know. Submit your DA Form 2028 (Recommended Changes to Equipment Technical
Publications), through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet
address is: https://aeps.ria.army.mil . The DA Form 2028 is located under the Public Applications section in
the AEPS Public Home Page. Fill out the form and click on SUBMIT. Using this form on the AEPS will
enable us to respond quicker to your comments and better manage the DA Form 2028 program. You may
also mail, fax or E-mail your letter or DA Form 2028 direct to: TACOM Life Cycle Management Com-
mand, ATTN: AMSTA-LC-LMPP/TECH PUBS, 1 Rock Island Arsenal, Rock Island, IL 61299-7630. The
E-mail address is ROCK-TACOM-TECH-PUBS@conus.army.mil. The fax number is DSN 793-0726 or
Commercial (309) 782-0726.
TM 5-3805-290-23P
ii
TABLE OF CONTENTS
WP 0001 00 FIELD MAINTENANCE (UNIT AND DIRECT SUPPORT MAINTENANCE) REPAIR
PARTS AND SPECIAL TOOLS LISTS (RPSTL) INTRODUCTION
WP 0002 00 REPAIR PARTS LIST
GROUP 01 ENGINE
0100 ENGINE ASSEMBLY ........................................................................ 0002 00-3
ENGINE AND ENGINE MOUNTING ................................................. 1 0002 00-3
0101 CRANKCASE, BLOCK, CYLINDER HEAD....................................... 0002 00-5
CYLINDER HEAD AND RELATED PARTS ...................................... 2 0002 00-5
0102 CRANKSHAFT .................................................................................. 0002 00-7
REAR AND FRONT MAIN SEAL ...................................................... 3 0002 00-7
VIBRATION DAMPER AND PULLEY ............................................... 4 0002 00-9
0103 FLYWHEEL ASSEMBLY................................................................... 0002 00-11
FLYWHEEL ASSEMBLY AND HOUSING ........................................ 5 0002 00-11
0105 VALVES, CAMSHAFTS, AND TIMING SYSTEM ............................. 0002 00-13
ROCKER ARM .................................................................................. 6 0002 00-13
VALVE COVER ................................................................................. 7 0002 00-15
FRONT HOUSING AND TIMING GEAR ........................................... 8 0002 00-17
0106 ENGINE LUBRICATION SYSTEM.................................................... 0002 00-19
BREATHER TUBE ............................................................................ 9 0002 00-19
ENGINE OIL SAMPLING VALVE ...................................................... 10 0002 00-21
ENGINE OIL PUMP, BYPASS VALVE, AND PISTON
COOLING JETS ................................................................................ 11 0002 00-23
ENGINE OIL FILTER, OIL COOLER LINES, FITTINGS,
HOSES, AND CORE ......................................................................... 12 0002 00-25
ENGINE OIL FILLER ......................................................................... 13 0002 00-27
OIL PAN AND RELATED PARTS ..................................................... 14 0002 00-29
ENGINE OIL DRAIN .......................................................................... 15 0002 00-31
0108 MANIFOLDS ..................................................................................... 0002 00-33
INTAKE AND EXHAUST MANIFOLD AND RELATED PARTS ........ 16 0002 00-33
GROUP 03 FUEL SYSTEM
0301 CARBURETOR, FUEL INJECTOR ................................................... 0002 00-35
FUEL INJECTOR ASSEMBLY .......................................................... 17 0002 00-35
0302 FUEL PUMPS ................................................................................... 0002 00-37
FUEL TRANSFER PUMP AND LINES.............................................. 18 0002 00-37
FUEL INJECTION PUMP, LINES, AND RELATED PARTS.............. 19 0002 00-39
0304 AIR CLEANER .................................................................................. 0002 00-41
AIR CLEANER, HOUSING, PRECLEANER, AND RESTRICTION
INDICATOR ....................................................................................... 20 0002 00-41
0305 SUPERCHARGER, BLOWER, TURBOCHARGER OR ALTITUDE
COMPENSATOR ....................................................................................... 0002 00-43
TURBOCHARGER AND RELATED PARTS ..................................... 21 0002 00-43
TM 5-3805-290-23P
TABLE OF CONTENTS (Con’t)
Illus/Fig Page
iii
AFTERCOOLER AND MOUNTING .................................................. 22 0002 00-45
TURBOCHARGER AND AFTERCOOLER AIR LINES AND
CLAMPS ............................................................................................ 23 0002 00-47
0306 TANKS, LINES, FITTINGS, HEADERS ............................................ 0002 00-51
FUEL LINES ...................................................................................... 24 0002 00-51
FUEL TANK, STANDARD ................................................................. 25 0002 00-53
0309 FUEL FILTERS ................................................................................. 0002 00-55
PRIMARY AND SECONDARY FUEL FILTERS (FUEL/WATER
SEPARATOR AND BASE) ................................................................ 26 0002 00-55
0311 ENGINE STARTING AIDS ................................................................ 0002 00-57
ETHER STARTING AID LINE ........................................................... 27 0002 00-57
ETHER STARTING AID AND MOUNTING ....................................... 28 0002 00-59
0312 ACCELERATOR, THROTTLE OR CHOKE CONTROLS ................. 0002 00-61
THROTTLE PEDAL AND RELATED PARTS.................................... 29 0002 00-61
GROUP 04 EXHAUST SYSTEM
0401 MUFFLER AND PIPES ..................................................................... 0002 00-63
EXHAUST PIPE ................................................................................ 30 0002 00-63
MUFFLER.......................................................................................... 31 0002 00-65
GROUP 05 COOLING SYSTEM
0501 RADIATOR, EVAPORATIVE COOLER, OR HEAT EXCHANGER .. 0002 00-67
RADIATOR AND MOUNTING ........................................................... 32 0002 00-67
0503 WATER MANIFOLD, HEADERS, THERMOSTATS AND
HOUSING GASKET ................................................................................... 0002 00-69
THERMOSTAT AND HOUSING ....................................................... 33 0002 00-69
COOLANT TANK LINES ................................................................... 34 0002 00-71
RADIATOR HOSES AND FITTINGS ................................................ 35 0002 00-73
0504 WATER PUMP .................................................................................. 0002 00-75
WATER PUMP AND MOUNTING ..................................................... 36 0002 00-75
0505 FAN ASSEMBLY............................................................................... 0002 00-77
HYDRAULIC FAN, MOTOR, AND RELATED PARTS ...................... 37 0002 00-77
GROUP 06 ELECTRICAL SYSTEM
0601 GENERATOR, ALTERNATOR ......................................................... 0002 00-79
ALTERNATOR, V-BELT, AND RELATED PARTS............................ 38 0002 00-79
0603 STARTING MOTOR.......................................................................... 0002 00-81
STARTING MOTOR (STARTER) ...................................................... 39 0002 00-81
TM 5-3805-290-23P
TABLE OF CONTENTS (Con’t)
Illus/Fig Page
iv
0607 INSTRUMENT OR ENGINE CONTROL PANEL .............................. 0002 00-83
WIPER SWITCH................................................................................ 40 0002 00-83
CONTROL SWITCHES AND PANEL................................................ 41 0002 00-85
INSTRUMENT PANEL (BLACKOUT) ............................................... 42 0002 00-87
CAB WIRING HARNESS AND CONTROL SWITCHES
(RIGHT SIDE) .................................................................................... 43 0002 00-91
0608 MISCELLANEOUS ITEMS................................................................ 0002 00-95
MACHINE (TRANSMISSION) ECM .................................................. 44 0002 00-95
ENGINE ECM .................................................................................... 45 0002 00-97
POWER CONVERTER AND RELAYS.............................................. 46 0002 00-99
0609 LIGHTS ............................................................................................. 0002 00-101
WORKLIGHTS AND RELATED PARTS ........................................... 47 0002 00-101
LIGHTS (SERVICE, REAR, BLACKOUT DRIVE, AND
TURN SIGNAL) ................................................................................. 48 0002 00-103
0610 SENDING UNITS AND WARNING SWITCHES ............................... 0002 00-105
HYDRAULIC OIL FILTER BYPASS SWITCH ................................... 49 0002 00-105
BRAKE CHARGING PRESSURE SENSOR ..................................... 50 0002 00-107
ELECTRICAL SENSORS, SWITCHES, AND RELATED PARTS..... 51 0002 00-113
FUEL LEVEL SENDING UNIT .......................................................... 52 0002 00-117
0611 HORN, SIREN................................................................................... 0002 00-119
HORN ................................................................................................ 53 0002 00-119
BACKUP ALARM .............................................................................. 54 0002 00-121
0612 BATTERIES, STORAGE................................................................... 0002 00-123
BATTERY (STANDARD AND ARCTIC) ............................................ 55 0002 00-123
BATTERY BOX AND WIRING (STANDARD) ................................... 56 0002 00-127
0613 HULL OR CHASSIS WIRING HARNESS ......................................... 0002 00-131
SECONDARY STEERING WIRING .................................................. 57 0002 00-131
ENGINE CONTROL WIRING HARNESS ......................................... 58 0002 00-133
RIDE CONTROL WIRING ................................................................. 59 0002 00-135
WORKLIGHT WIRING ...................................................................... 60 0002 00-137
CAB WIRING ..................................................................................... 61 0002 00-139
ENGINE WIRING HARNESS ............................................................ 62 0002 00-141
REAR WIRING HARNESS ................................................................ 63 0002 00-143
FRONT WIRING HARNESS ............................................................. 64 0002 00-145
TRANSMISSION CONTROL WIRING .............................................. 65 0002 00-147
GROUP 07 TRANSMISSION
0705 TRANSMISSION SHIFTING COMPONENTS .................................. 0002 00-149
TRANSMISSION CONTROL AND RELATED PARTS...................... 66 0002 00-149
0710 TRANSMISSION ASSEMBLY........................................................... 0002 00-151
TORQUE CONVERTER.................................................................... 67 0002 00-151
TM 5-3805-290-23P
TABLE OF CONTENTS (Con’t)
Illus/Fig Page
v
TRANSMISSION AND TRANSMISSION MOUNTING...................... 68 0002 00-153
0714 SERVE UNIT ..................................................................................... 0002 00-157
TRANSMISSION CONTROL VALVE AND RELATED PARTS ......... 69 0002 00-157
0721 COOLERS, PUMPS, MOTORS ........................................................ 0002 00-159
TRANSMISSION OIL FILLER ........................................................... 70 0002 00-159
TRANSMISSION OIL STRAINER ..................................................... 71 0002 00-161
TRANSMISSION AND HYDRAULIC COOLER................................. 72 0002 00-163
TRANSMISSION OIL LINES AND FILTER ....................................... 73 0002 00-165
TRANSMISSION OIL PUMP AND MOUNTING ................................ 74 0002 00-167
TORQUE CONVERTER OIL COOLER LINES ................................. 75 0002 00-169
GROUP 09 PROPELLER, PROPELLER SHAFTS, UNIVERSAL JOINTS,
COUPLER AND CLAMP ASSEMBLY
0900 PROPELLER SHAFTS...................................................................... 0002 00-171
DRIVE SHAFTS AND RELATED PARTS ......................................... 76 0002 00-171
GROUP 10 FRONT AXLE
1000 FRONT AXLE ASSEMBLY ............................................................... 0002 00-173
FRONT AXLE ASSEMBLY................................................................ 77 0002 00-173
GROUP 11 REAR AXLE
1100 REAR AXLE ASSEMBLY .................................................................. 0002 00-175
REAR AXLE ASSEMBLY .................................................................. 78 0002 00-175
GROUP 12 BRAKES
1201 HAND BRAKES................................................................................. 0002 00-177
PARKING BRAKE CONTROL AND RELATED PARTS.................... 79 0002 00-177
PARKING BRAKE HANDLE AND RELATED PARTS ...................... 80 0002 00-179
1202 SERVICE BRAKES ........................................................................... 0002 00-181
SERVICE BRAKE CONTROL AND RELATED PARTS .................... 81 0002 00-181
1204 HYDRAULIC BRAKE SYSTEM......................................................... 0002 00-183
SERVICE BRAKE LINES .................................................................. 82 0002 00-183
1206 MECHANICAL BRAKE SYSTEM...................................................... 0002 00-187
BRAKE PEDALS ............................................................................... 83 0002 00-187
GROUP 13 WHEELS AND TRACKS
1311 WHEEL ASSEMBLY ......................................................................... 0002 00-189
WHEEL ASSEMBLY AND RELATED PARTS .................................. 84 0002 00-189
1313 TIRES, TUBES, TIRE CHAINS ......................................................... 0002 00-191
TIRES ................................................................................................ 85 0002 00-191
TM 5-3805-290-23P
TABLE OF CONTENTS (Con’t)
Illus/Fig Page
vi
GROUP 14 STEERING
1401 MECHANICAL STEERING GEAR ASSEMBLY ................................ 0002 00-193
STEERING WHEEL AND RELATED PARTS ................................... 86 0002 00-193
1410 HYDRAULIC PUMP OR FLUID MOTOR ASSEMBLY...................... 0002 00-195
SECONDARY STEERING AND METERING PUMPS ...................... 87 0002 00-195
HYDRAULIC STEERING PUMP ....................................................... 88 0002 00-197
1411 HOSES, LINES, FITTINGS ............................................................... 0002 00-199
STEERING LINES ............................................................................. 89 0002 00-199
1412 HYDRAULIC OR AIR CYLINDERS................................................... 0002 00-203
STEERING CYLINDER AND MOUNTING ........................................ 90 0002 00-203
1414 STEERING SYSTEM VALVES ......................................................... 0002 00-205
SECONDARY STEERING RELIEF VALVE ...................................... 91 0002 00-205
GROUP 15 FRAME, TOWING ATTACHMENTS, DRAWBARS, AND
ARTICULATION SYSTEMS
1501 FRAME ASSEMBLY ......................................................................... 0002 00-207
REAR AXLE STOP............................................................................ 92 0002 00-207
COMPONENT VALVE MOUNTING .................................................. 93 0002 00-209
RADIATOR FRAME AND RELATED PARTS ................................... 94 0002 00-211
REMOTE LUBRICATION LINES....................................................... 95 0002 00-215
WORKLIGHT FRAME AND MOUNTING .......................................... 96 0002 00-217
FRAME .............................................................................................. 97 0002 00-219
1502 COUNTERWEIGHTS ........................................................................ 0002 00-221
COUNTERWEIGHTS ........................................................................ 98 0002 00-221
1503 PINTLES AND TOWING ATTACHMENTS ....................................... 0002 00-223
ARTICULATING HITCH AND RELATED PARTS ............................. 99 0002 00-223
GROUP 18 BODY, CAB, HOOD AND HULL
DASH ASSEMBLY ............................................................................ 100 0002 00-225
REAR COVER AND RELATED PARTS............................................ 101 0002 00-227
CAB MOUNTING............................................................................... 102 0002 00-229
CAB ................................................................................................... 103 0002 00-231
DOOR ASSEMBLY (LEFT SIDE) ...................................................... 104 0002 00-233
DOOR ASSEMBLY (RIGHT SIDE) ................................................... 105 0002 00-235
CHASSIS GUARDS AND COVERS.................................................. 106 0002 00-237
LADDER AND RELATED PARTS ..................................................... 107 0002 00-239
HOOD, SIDE COVERS, AND RELATED PARTS ............................. 108 0002 00-241
JOYSTICK CONSOLE ...................................................................... 109 0002 00-243
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Get access to a comprehensive parts manual, parts list, and parts catalog featuring detailed exploded diagrams and manufacturer part numbers for every component. This resource is invaluable for both professional mechanics and DIY enthusiasts.
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