Service manual Caterpillar 924K Small Wheel Loader with C7.1 Engine | HJF00001-UP

924K, 930K and 938K Wheel Loaders Electrohydraulic System
– Accumulator (Hydrostatic)
– Articulated Hitch
– Articulated Hitch
– Axle Housing and Bearing Preload – Adjust
– Axle Housing and Bearing Preload – Adjust
– Axle Mounting
– Axle Mounting
– Bevel Gear and Pinion (Fixed Axle) (Oscillating Axle)
– Bevel Gear and Pinion (Fixed Axle) (Oscillating Axle)
– Bevel Gear and Pinion (Fixed Axle) (Oscillating Axle)
– Bevel Gear and Pinion (Fixed Axle) (Oscillating Axle)
– Bevel Gear and Pinion (Fixed Axle) (Oscillating Axle)
– Bevel Gear and Pinion (Fixed Axle) (Oscillating Axle)
– Brake Accumulator
– Brake Accumulator
– Brake Accumulator
– Brake Accumulator – Test and Charge
– Brake and Planetary
– Brake and Planetary
– Brake Control Valve (Service)
– Brake Pedal – Calibrate
– Brake System Air – Purge
– Brake System Air – Purge
– Bucket Control Group
– Bucket Control Group
– Bucket Control Group
– Bucket Control Group
– Bucket Control Group
– Bucket Control Group
– Bucket Control Group
– Check Valve (Secondary Steering)
– Control Manifold
– Control Valve (Auxiliary)
– Control Valve (Auxiliary)
– Control Valve (Lift)
– Control Valve (Tilt)
– Control Valve (Tilt)
– Control Valve and Mounting (Quick Coupler)
– Coupler Cylinder
– Coupler Lines
– Coupler Lines
– Differential (Locking)
– Differential (Locking)
– Differential (Locking)
– Differential (Locking)
– Differential (Locking)
– Differential (Standard)
– Differential (Standard)
– Differential (Standard)
– Differential Backlash and Bearings – Adjust
– Differential Backlash and Bearings – Adjust
– Differential Pinion Preload – Adjust
– Differential Pinion Preload – Adjust
– Drive Shaft
– Drive Shaft
– Electrical Input Components
– Electrical Output Components
– Electrohydraulic Control
– Electrohydraulic Control
– Electronic Control Module
– Electronic Control Module
– Features (Fan Hydraulic System)
– Features (Hydraulic System)
– Features (Power Train System)
– Features (Steering System)
– Fixed Axle and Oscillating Axle
– Fixed Axle Housing
– Fixed Axle Housing
– Fixed Axle Housing
– Fixed Axle Housing
– Fixed Axle Housing
– Front Lines
– Gear Motor (Hydraulic Fan)
– Gear Motor (Hydraulic Fan)
– Gear Motor (Hydraulic Fan)
– Gear Motor (Reversing Fan)
– Gear Motor (Reversing Fan)
– Gear Pump (Brake)
– Gear Pump (Brake, Hydraulic Fan)
– Gear Pump (Brake, Hydraulic Fan)
– Gear Pump (Charge, Hydrostatic Drive)
– Gear Pump (Hydraulic Fan)
– Gear Pump (Implement Pilot)
– Gear Pump (Steering)
– General Information
– General Information (Brake System)
– General Information (Fan Hydraulic System)
– General Information (Fan Hydraulic System)
– General Information (Hydraulic System)
– General Information (Power Train System)
– General Information (Steering System)
– Graphic Color Codes
– Hydraulic Cylinder
– Hydraulic Fan Speed – Calibrate
– Hydraulic Oil Contamination – Test
– Hydraulic Oil Cooler
– Hydraulic Oil Lines
– Hydraulic Oil Lines
– Hydraulic Tank
– Hydrostatic Charge Accumulator – Test and Charge
– Hydrostatic Charge Pressure – Check
– Hydrostatic Drive System
– Hydrostatic System – Flush and Fill
– Hydrostatic System – Test and Adjust
– Implement Cycle Time – Check
– Implement System High Pressure Stall – Check
– Joystick Control
– Joystick Control – Calibrate
– Lift and Tilt Cylinder Drift – Check
– Lift Cylinder
– Lift Cylinder
– Lift Cylinder
– Lift Cylinder
– Limited Slip Differential
– Limited Slip Differential
– Limited Slip Differential
– Limited Slip Differential
– Limited Slip Differential
– Lines (Lift Cylinder)
– Lines (Lift Cylinder)
– Lines (Tilt Cylinder)
– Lines (Tilt Cylinder)
– Location of Components (Brake System)
– Location of Components (Brake System)
– Location of Components (Fan Hydraulic System)
– Location of Components (Fan Hydraulic System)
– Location of Components (Hydraulic System)
– Location of Components (Power Train System)
– Location of Components (Steering System)
– Machine Power – Test
– Machine Preparation for Testing and Adjusting
– Magnetic Switch (Secondary Steering Relay)
– Magnetic Switch (Secondary Steering Relay)
– Main Control Valve
– Main Control Valve
– Main Control Valve
– Main Control Valve
– Metering Pump (HMU)
– Metering Pump (HMU)
– Metering Pump (HMU)
– Modulating Valve (Transmission)
– Monitoring System
– Oil Filter (Hydraulic)
– Oil Filter (Hydraulic)
– Oscillating Axle Housing
– Oscillating Axle Housing
– Oscillating Axle Housing
– Oscillating Axle Housing
– Parking Brake
– Parking Brake
– Parking Brake
– Parking Brake – Test and Adjust
– Pilot Oil Accumulator
– Pilot Oil Accumulator (Dead Engine, Lift Arm Lower) – Test
– Pilot Pressure to the Main Control Valve – Check
– Piston Motor (Hydrostatic)
– Piston Motor (Hydrostatic)
– Piston Motor (Hydrostatic)
– Piston Motor (Hydrostatic)
– Piston Pump (Brake)
– Piston Pump (Brake, Hydraulic Fan)
– Piston Pump (Brake, Hydraulic Fan) High Pressure – Test and
– Piston Pump (Brake, Hydraulic Fan) Margin Pressure – Test
– Piston Pump (Hydraulic Fan)
– Piston Pump (Hydrostatic)
– Piston Pump (Hydrostatic)
– Piston Pump (Hydrostatic)
– Piston Pump (Hydrostatic)
– Piston Pump (Implement)
– Piston Pump (Implement)
– Piston Pump (Implement)
– Piston Pump (Implement)
– Piston Pump (Implement)
– Piston Pump (Implement) High Pressure Cutoff – Test and
– Piston Pump (Implement) Low Pressure Standby – Test and
– Piston Pump (Implement) Margin Pressure – Test and Adjust
– Piston Pump (Implement, Steering)
– Piston Pump (Steering)
– Piston Pump (Steering)
– Piston Pump (Steering) High Pressure Stall – Test and Adjust
– Piston Pump (Steering) Low Pressure Standby – Test and
– Piston Pump (Steering) Margin Pressure – Test and Adjust
– Position Sensor for the Lift and Tilt Linkage (Electronic
– Pressure Reducing Valve
– Pressure Reducing Valve (Differential Lock) – Test and Adjust
– Pressure Reducing Valve (Quick Coupler) – Test and Adjust
– Pressure Sensor (Secondary Steering Oil)
– Pressure Tap Locations
– Pressure Tap Locations
– Pressure Tap Locations
– Quick Coupler System
– Relief Valve (Line)
– Relief Valve (Load Sensing Signal)
– Relief Valve (Load Sensing Signal) – Test and Adjust
– Ride Control Accumulator
– Ride Control Accumulator
– Ride Control Accumulator – Test and Charge
– Ride Control Configuration – Program
– Ride Control System
– Ride Control Valve
– Rim Mounting
– Rim Mounting
– Rim Mounting
– Secondary Steering – Test
– Secondary Steering Pump and Electric Motor
– Secondary Steering Pump and Electric Motor
– Secondary Steering System
– Service Brake
– Service Brake – Test
– Service Brake Discs – Check
– Service Brake Discs – Check
– Service Brake System Pressure – Test
– Service Brakes
– Solenoid Valve (Hydraulic Fan)
– Solenoid Valve (Quick Coupler)
– Solenoid Valve (Quick Steer)
– Solenoid Valve (Reversing Fan)
– Solenoid Valve and Mounting (Differential Lock)
– Solenoid Valve and Mounting (Differential Lock)
– Solenoid Valves (Implement)
– Steering Control
– Steering Control
– Steering Cylinder
– Steering Cylinder
– Steering Cylinder Mounting
– Steering Lines
– Steering Lines
– Steering Time – Check
– System Pressure – Release
– System Pressure – Release
– Temperature Sensor (Hydraulic Oil)
– Temperature Sensor (Transmission Oil)
– Tilt Cylinder
– Tilt Cylinder
– Tilt Cylinder
– Tilt Cylinder
– Tilt Cylinder
– Tilt Cylinder
– Transmission
– Transmission
– Transmission Lubrication
– Transmission Oil Cooler
– Transmission Pressures – Check – Gearbox Pressures
– Transmission System
– Warning Operation
– Worksheets
– Worksheets
– Worksheets
– Worksheets
924K, 930K and 938K Wheel Loaders InstrClstrCMPD Monitoring
– Camera Menu
– Connector Contact Description
– Connector Locations
– Data Link
– Diagnostic Capabilities
– Display Has Blue Lines or Is Solid Blue During Camera
– Display Shows Asterisks Instead of Parameter Value
– Electrical Connector – Inspect
– Emerging Symptom Information
– Features
– General Information
– General Information
– Input Components
– Instrument Cluster
– Location of Electrical Components
– Machine Status Menu
– Main Menu
– Module – Flash Program
– Module – Replace
– Monitor Display
– Output Components
– Performance Screen
– Power Supply Circuit
– Self Test
– Service Menu
– Service Tools
– Settings Menu
– Switch Circuits
– Symptom Troubleshooting
– System Schematic
– Totals Menu
– Warning Operation
– Wiring Harness (Open Circuit) – Test
– Wiring Harness (Short Circuit) – Test
Air Conditioning and Heating R134a for All Caterpillar Machines
– Refrigerant Compressor
– System Capacities for Refrigerant (Off-Highway Trucks)
– General Information
– Identifying the Refrigerant
– Identifying the Air Conditioning System
– Identifying the Heating System
– Refrigerant Expansion Valve System
– Refrigerant Orifice Tube System
– Refrigerant Compressor
– Refrigerant Condenser
– Refrigerant Receiver-Dryer
– Refrigerant Compressor
– Refrigerant Expansion Valve
– In-line Refrigerant Dryer
– Refrigerant Orifice Tube Assembly
– Evaporator Coil
– Refrigerant Accumulator
– Refrigerant Compressor Protection System
– Temperature Control
– Pressure Switch (Refrigerant)
– Cab Pressurization and Filtration System
– Condensate Drainage System
– Refrigerant Compressor
– Service Intervals
– Glossary of Terms
– Required Tools
– Machine Preparation for Troubleshooting
– General Troubleshooting Information
– General Troubleshooting Information
– Visual Inspection (Troubleshooting)
– Air Conditioning System Troubleshooting
– Heating System Troubleshooting
– Automatic Temperature Control System (ECM Controlled)
– Refrigerant Compressor
– Troubleshooting Heating and Air Conditioning Control System
– Troubleshooting Heating and Air Conditioning Control System
– Automatic Temperature Control Panel Troubleshooting – 584
– Troubleshooting Condensate Drainage System
– Machine Preparation for Testing and Adjusting
– Air Conditioning Performance – Test
– Refrigerant Leakage – Test
– Manifold Gauge Set (Refrigerant) – Install
– Refrigerant Recovery
– Refrigerant System – Flush
– Refrigerant Compressor
– Refrigerant Oil – Test
– Refrigerant Compressor – Test
– Refrigerant System – Evacuate
– Refrigerant System – Charge
– Manifold Gauge Set (Refrigerant) – Remove
– Compressor Protection System – Test
– Electronic Heat Control – Test
– Heater Performance – Test
– Heating and Air Conditioning Service Publications
– General Information
– Refrigerant Compressor
– Machine Preparation for Disassembly and Assembly
– Air Conditioner Lines – Remove and Install
– Refrigerant Compressor – Remove and Install
– Refrigerant Accumulator – Remove and Install
– Refrigerant Expansion Valve – Remove and Install
– Refrigerant Receiver-Dryer – Remove and Install
– In-Line Refrigerant Dryer – Remove and Install
– Refrigerant Orifice Tube Assembly – Remove and Install
– Refrigerant Compressor
– System Capacities for Refrigerant (Motor Graders)
– System Capacities for Refrigerant (Off-Highway Trucks) –
– Refrigerant Compressor
Disassembly and Assembly 924K, 930K and 938K Wheel Loaders Power Train
– Accumulator (Hydrostatic)
– Axle Housing – Front and Rear Axle Housings
– Axle Housing – Front Axle
– Axle Housing – Rear Axle
– Brake and Planetary
– Control Valve (Differential Lock)
– Control Valve (Differential Lock)
– Differential – Rear
– Differential and Pinion – Front
– Differential and Pinion – Limited Slip
– Differential and Pinion – Locking
– Differential and Pinion – Rear
– Differential and Pinion – Standard
– Drive Shaft
– Duo-Cone Conventional Seals
– Fixed Axle (Front)
– Fixed Axle (Front)
– Gear Pump (Hydrostatic, Charge)
– Manifold (Hydrostatic)
– Oscillating Axle (Rear)
– Oscillating Axle (Rear)
– Piston Motor (Hydrostatic) – Assemble – Front Hydrostatic
– Piston Motor (Hydrostatic) – Assemble – Front Hydrostatic
– Piston Motor (Hydrostatic) – Assemble – Rear Hydrostatic
– Piston Motor (Hydrostatic) – Assemble – Rear Hydrostatic
– Piston Motor (Hydrostatic) – Disassemble – Front Hydrostatic
– Piston Motor (Hydrostatic) – Disassemble – Front Hydrostatic
– Piston Motor (Hydrostatic) – Disassemble – Rear Hydrostatic
– Piston Motor (Hydrostatic) – Disassemble – Rear Hydrostatic
– Piston Motor (Hydrostatic) – Remove and Install – Front
– Piston Motor (Hydrostatic) – Remove and Install – Front
– Piston Motor (Hydrostatic) – Remove and Install – Rear
– Piston Motor (Hydrostatic) – Remove and Install – Rear
– Piston Pump (Hydrostatic) – Assemble
– Piston Pump (Hydrostatic) – Assemble
– Piston Pump (Hydrostatic) – Disassemble
– Piston Pump (Hydrostatic) – Disassemble
– Piston Pump (Hydrostatic) – Remove and Install
– Power Train Guard (Transmission)
– Service Brake Lines (Inner Axle)
– Service Brakes
– Service Brakes – Single Disc Brakes
– Steering Frame Lock – Separate and Connect
– System Pressure – Release
– Tire and Rim
– Transmission
– Trunnion Support
– Trunnion Support
Disassembly and Assembly 924K, 930K and 938K Wheel Loaders
– Accumulator (Pilot)
– Brake Accumulator
– Brake Control Valve (Parking)
– Brake Control Valve (Service)
– Bucket
– Cab
– Control Manifold (Brake Charge) (Hydraulic Fan Control)
– Control Valve (Quick Coupler)
– Counterweight
– Counterweight
– Coupler Cylinder
– Disconnecting Snap To Connect Fittings
– Electrohydraulic Control (Joystick)
– Electronic Control Module (ECM) – Auxiliary Hydraulic
– Electronic Control Module (ECM) – Machine
– Gear Pump (Brake, Hydraulic Fan)
– Heating and Air Conditioning
– Hydraulic Tank
– Instrument Panel
– Lift Arms
– Lift Cylinder
– Lift Position Sensor and Mounting (Lift Kickout Control)
– Loader Frame
– Main Control Valve
– Metering Pump
– Oil Filter (Hydraulic)
– Parking Brake
– Piston Pump (Brake, Hydraulic Fan)
– Piston Pump (Implement)
– Piston Pump (Steering)
– Quick Coupler
– Refrigerant Accumulator
– Ride Control Accumulator
– Seat
– Secondary Steering Pump and Electric Motor
– Steering Column – Install
– Steering Column – Remove
– Steering Cylinder
– Steering Frame Lock – Separate and Connect
– Steering Shaft
– Steering Wheel
– System Pressure – Release
– Tilt Cylinder
– Tilt Lever
– Tilt Link
– Tilt Position Sensor and Mounting (Worktool Positioner
– Water Valve (Cab Heater)
– Window Wiper and Wiper Motor (Front)
– Window Wiper and Wiper Motor (Rear)
Disassembly and Assembly 924K, 930K and 938K Wheel Loaders
– Aftercooler
– Air Cleaner
– Alternator
– Battery
– Belt Tensioner
– Cooling System Package (Radiator, Aftercooler, Oil Cooler)
– Disconnecting Snap To Connect Fittings
– Electric Starting Motor
– Electronic Control Module (ECM)
– Engine
– Engine Oil Filter Base and Oil Cooler
– Fan
– Flywheel
– Fuel Tank
– Fumes Disposal Filter
– Gear Motor (Hydraulic Fan)
– Hood
– Hydraulic Oil Cooler
– Muffler
– Oil Pan
– Primary Fuel Filter and Base
– Radiator
– Radiator Top Tank
– Refrigerant Compressor
– Refrigerant Condenser
– Refrigerant Receiver-Dryer
– Secondary Fuel Filter and Base
– Steering Frame Lock – Separate and Connect
– System Pressure – Release
– Torsional Coupling – Type 1
– Torsional Coupling – Type 2
– Turbocharger
– Valve Mechanism Cover
– Water Pump
– Water Temperature Regulator
Disassembly and Assembly C7.1 Engines
– Accessory Drive – Remove and Install – Accessory Drive SAE
– Accessory Drive – Remove and Install – Accessory Drive SAE
– Accessory Drive – Remove and Install – Accessory Drive SAE “A” –
– Air Compressor – Remove and Install – Single Cylinder Air
– Air Compressor – Remove and Install – Twin Cylinder Air
– Alternator – Install
– Alternator – Remove
– Alternator Belt – Remove and Install
– Bearing Clearance – Check
– Belt Tensioner – Remove and Install
– Boost Pressure Sensor – Remove and Install
– Camshaft – Remove and Install
– Camshaft Bearings – Remove and Install
– Camshaft Gear – Remove and Install
– Camshaft Position Sensor – Remove and Install
– Connecting Rod Bearings – Install – Connecting rods in position
– Connecting Rod Bearings – Remove – Connecting rods in
– Coolant Temperature Sensor – Remove and Install
– Crankcase Breather – Install – Filtered Breather
– Crankcase Breather – Install – Unfiltered Breather
– Crankcase Breather – Remove – Filtered Breather
– Crankcase Breather – Remove – Unfiltered Breather
– Crankshaft – Install
– Crankshaft – Remove
– Crankshaft Front Seal – Remove and Install
– Crankshaft Front Seal – Remove and Install – Crankshaft Front
– Crankshaft Gear – Remove and Install
– Crankshaft Main Bearings – Remove and Install – Crankshaft
– Crankshaft Position Sensor – Remove and Install
– Crankshaft Rear Seal – Install
– Crankshaft Rear Seal – Remove
– Crankshaft Timing Ring – Remove and Install
– Cylinder Head – Install
– Cylinder Head – Remove
– ECM Mounting Bracket – Remove and Install
– Electric Starting Motor – Remove and Install
– Electronic Control Module – Remove and Install
– Electronic Unit Injector – Install
– Electronic Unit Injector – Remove
– Engine Oil Cooler – Install – Engine Oil Cooler with a High
– Engine Oil Cooler – Install – Engine Oil Cooler with a Low
– Engine Oil Cooler – Remove – Engine Oil Cooler with a High
– Engine Oil Cooler – Remove – Engine Oil Cooler with a Low
– Engine Oil Filter Base – Remove and Install
– Engine Oil Pan – Install – Aluminum Oil Pan
– Engine Oil Pan – Remove – Aluminum Oil Pan
– Engine Oil Pressure Sensor – Remove and Install
– Engine Oil Pump – Install
– Engine Oil Pump – Remove
– Exhaust Elbow – Remove and Install
– Exhaust Manifold – Remove and Install – Side Mounted Exhaust
– Exhaust Manifold – Remove and Install – Top Mounted Exhaust
– Fan – Remove and Install
– Fan Drive – Remove and Install
– Flow Control Valve – Remove and Install
– Flywheel – Install
– Flywheel – Install – Equipped with Rear Power Take-Off
– Flywheel – Remove
– Flywheel – Remove – Equipped with Rear Power Take-Off
– Flywheel Housing – Remove and Install – Flywheel Housing that is
– Flywheel Housing – Remove and Install – Standard Housing
– Flywheel Housing – Remove and Install – Type A and Type B
– Front Cover – Remove and Install
– Front Cover – Remove and Install – Heavy Duty Front Cover
– Fuel Filter Base – Remove and Install
– Fuel Injection Lines – Install
– Fuel Injection Lines – Remove
– Fuel Injection Pump – Install
– Fuel Injection Pump – Remove
– Fuel Injection Pump Gear – Install
– Fuel Injection Pump Gear – Remove
– Fuel Manifold (Rail) – Remove and Install
– Fuel Pressure Sensor – Remove and Install
– Fuel Priming Pump – Remove and Install – Electric Fuel Lift
– Fuel Priming Pump – Remove and Install – Mechanical Priming
– Gear Group (Front) – Remove and Install
– Gear Group (Front) – Remove and Install – Heavy Duty Gear
– Glow Plugs – Remove and Install
– Housing (Front) – Install
– Housing (Front) – Install – Heavy Duty Housing (Front)
– Housing (Front) – Remove
– Housing (Front) – Remove – Heavy Duty Housing (Front)
– Idler Gear – Install
– Idler Gear – Remove
– Idler Pulley – Remove and Install – Flat Idler Pulley
– Idler Pulley – Remove and Install – Grooved Idler Pulley
– Inlet Air Temperature Sensor – Remove and Install
– Inlet and Exhaust Valve Springs – Remove and Install
– Inlet and Exhaust Valves – Remove and Install
– Inlet Manifold – Remove and Install
– Lifter Group – Remove and Install
– Piston Cooling Jets – Remove and Install
– Pistons and Connecting Rods – Assemble
– Pistons and Connecting Rods – Disassemble
– Pistons and Connecting Rods – Install
– Pistons and Connecting Rods – Remove
– Rear Power Take-Off (RPTO) – Install
– Rear Power Take-Off (RPTO) – Remove
– Refrigerant Compressor – Remove and Install
– Relief Valve (Fuel) – Remove and Install
– Rocker Shaft – Assemble
– Rocker Shaft – Disassemble
– Rocker Shaft and Pushrod – Install
– Rocker Shaft and Pushrod – Remove
– Turbocharger – Install – Turbocharger for Side Mounted
– Turbocharger – Install – Turbocharger for Top Mounted
– Turbocharger – Remove – Turbocharger for Side Mounted
– Turbocharger – Remove – Turbocharger for Top Mounted
– Valve Mechanism Cover – Remove and Install
– Valve Mechanism Cover Base – Remove and Install
– Vibration Damper and Pulley – Install
– Vibration Damper and Pulley – Remove
– Wastegate Solenoid – Remove and Install
– Water Pump – Install
– Water Pump – Remove
– Water Separator and Fuel Filter (Primary) – Remove and
– Water Temperature Regulator – Remove and Install
Machine Security System (MSS3i) Integrated
– System Overview
– System Components
– Data Link
– General Information
– Troubleshooting
– Key – Program
– Scheduled Access – Program – Security System Bypass
– Time – Set
– Factory Password – Obtain
– Configuration
– Machine Security System – Uninstall
– Normal Operation
– Glossary of Terms
– System Schematic
– Operation of Status Indicator
– Key Information
– Scheduled Access – “Security System Bypass Times”
– Diagnostic Operation
– Protected Functions
– Service Operation Using Service Tool
– Electronic Control Module (ECM)
– General Information
Schematic Caterpillar 924K, 930K & 938K Wheel Loader Electrical System
– Feature
– Cover Page
– Information
– Component Location
– Cab
– Canopy
– Chassis and Engine
– Connector Location
– Cab
– Canopy
– Chassis and Engine
– Schematics
– Cab
– Canopy
– Chassis and Engine
– Machine Views
– Cab
– Dash View
– Fuse Panel
– Headliner View
– Operators Seat
– Rear Cab Interior View
– RH Console View
– Canopy
– Dash View
– Fuse Panel
– Operator seat
– Rear Cab Interior View
– RH Console View
– RH Rear Cab View
– Chassis and Engine
– ECM Compartment
– Front Frame View
– Gear Box
– LH Engine View
– LH Ladder View
– LH Rear Chassis View
– Rear Chassis View
– RH Engine View
– RH Rear Chassis View
Schematic Caterpillar 924K, 930K & 938K Wheel Loader Electrical System
– Feature
– Cover Page
– Information
– Component Location
– Cab
– Canopy
– Chassis and Engine
– Connector Location
– Cab
– Canopy
– Chassis and Engine
– Schematics
– Cab
– Canopy
– Chassis and Engine
– Machine Views
– Cab
– Cab Rear View
– Dash View
– Fuse Panel
– Head Liner View
– Operator Seat
– Rear Cab Interior View
– RH Console View
– Canopy
– Dash View
– Fuse Panel
– Operator Seat
– Rear Cab Interior View
– RH Console View
– RH Rear Cab View
– Chassis and Engine
– ECM Compartment
– Front Frame View
– Gear Box
– LH Engine View
– LH Ladder View
– LH Rear Chassis View
– Rear Chassis View
– RH Engine View
– RH Rear Chassis View
Schematic Caterpillar 924K, 930K & 938K Wheel Loader Hydraulic System
Specifications C7.1 Engines for Caterpillar Built Machines
– Alternator
– Belt Tensioner
– Boost Pressure Sensor
– Camshaft
– Camshaft Bearings
– Connecting Rod
– Connecting Rod Bearing Journal
– Coolant Temperature Sensor
– Crankcase Breather
– Crankshaft
– Crankshaft Seals
– Cylinder Block
– Cylinder Head
– Cylinder Head Valves
– Electronic Control Module
– Engine Design
– Engine Lifting Bracket
– Engine Oil Cooler
– Engine Oil Filter Base
– Engine Oil Pan
– Engine Oil Pressure
– Engine Oil Pressure Sensor
– Engine Oil Pump
– Exhaust Manifold
– Fan Drive
– Flywheel
– Flywheel Housing
– Front Housing and Covers
– Fuel Filter Base – Twin Secondary Fuel Filter Base
– Fuel Injection Lines
– Fuel Injection Nozzles
– Fuel Injection Pump
– Fuel Manifold (Rail)
– Fuel Priming Pump – Electric Fuel Priming Pump
– Gear Group (Front)
– Glow Plugs
– Inlet Manifold
– Inlet Manifold Temperature Sensor
– Lifter Group
– Main Bearing Journal
– Piston and Rings
– Piston Cooling Jet
– Refrigerant Compressor
– Rocker Shaft
– Speed/Timing Sensor
– Starter Motor
– Turbocharger
– Valve Mechanism Cover
– Vibration Damper and Pulley
– Water Pump
– Water Temperature Regulator and Housing
Systems Operation & Testing and Adjusting C7.1 Engines for Caterpillar Built Machines
– Air in Fuel – Test
– Air Inlet and Exhaust System
– Air Inlet and Exhaust System – Inspect
– Alternator – Test
– Basic Engine
– Battery – Test
– Charging System – Test
– Cleanliness of Fuel System Components
– Compression – Test
– Connecting Rod – Inspect
– Cooling System
– Cooling System – Check
– Cooling System – Inspect
– Cooling System – Test
– Cylinder Block – Inspect
– Cylinder Head – Inspect
– Electric Starting System – Test
– Electrical System
– Electronic Control System
– Engine Oil Cooler – Inspect
– Engine Oil Pressure – Test
– Engine Oil Pump – Inspect
– Engine Valve Lash – Inspect/Adjust
– Excessive Bearing Wear – Inspect
– Excessive Engine Oil Consumption – Inspect
– Finding Top Center Position for No. 1 Piston
– Flywheel – Inspect
– Flywheel Housing – Inspect
– Fuel Injection
– Fuel Injection – Engines with a Primary and Secondary Fuel
– Fuel Injection Timing – Check
– Fuel Quality – Test
– Fuel System – Inspect
– Fuel System – Prime
– Gear Group (Front) – Time
– Gear Group – Inspect
– Glossary of Electronic Control Terms
– Increased Engine Oil Temperature – Inspect
– Introduction
– Lubrication System
– Piston Height – Inspect
– Piston Ring Groove – Inspect
– Power Sources
– Turbocharger – Inspect
– V-Belt – Test
– Valve Depth – Inspect
– Valve Guide – Inspect
– Vibration Damper – Check
– Water Pump – Inspect
– Water Temperature Regulator – Test
Troubleshooting 924K, 930K and 938K Wheel Loaders Machine Electronic Control System
– Alert Indicator Is Always Flashing
– Alert Indicator Never Flashes
– Axle and Differential
– Backlight Does Not Illuminate
– Brake and Hydraulic Fan System
– CAN Data Link – Test
– Cat Data Link – Test
– Condition Switch (Two Wire) – Test
– Connector Contact Description
– Connector Locations
– Determining Diagnostic Trouble Codes
– Diagnostic Capabilities
– Diagnostic Trouble Codes
– Drive Shaft
– ECM – Configure
– ECM – Replace
– ECM Software – Install
– Electrical Connector – Inspect
– Electrical Power Supply – Test
– Emerging Symptom Information
– Event Codes
– General Information
– Hydraulic System
– Machine Movement Without Request
– Machine Performance Is Not Proper
– Machine Preparation for Troubleshooting
– Operational Checks (Power Train)
– Operator Control Switch (Switch to Battery) – Test
– Operator Control Switch (Switch to Ground) – Test
– Parking Brake System
– Quick Coupler Pins Do Not Engage and/or Disengage
– Relay – Test
– Sensor Signal (Analog, Active) – Test
– Sensor Signal (Analog, Passive) – Test
– Sensor Signal (PWM) – Test
– Sensor Supply – Test
– Service Tools
– Solenoid Return – Test
– Solenoid Valve – Test
– Speed Sensor – Test
– Steering System
– Symptom Troubleshooting
– System Schematic
– Transmission
– Visual Inspection
– Wiring Harness (Open Circuit) – Test
– Wiring Harness (Short Circuit) – Test
Troubleshooting C4.4 and C7.1 Engines
– Welding Precaution
– Diagnostic Trouble Codes
– Customer Passwords
– Factory Passwords
– ECM Will Not Accept Factory Passwords
– Electronic Service Tool Does Not Communicate
– Test ECM Mode
– ECM Software – Install
– ECM – Replace
– Electrical Connectors – Inspect
– Cooling Fan – Calibrate – If Applicable
– Event Codes
– Acceleration Is Poor or Throttle Response Is Poor
– Alternator Problem – Charging Problem and/or Noisy
– Battery Problem
– Belt Tensioner Noise
– Coolant Contains Oil
– Coolant Level Is Low
– Coolant Temperature Is High
– Coolant Temperature Is Low
– Electronic Service Tools
– Cylinder Is Noisy
– Engine Cranks but Does Not Start
– Engine Does Not Crank
– Engine Has Early Wear
– Engine Has Mechanical Noise (Knock)
– Engine Misfires, Runs Rough or Is Unstable
– Engine Overcrank Occurrence
– Engine Overspeeds
– Engine Shutdown Occurrence
– Engine Shutdown Occurs Intermittently
– Service Information Report
– Engine Stalls at Low RPM
– Engine Top Speed Is Not Obtained
– Engine Vibration Is Excessive
– Exhaust Has Excessive Black Smoke
– Exhaust Has Excessive White Smoke
– Exhaust Has Excessive White Smoke
– Exhaust System Contains Coolant
– Exhaust System Contains Oil
– Fuel Consumption Is Excessive
– Fuel Contains Water
– System Overview
– Fuel Filter Is Restricted
– Fuel Pressure Is Low
– Fuel Pressure Problem
– Fuel Rail Pressure Problem
– Inlet Air Is Restricted
– Intake Manifold Air Pressure Is High
– Intake Manifold Air Pressure Is Low
– Intake Manifold Air Temperature Is High
– Oil Consumption Is Excessive
– Oil Contains Coolant
– Component Location
– Oil Contains Fuel
– Oil Pressure Is Low
– Oil Pressure Is Low
– Power Is Intermittently Low or Power Cutout Is Intermittent
– Valve Lash Is Excessive
– CAN Data Link – Test
– CAN Data Link – Test
– Cooling Fan Control – Test – Hydraulic Driven Fan
– Cooling Fan Control – Test
– Cooling Fan Reversing – Test
– Engine Monitoring System
– Data Link – Test
– Data Link – Test
– Data Link Configuration Status – Test
– Electrical Power Supply – Test
– Electrical Power Supply – Test
– Ether Starting Aid – Test
– Glow Plug Starting Aid – Test
– Glow Plug Starting Aid – Test
– Idle Validation – Test
– Idle Validation – Test
– Diagnostic Capabilities
– Injector Solenoid – Test
– Injector Solenoid – Test
– Mode Selection – Test
– Mode Selection – Test
– Power Take-Off – Test
– Relay – Test – Start Relay
– Relay – Test – Electric Fuel Lift Pump Relay
– Relay – Test – ECM Power Relay
– Relay – Test – ECM Power Relay
– Sensor Calibration Required – Test
– Electrical Connectors
– Sensor Signal (Analog, Active) – Test
– Sensor Signal (Analog, Active) – Test
– Sensor Signal (Analog, Passive) – Test
– Sensor Signal (Analog, Passive) – Test
– Sensor Supply – Test
– Sensor Supply – Test
– Shutdown – Test
– Solenoid Valve – Test
– Solenoid Valve – Test
– Speed Control – Test – Analog
– Configuration Parameters
– Speed Control – Test – Analog
– Speed Control – Test – PWM
– Speed/Timing – Test
– Speed/Timing – Test
– Switch Circuits – Test – Multiposition Throttle Switch
– Switch Circuits – Test
– Throttle Lock – Test
– Water in Fuel – Test
– Service Tool Features
– Service Tool Error Identifiers
– General Information