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TM 5-3805-290-23-1
THEORY OF OPERATION
Maintenance Task Title
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-1
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-5
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-18
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-19
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-31
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-94
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-100
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-102
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-120
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-134
Air Conditioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-192
0003 00
INTRODUCTION
This work package explains how 924G Wheel Loader components work together. A functional description for equip-
ment operation is given for: transmission, engine lubrication system, fuel system, air inlet and exhaust system, engine cooling
system, steering and brake system, electrical system, and machine.
ENGINE
0003 00
1.
General. The major components of basic engine: cylinder block, cylinder head, pistons, connecting rods, crankshaft,
vibration damper, timing gear case and gears, and camshaft.
2.
Cylinder Block.
a.
Cylinder block is made of cast iron. Cylinder block provides support for full length of dry cylinder liners. Cylinder
block has flame ring above cylinder liner flange.
b.
Cylinder liners are made of cast iron. Production liners and replacement liners are press fit in cylinder block. Both
types of cylinder liners are honed to specially controlled finish to ensure long life and low oil consumption.
c.
Cylinder block has bushing installed for front camshaft journal.
d.
Other camshaft journals run directly into cylinder block.
3.
Cylinder Head.
a.
Cylinder head assembly has one inlet valve and one exhaust valve for each cylinder. Each cylinder valve has single
valve spring. Valve and valve spring are held in position by valve spring cap and two collets.
b.
Inlet valve and exhaust valve move in phosphated guides. An oil seal fits over top of each valve guide.
c.
Inlet valve and exhaust valve ports are on right side of cylinder head.
4.
Pistons.
a.
Pistons have Fastram combustion chamber at top. This chamber ensures an efficient mix of fuel and air.
b.
Pistons have two compression rings and an oil control ring. Groove for top ring has hard metal insert that reduces
groove wear. Skirt has a layer of graphite that reduces wear. Off-center piston pin reduces noise level.
c.
Engine has piston cooling jets installed in cylinder block for each cylinder. Piston cooling jets spray lubricating oil
onto inner surface of piston to cool piston.
