Caterpillar 924G Loader Repair Parts & Special Tools Lists (TM 5-3805-290-23P)

The US Department of the Army publication TM 5-3805-290-23P, dated November 2007, contains the Repair Parts and Special Tools Lists (RPSTL) for the Caterpillar 924G Loader, Light Type II. Coverage is for the diesel-powered, four-wheel-drive machine with the multipurpose clamshell bucket, identified by NSN 3805-01-533-1768.

Text search and illustrated parts lookup: Main text, parts tables, and indexes support text search. Embedded bookmarks link to work packages, functional groups, figures, and parts-list pages. Lettering within illustrations and portions of the feedback forms is not searchable; small harness labels benefit from zooming.

• Engine and fuel system: Illustrated parts identification for engine mounts, cylinder heads, timing gears, fuel injectors, injection pumps, air cleaners, and cooling components.

• Transmission, axles, and brakes: Parts breakdowns for transmission shift components, the torque converter, propeller shafts, front and rear axles, and service and parking brakes.

• Hydraulics and steering: Pump and motor assemblies, main and pilot control valves, lift and tilt cylinders, coupler lines, and mechanical steering gear and hydraulic steering components.

• Electrical equipment: Harness and mounting illustrations for engine and transmission controls, cab wiring, secondary steering, starter motor, alternator, and V-belt components.

• Cab and attachments: Cab accessories, A/C compressor and related assemblies, quick coupler, bucket, forklift attachment, and Arctic-equipment parts lists.

• Tools and parts references: Unit and Direct Support tool illustrations, repair-kit listings, bulk materials, and NSN/part-number indexes tied to figure and item numbers.

This RPSTL is suited to maintenance and parts personnel who need to identify components and interpret Army supply and maintenance authorization codes.

Parts Identification and Maintenance References

Each parts-list entry ties an illustration item to its part number, CAGEC supplier code, SMR code, and quantity, with an NSN where assigned. The cross-reference indexes also work from a known stock number or part number back to the relevant figure.

That link helps distinguish a complete assembly from its listed subcomponents before ordering repair parts. Source, Maintenance, and Recoverability codes identify supply sources, authorized maintenance levels, and disposition requirements; they do not describe the repair procedure.

Repair scope: The exploded views show component relationships, not step-by-step teardown or overhaul sequences. Troubleshooting charts, torque tables, pressure-testing procedures, and electrical test specifications are outside this volume. The associated field maintenance manuals, TM 5-3805-290-23-1 and TM 5-3805-290-23-2, are referenced but not included.

Engine, Drivetrain, and Hydraulic Assemblies

The engine coverage extends to intake and exhaust manifolds, turbocharger and aftercooler air lines, and lubrication components. Figure 8, Front Housing and Timing Gear, identifies the separate gears and related hardware; Figure 69, Transmission Control Valve and Related Parts, breaks out the valve and its fittings.

Hydraulic illustrations distinguish lift-cylinder, tilt-cylinder, quick-coupler, and third-function coupler lines. Figure 125, Main Hydraulic Control Valve, shows the valve and mounting hardware, while Figure 173, Bucket and Related Parts, identifies the bucket's replaceable components.

Electrical Harnesses and Arctic Equipment

Figure 57, Secondary Steering Wiring, and Figure 61, Cab Wiring, provide harness and connection-location views with item callouts. These are parts illustrations, not circuit schematics or pin-by-pin diagnostic diagrams. Engine and machine/transmission ECM listings cover component identification without programming instructions.

Separate standard and Arctic entries cover batteries, battery boxes and wiring, fan supply lines, and the Arctic heater installation. These distinctions help match the parts list to the installed equipment before selecting replacement components.

Special Tools and Repair Materials

The special-tools work package lists equipment by maintenance level, including communication adapter P/N 2755120, steering puller kit P/N 1455242, and fuel-pump timing pin P/N 1503992.

The repair-kit section identifies oil-cooler kit P/N 2192172 and its constituent seals and gaskets. Bulk-material entries support the hose, tubing, and seal references used throughout the parts lists.

Always consult a certified technician before performing heavy structural or hydraulic service on this equipment.

PDF Contents and Included Pages

One printable English-language PDF contains 548 pages total: four work packages covering the introduction (6 pages), repair parts (406), special tools (12), and cross-reference indexes (96), plus 28 pages of front/rear matter. Those 28 pages include covers, contents, effective-page information, publication authentication, eight DA Form 2028 sample/blank form pages, and blank pages, all already included in the total.