Caterpillar Cat 924F Wheel Loader (Prefix 6MN) Service Repair Manual (6MN00001 and up)

1
Service Repair Manual
Models 924F Wheel Loader
2
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Product WHEEL LOADER Model 924F WHEEL LOADER
6MN Configuration 924F Wheel Loader 6MN00001-UP
(MACHINE) POWERED BY 3114 Engine Disassembly and
Assembly 924F WHEEL LOADER AND IT24F INTEGRATED
TOOLCARRIER POWER TRA Media Number
-SENR6726-03 Publication Date -01/04/2006 Date
Updated -09/03/2011
SENR67260015
Transmission Oil Pump SMCS - 3153-017 Dissemble
Assemble Transmission Oil Pump
NOTE The transmission oil pump can be removed
from the transmission case at any time except in
chassis. The following illustrations shown are
for better photo illustration.
1. Remove covers (1) and (2) from the
transmission oil pump. Remove seven bolts (3)
that hold the transmission oil pump to the
transmission case.
3
2. Install two bolts (3) and use them as forcing
screws to separate the pump from the transmission
housing. Remove the transmission oil pump.
3. Remove bolts (4) and plate (5). Remove splined
input shaft (6) from the pump housing.
4. Remove retainer ring (7) from the groove in
the gear shaft.
5. Install tooling (A) through the holes in gear
(8). Pull gear (8) off of the gear shaft.
6. Remove bearing from gear (8) if necessary.
4
7. Remove bolts (10) and (14) from pump bodies
(12) and (13).

1. Remove gear assemblies (16) from pump body (12).
2. Remove O-ring seal (15) from the pump body.

10. Inspect bearings (17). Remove them from pump
body (12) only if necessary.
11. Inspect bearings (18). Remove them from pump
body (13) only if necessary. NOTE The following
steps are for the assembly of the transmission
oil pump.
5

• Typical Example Of Bearing Installation
• Install bearings (18) in pump body (13) with a
  suitable driver.
• The bearing joint is 30 15 degrees from the
  centerline as shown. The depth from the top of
  the bearing to the pump body surface is 1.5 0.5
  mm (.059 .020 in).

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1. Install bearings (17) in pump body (12) with a
   suitable driver.
2. The bearing joint line is 30 15 degrees from
   the centerline as shown. The depth from the top
   of the bearing to the pump body surface is 1.5
   0.5 mm (.059 .029 in).

16. Install gear assemblies (16) in pump body
(12). Lubricate and install a new O-ring seal
(15).
17. Install pump body (13) on pump body (12).
8
18. Install bolts (10) and (14) that holds pump
bodies (12) and (13) together.
19. Install a new bearing (9) in gear (8) if it
had to be removed for damage.
20. Install gear and bearing assembly on the gear
shaft. Install retainer ring (7).
21. Install splined input shaft (6). Install
plate (5) and bolts (4).
22. Put the transmission oil pump in position on
the transmission case. Install bolts (3) and then
install covers (1) and (2) on the transmission
oil pump.
9
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Product WHEEL LOADER Model 924F WHEEL LOADER
6MN Configuration 924F Wheel Loader 6MN00001-UP
(MACHINE) POWERED BY 3114 Engine Disassembly and
Assembly 924F WHEEL LOADER AND IT24F INTEGRATED
TOOLCARRIER POWER TRA Media Number
-SENR6726-03 Publication Date -01/04/2006 Date
Updated -09/03/2011
SENR67260016
Transmission Magnetic Filter SMCS -
3179-010 Remove Install Transmission Magnetic
Filter
1. Remove bolts (2) and magnetic filter cover (1).
2. Remove and inspect O-ring seal (3) on the
magnetic filter cover.
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3. Remove magnetic filter (4) and suction screen
(5) from the housing. NOTE The following steps
are for installation of the transmission magnetic
filter.
4. Install a new suction screen (5) and a new
magnetic filter (4) in the housing if necessary.
5. Install a new O-ring seal (3) on the filter
cover if necessary.
6. Install filter cover (1) with the bolts (2)
that hold it.
Copyright 1993 - 2021 Caterpillar Inc. All Rights
Reserved.
Wed Feb 10 095627 UTC0800 2021
11
Shutdown SIS
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Product WHEEL LOADER Model 924F WHEEL LOADER
6MN Configuration 924F Wheel Loader 6MN00001-UP
(MACHINE) POWERED BY 3114 Engine Disassembly and
Assembly 924F WHEEL LOADER AND IT24F INTEGRATED
TOOLCARRIER POWER TRA Media Number
-SENR6726-03 Publication Date -01/04/2006 Date
Updated -09/03/2011
SENR67260017
Flow Control Valve SMCS - 5137-010 Remove
Install Flow Control Valve
1. Remove plug (2) and adapter (1) from the
torque converter housing.
2. Remove flow control valve assembly (3) from
the torque converter housing.
3. Remove retainer ring (4) from the piston in
the flow control valve.
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4. Remove screen (8).

• Remove piston (6) and spring (5) from the body of
  the flow control valve.
• Remove and inspect O-ring seals (7).
• NOTE The following steps are for the
  installation of the flow control valve.

1. Install new O-ring seals (7) on the flow control
   valve body if necessary.
2. Install spring (5) and piston (6) in the flow
   control valve body.

9. Install retainer ring (4) over the piston in
the flow control valve body.
13
10. Install flow control valve assembly (3) in
the torque converter housing.
11. Install adapter (1) and plug (2) in the
torque converter housing.
Copyright 1993 - 2021 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Wed Feb 10 095715 UTC0800 2021
14
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Product WHEEL LOADER Model 924F WHEEL LOADER
6MN Configuration 924F Wheel Loader 6MN00001-UP
(MACHINE) POWERED BY 3114 Engine Disassembly and
Assembly 924F WHEEL LOADER AND IT24F INTEGRATED
TOOLCARRIER POWER TRA Media Number
-SENR6726-03 Publication Date -01/04/2006 Date
Updated -09/03/2011
SENR67260018
Transmission Control Valve SMCS -
3152-017 Disassemble Assemble Transmission
Control Valve

• Start By
• remove engine, transmission and transfer gears
• separation of transmission from engine

1. Put the transmission assembly in position on tool
   (A).
2. Disconnect five wire connectors (2) from the
   transmission control valve body.
3. Remove wire clamp (3) and remove wiring harness
   (4) from the transmission control valve body.

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4. Remove seventeen hex head bolts (5) that hold
the transmission control body to the
transmission. Remove transmission control valve
body (1) from the transmission. Install tool (B)
over the control valve body porting.
5. Remove allen head bolt (7) and then remove
dump valve (6) from the transmission control
valve body.
6. Remove manifold plate (9) and two dowels (8)
from the control valve body if necessary.
7. Remove seal (10) and O-ring seal (11) from the
dump valve manifold. Inspect the seals for damage.
8. Remove rubber seal (12) from the back side of
the dump valve. Inspect the seal for damage.
16

1. Turn dump valve (6) over. Remove plugs (13) and
   (16). Inspect the O-ring seals on the plugs for
   damage. Remove spring (15) and valve spool (14)
   from the valve body.
2. Remove the plugs (17) and (24). Inspect the
   O-ring seals on the plugs for damage. Remove
   spring (23), piston (22) and valve spool (20)
   from the dump valve body.
3. Remove plug (19) and inspect the O-ring seals.
   Remove screen plug (21) from valve spool (20).
4. Remove plug (18) and inspect the O-ring seal.

13. Remove allen head bolts (25) and (26) to
separate manifold (28) from valve body (27).
14. Remove spacer plate (29) from manifold (28).
15. Remove and inspect seal (30). Remove two
dowels (31) from the manifold (28).
17

1. Turn manifold (26) over and remove seal (32).
2. Remove retainer ring (33) and then remove flow
   valve (34).

18. Turn valve body (27) over. Remove seal (35),
retainer (36) and spring (37) from the backside
of valve body (27).

• Remove plugs (46) and remove valve spools (47)
  and springs (39). Remove slugs (48) and
• slug (40).
• Remove plugs (45) and remove springs (44) and
  slugs (42). Remove selector valve spool (43) and
  valve spools (41) from the valve body.
• Remove solenoid valve assemblies (38) and (49)
  from the valve body.

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22. Remove ball, seat and spring assembly (54)
from slug (40). Remove retainer ring (50),
spacer (55) and spool (56) from valve spool (43).
Remove screen plug (51) from spool (56). Remove
slug (52) from spool (43). Remove slug (53) from
spool (43). NOTE The following steps are for the
assembly of the transmission control valve.
23. Install slug (53) and slug (52) in spool
(43). Install screen plug (51) in spool (56).
Install spool (56), spacer (55) and retainer ring
(50) in valve spool (43).

1. Install solenoid valve assemblies (38) and (49)
   in valve body (27). Tighten the solenoid
   assemblies to a torque of 50 5 Nm (37 4 lb
   ft).
2. Install valve spools (41) selector valve spool
   (43) in the valve body.
3. Install slugs (42), springs (44) and plugs (45)
   in the valve body.
4. Install valve spools (47), slugs (48) slug (40),
   springs (39) and plugs (46) in the valve body.
   Tighten the smaller plugs in numbers (45) and
   (46) to a torque of 37 3 Nm (27 2 lb ft.).
   Tighten the larger plugs in numbers (45) and (46)
   to a torque of 75 10 Nm (55 7 lb ft).

28. Turn valve body (27) over and install spring
(37), retainer (36) and seal (35).
19

1. Install flow valve (34) and retainer ring (33) in
   manifold (28).
2. Install seal (32).

31. Install dowels (31) and seal (30) in manifold
(28).
32. Install spacer plate (29) on the manifold.
33. Connect manifold (28) valve body (27) with
allen head bolts (25) and (26).
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• 34. Install O-ring seal on plug (18) and then
  install plug (18) in the dump valve body. Tighten
  plug
• (18) to a torque of 14 2 Nm (10 1 lb ft).
• Install plugs (13) and (17) in the dump valve
  body. Install plug (19) in the valve body.
  Install screen plug (21) in valve spool (20).
  Install valve spool (20), piston (22) and spring
  (23) in the valve body. Install plug (24).
• Install valve spool (14) and spring (15) in the
  valve body. Install plug (16). Tighten plugs (17)
  and (24) to a torque of 37 5 Nm (27 4 lb
  ft). Tighten plugs (13) and (16) to a torque 25
  4
• Nm (18 3 lb ft).

37. Install rubber seal (12) on the backside of
the dump valve.
38. Install O-ring seal (11) and seal (10) on the
dump valve manifold.
39. Install dowels (8) manifold plate (9).
40. Install dump valve (6) on the transmission
control valve body with allen head bolt (7).
21

• Install transmission control valve body (1) on
  the transmission with seventeen hex head bolts
  (5).
• Install wiring harness (4) on the transmission
  control valve body. Install wire clamp (3).
• Connect five wire connectors (2) to the
  transmission control valve body.
• 42. Remove the transmission assembly from tool
  (A). End By
• connection of transmission to engine
• install engine, transmission and transfer gears

Copyright 1993 - 2021 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Wed Feb 10 095803 UTC0800 2021
22
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Product WHEEL LOADER Model 924F WHEEL LOADER
6MN Configuration 924F Wheel Loader 6MN00001-UP
(MACHINE) POWERED BY 3114 Engine Disassembly and
Assembly 924F WHEEL LOADER AND IT24F INTEGRATED
TOOLCARRIER POWER TRA Media Number
-SENR6726-03 Publication Date -01/04/2006 Date
Updated -09/03/2011
SENR67260019
Rim Tire (Front Rear) SMCS - 4202-010 Remove
Install Rim Tire (Front Rear)
1. Remove fender (1) so tire and rim can be
removed.
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2. Support lift arms using tooling (B). Support
frame with tooling (A). Support tire and rim with
straps as shown. Remove bolts (2) and remove tire
and rim. Weight of tire and rim assembly 204 kg
(450 lb). NOTE Install in the reverse order.
Copyright 1993 - 2021 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Wed Feb 10 095850 UTC0800 2021
24
Shutdown SIS
Previous Screen
Product WHEEL LOADER Model 924F WHEEL LOADER
6MN Configuration 924F Wheel Loader 6MN00001-UP
(MACHINE) POWERED BY 3114 Engine Disassembly and
Assembly 924F WHEEL LOADER AND IT24F INTEGRATED
TOOLCARRIER POWER TRA Media Number
-SENR6726-03 Publication Date -01/04/2006 Date
Updated -09/03/2011
SENR67260020
Duo-Cone Seals (Conventional Inverted) SMCS -
7561-016 Assembly Installation Of Conventional
Duo-Cone Seals Introduction This instruction
gives the procedure for installing Conventional
Duo-Cone Seals It is most important that correct
assembly and installation procedures are followed
when Duo- Cone Seals are used. Many of the
Duo-Cone Seal failures are the direct result of
one or more mistakes made during assembly or
installation of the seal components.

1. Seal
2. Rubber toric Ring
3. Housing retaining lip
4. Housing ramp
5. Seal ring housing

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• Seal ring face
• Seal ring ramp
• Seal ring retaining lip
• Installation tool
• 1. Remove any oil film, dust or other foreign
  matter from toric rubber rings (2) and from ramps
  (4) and (7) and lips (3) and (8) of both seal
  rings (1) and housings (5). Use isopropyl alcohol
  and clean cloth or paper towels for wiping.
• NOTICE
• Never permit oil to get on the toric rings or
  ramps before both seal rings are put together in
  their final assembled position (Step 10).

Avoid prolonged skin contact with isopropyl
alcohol. Avoid breathing the vapors in enclosed
areas without adequate ventilation and do not
smoke. Do not use near open flame or welding
operations or other heated surfaces exceeding
482C (900F).
26
2. Put toric ring (2) on seal ring (1), at the
bottom of seal ring ramp (7) and against
retaining lip (8). NOTICE Make sure that toric
ring (2) is straight on seal ring (1) and is not
twisted. Be careful when you work on the rubber
toric ring. Nicks, cuts and scratches can cause
leaks.
27
3. Put installation tool (9) onto seal ring (1)
with toric ring (2). Lower the rings into a
container with isopropyl alcohol until all
surfaces of toric ring (2) are wet. NOTICE Do
not use Stanisol or any other liquid that leaves
an oil film or does not evaporate quickly.
4. With all surfaces of toric ring (2) wet, use
installation tool (9) to position seal ring (1)
and toric ring (2) squarely against housing (5)
as shown. Use sudden and even pressure to pop
(push) toric ring (2) under retaining lip (3) of
housing (5).
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5. Check assembled height (A) in at least four
places, 90 degrees apart. The difference in
height around the ring must not be more than 1 mm
(.04 in).

• If small adjustments are necessary, do not push
  directly on seal ring (1) use installation tool
  (9).
• Toric ring (2) can twist if it is not wet all
  around during installation or if there are burrs
  or fins on retaining lip (3) of housing (5).
• NOTICE
• Misalignment, twists and bulges of the toric ring
  will cause Duo-Cone Seal failures. If correct
  installation is not obvious, remove seal from
  housing and repeat Steps 3 thru 6.

IMPORTANT Toric rings (2) must never slip on the
ramps of either seal rings (1) or seal ring
housings (5). To prevent slippage, wait a minimum
of two minutes to let the isopropyl alcohol
evaporate before further assembly. Once correctly
in place, the toric ring must roll on the ramps
only.
29
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8. Wipe seal faces (6) of seal rings (1) clean.
Use a lint free cloth or paper towel. No
particles of any kind are permissible on the
sealing surfaces. Even a small piece from a paper
towel can hold the seal faces apart and cause
leakage.
31
9. Put a thin film of clean oil on the seal
faces. Use an applicator, a disposable tissue or
a clean finger to distribute the oil evenly. Be
careful not to get any oil on the rubber toric
rings.
10. Make sure both housings (5) are in correct
alignment and are concentric. Move the parts
slowly and carefully toward each
other. NOTICE Do not slam seals together. High
impact can scratch or break the seal components.
11. Once in place, fasten all parts
tightly. Assembly Installation Of Inverted
Duo-Cone Seals Introduction This instruction
gives the procedure for installing Inverted
Duo-Cone Seals Reference Special Instruction
Forms SMHS8482-01, SMHS8484-01 and SMHS8689. It
is most important that correct assembly and
installation procedures are followed when Duo-
Cone Seals are used. Many of the Duo-Cone Seal
failures are the direct result of one or more
mistakes made during assembly or installation of
the seal components.
32

• Shaft
• Shaft seal ring
• Rubber toric
• Toric stabilizer
• Shaft ramp
• Seal ring retaining lip
• Seal ring ramp
• ring ramp
• Seal ring face
• Installation tool
• Retainer
• Retainer seal ring
• Rubber O-ring
• 1. Remove any oil film, dust or other foreign
  matter from rubber toric (3), and from ramps (5)
  and
• (7) and lip (6) of shaft seal ring (2) and shaft
  (1). Use isopropyl alcohol and a clean cloth or
  paper towels for wiping.
• IMPORTANT Never permit oil to get on rubber
  toric (3), shaft ramp (5) or seal ring ramp (7)
  before both seal rings are put together in their
  final assembled position (Step 14).

Avoid prolonged skin contact with isopropyl
alcohol. Avoid breathing the vapors in enclosed
areas without adequate ventilation and do not
smoke. Do not use near open flame or welding
operations or other heated surfaces exceeding
482 C (900 F).
33
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