924H 924Hz Wheel Loader PED00001-UP (MACHINE) POWERED BY C6.6 Engin...

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Product:  WHEEL LOADER 
Model:  924HZ WHEEL LOADER  PED00910 
Configuration:  924H 924Hz Wheel  Loader PED00001-UP (MACHINE) POWERED BY C6.6 Engine 

Disassembly and Assembly

924H, 924Hz, 928Hz and 930H Wheel Loaders Machine Systems
Media Number -KENR7617-01 Publication Date -01/04/2010 Date Updated -21/04/2010 
 
 
i02822329

Main Control Valve - Assemble

SMCS - 5051-016-MV

S/N - HXC1-UP

S/N - JTM1-UP

S/N - KLN1-UP

S/N - PED1-UP

S/N - RCB1-UP

S/N - WLB1-UP

Assembly Procedure
Note: Cleanliness is an important factor. Before assembly, thoroughly clean all parts in cleaning
fluid. Allow the parts to air dry. Do not use wiping cloths or rags to dry parts. Lint may be
deposited on the parts which may cause trouble. Inspect all parts. If any parts are worn or
damaged, use new parts for replacement. Dirt and other contaminants can damage the precision
component. Perform assembly procedures on a clean work surface. Keep components covered and
protected at all times.

Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the
components, if necessary.

Note: Lubricate all seals with the lubricant that is being sealed.

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
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before opening any compartment or disassembling any component

containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Illustration 1 g01406664

Note: This component is being displayed for CLEANING PURPOSES ONLY. Many
internal parts are not available for this component. Care must be taken during
disassembly and assembly in order to prevent damage to unavailable parts.

1. Install O -ring seals (86) and (87) onto valve (88). Install valve (88) into body (85). Install O
-ring seal (84), backup ring (83), and O -ring seal (82).

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Illustration 2 g01406105

Improper assembly of parts that are spring loaded can cause bodily
injury.

To prevent possible injury, follow the established assembly procedure

and wear protective equipment.

2. Repeat Step 1 for the assembly of relief valve (58) .

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3. Install relief valves (58) and (73). Tighten relief valves (58) and (73) to a torque of 90 ±9
N·m (66 ± 7 lb ft).

4. Install the O -ring seals, check valve (54), check valve (59), and check valve (65) .

5. Tighten check valves (54), (59), and (65) to a torque of 40 ± 4 N·m (30 ± 3 lb ft).

6. Install check valve (60). Tighten check valve (60) to a torque of 60 ± 6 N·m (44 ± 4 lb ft).

7. Install check valve (67). Tighten check valve (67) to a torque of 10 ± 1.5 N·m (89 ± 13 lb
in).

8. Install relief valves (66) and (68). Tighten relief valves (66) and (68) to a torque of 120 ± 12
N·m (89 ± 9 lb ft).

9. If necessary, install the O -ring seals onto relief valve (74). Install relief valve (74). Tighten
relief valve (74) to a torque of 20 ± 5 N·m (15 ± 4 lb ft).

10 . Install pilot (75), orifice (76), and screw (77). Tighten pilot (75) to a torque of 15 ± 1.5 N·m
(133 ± 13 lb in).

Note: Make sure that the large notch of orifice (76) faces screw (77) .

11 . Install stem (69), spring (70), O-ring seal (71), and plug (72). Tighten plug (72) to a torque
of 60 ± 6 N·m (44 ± 4 lb ft).

12 . Install stem (78), spring (79), O -ring seal (80), and plug (81). Tighten plug (81) to a torque
of 60 ± 6 N·m (44 ± 4 lb ft).

13 . Install orifices (62), springs (63), and plugs (64). Tighten plugs (64) to a torque of 60 ±6
N·m (44 ± 4 lb ft).

14 . If necessary, install the O-rings onto check valve (57) and flow control valve (61). Install
check valve (57) and flow control valve (61). Tighten check valve (57) to a torque of 100 ±
10 N·m (74 ± 7 lb ft). Tighten flow control valve (61) to a torque of 20 ± 5 N·m (15 ± 4 lb
ft).

15 . Install remaining O-ring seals (55) onto body (56) .

Illustration 3 g01405636
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Improper assembly of parts that are spring loaded can cause bodily
injury.

To prevent possible injury, follow the established assembly procedure

and wear protective equipment.

16 . Install retainer (53), spring (52), block assembly (51), and bolts (50). Tighten bolts (50) to a
torque of 6 ± 1.5 N·m (53 ± 13 lb in).

Illustration 4 g01405870

Illustration 5 g01405846

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Improper assembly of parts that are spring loaded can cause bodily
injury.

To prevent possible injury, follow the established assembly procedure

and wear protective equipment.

17 . Install spool (47), retainer (48), spring (49), block assembly (45), and bolts (46). Tighten
bolts (46) to a torque of 6 ± 1.5 N·m (53 ± 13 lb in).

Illustration 6 g01405635

Improper assembly of parts that are spring loaded can cause bodily
injury.

To prevent possible injury, follow the established assembly procedure

and wear protective equipment.

18 . Install O -ring seal (44), spool (43), retainer (42), and spring (41) .

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Illustration 7 g01405634

Improper assembly of parts that are spring loaded can cause bodily
injury.

To prevent possible injury, follow the established assembly procedure

and wear protective equipment.

19 . Install valve assembly (40) and bolts (39). Tighten bolts (39) to a torque of 6 ± 1.5 N·m (53
± 13 lb in).

Illustration 8 g01405629

Improper assembly of parts that are spring loaded can cause bodily
injury.
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To prevent possible injury, follow the established assembly procedure

and wear protective equipment.

20 . Install O -ring seal (35), spacer (36), retainer (37), and spring (38) .

Illustration 9 g01405628

Improper assembly of parts that are spring loaded can cause bodily
injury.

To prevent possible injury, follow the established assembly procedure

and wear protective equipment.

21 . Install block assembly (33) and bolts (34). Tighten bolts (34) to a torque of 6 ± 1.5 N·m (53
± 13 lb in).

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Illustration 10 g01405626

22 . Install fittings (32) .

Illustration 11 g01405324

Improper assembly of parts that are spring loaded can cause bodily
injury.

To prevent possible injury, follow the established assembly procedure

and wear protective equipment.

23 . If necessary, install stud (24), nut (26), and cap nut (27) into block assembly (14). Repeat
for the remaining block assembly (14) .

24 . Install retainer (18), spring (19), and O -ring seal (15). Install block assembly (14) and bolts
(13). Tighten bolts (13) to a torque of 6 ± 1.5 N·m (53 ± 13 lb in).
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25 . Install spool (20), retainer (16), spring (17), and O -ring seal (25). Install remaining block
assembly (14) and bolts (13). Tighten bolts (13) to a torque of 6 ± 1.5 N·m (53 ± 13 lb in).

26 . Install O -ring seal (22) and check valve (21). Tighten check valve (21) to a torque of 40 ±4
N·m (30 ± 3 lb ft).

27 . Install stem (30), spring (31), O -ring seal (28), and plug (29). Tighten plug (29) to a torque
of 60 ± 6 N·m (44 ± 4 lb ft).

28 . Install remaining O-ring seals (23) .

29 . Repeat Step 23 through Step 28 in order to assemble valve assembly (1) .

Illustration 12 g01405533

Note: This component is being displayed for CLEANING PURPOSES ONLY. Many
internal parts are not available for this component. Care must be taken during
disassembly and assembly in order to prevent damage to unavailable parts.

30 . Install O -ring seals (10) and (11) onto valve (12). Install valve (12) into body (9). Install O -
ring seal (8), backup ring (7), and O -ring seal (6) .

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Illustration 13 g01405325

31 . Install relief valve (5) into valve assembly (2). Repeat for the opposite side. Tighten the
relief valves to a torque of 90 ± 9 N·m (66 ± 7 lb ft).

Illustration 14 g01405323

32 . Install valve assemblies (1) and (2). Install plate (4) and bolts (3) .

End By: Install the main control valve. Refer to Disassembly and Assembly, "Main Control Valve
- Install".

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