CAT 924G Bucket Lift Kickout Not Working: Troubleshooting and Solutions

[MikePhua]

Introduction
The CAT 924G is a versatile wheel loader commonly used for lifting, loading, and transporting materials in construction and mining operations. One of the key features of the loader is the bucket lift kickout, which automatically raises the bucket to a preset angle when the lift arms reach the desired height. This feature improves operator efficiency and ensures consistent bucket positioning for loading or unloading tasks. However, if the bucket lift kickout feature is not working, it can cause frustration and reduce the loader’s performance.
This article discusses potential causes of the malfunction and provides troubleshooting steps to help resolve the issue.
Symptoms of Bucket Lift Kickout Failure
When the bucket lift kickout system fails, operators may experience several symptoms:

1. No Automatic Kickout: The bucket fails to automatically lift to the preset angle when the lift arms reach the top.
   
2. Erratic or Delayed Response: The bucket lift system may respond intermittently or with a delay, which can be frustrating for the operator.
   
3. Inconsistent Bucket Positioning: The bucket does not maintain a consistent angle, requiring manual adjustments every time.
   
4. Warning Lights or Fault Codes: The loader may display warning lights on the dashboard or trigger fault codes related to the lift system.
   

If you notice any of these symptoms, it’s essential to address the issue as soon as possible to avoid affecting the loader’s performance.
Potential Causes of Bucket Lift Kickout Failure
Several factors can contribute to a malfunctioning bucket lift kickout system. Below are some of the most common causes:

1. Hydraulic System Issues
   • What it means: The bucket lift kickout relies on the hydraulic system to operate effectively. Low hydraulic fluid levels, air in the lines, or faulty hydraulic valves can cause the system to malfunction.
     
   • Solution: Check the hydraulic fluid levels and top up if necessary. Inspect the hydraulic hoses, filters, and valves for any signs of leaks or damage. If there are any air pockets in the system, perform a proper bleed to remove them.
     
2. Faulty Kickout Switch or Sensor
   • What it means: The bucket lift kickout is typically controlled by a switch or sensor that detects when the bucket reaches the preset height. A faulty switch or sensor can prevent the kickout function from engaging.
     
   • Solution: Inspect the switch and sensor for any signs of wear or damage. Test the switch for continuity using a multimeter and replace it if necessary. Clean any dirt or debris from the sensor to ensure accurate readings.
     
3. Worn or Misaligned Linkage
   • What it means: The linkage components that connect the lift arms to the bucket may wear out or become misaligned over time. This can affect the proper functioning of the bucket lift kickout.
     
   • Solution: Inspect the linkage for signs of wear, damage, or misalignment. Replace any worn parts, and ensure that all linkage components are properly aligned. Lubricate moving parts to reduce friction and wear.
     
4. Faulty or Miscalibrated Kickout Valve
   • What it means: The kickout function may be controlled by a hydraulic valve. If this valve becomes faulty or miscalibrated, it can prevent the kickout from functioning correctly.
     
   • Solution: Check the kickout valve for proper calibration. If the valve is malfunctioning, it may need to be replaced or serviced. Ensure that the valve is set to the correct pressure specifications as outlined in the operator’s manual.
     
5. Electrical System Malfunction
   • What it means: The bucket lift kickout system may be integrated with the loader’s electrical system, and any issues such as blown fuses, damaged wiring, or poor connections can disrupt the functionality of the system.
     
   • Solution: Inspect the electrical wiring and connections for any visible signs of damage or corrosion. Test the fuses and replace any that are blown. Ensure all electrical components are securely connected, and use a multimeter to check for continuity.
     
6. Control Lever or Joystick Issues
   • What it means: The operator’s control lever or joystick plays a crucial role in operating the bucket lift. If the control lever is faulty or not calibrated correctly, it may not trigger the kickout function as intended.
     
   • Solution: Inspect the control lever or joystick for any signs of malfunction. Test the control inputs for proper response and adjust or recalibrate the lever if necessary. In some cases, replacing the joystick or lever may be required.
     
7. Software or Electronic Control Module (ECM) Issues
   • What it means: The CAT 924G may be equipped with an electronic control module (ECM) that manages the operation of various systems, including the bucket lift kickout. If the ECM malfunctions or loses its calibration, it can cause issues with the kickout function.
     
   • Solution: Use a diagnostic tool to check for any fault codes or software issues related to the ECM. If the ECM is faulty or uncalibrated, it may need to be reset or replaced by a qualified technician.
     

Troubleshooting Steps for Bucket Lift Kickout Failure
If the bucket lift kickout function on your CAT 924G is not working, follow these steps to diagnose and fix the issue:

1. Step 1: Check Hydraulic Fluid Levels
   • Verify that the hydraulic fluid is at the recommended level. Top up if necessary and check for any leaks around the hydraulic lines, valves, and cylinders.
     
2. Step 2: Inspect the Kickout Switch or Sensor
   • Test the kickout switch and sensor to ensure they are functioning correctly. Clean the sensor and replace the switch if it is defective.
     
3. Step 3: Examine the Linkage
   • Inspect the linkage for any signs of wear, misalignment, or damage. Lubricate and replace parts as necessary.
     
4. Step 4: Check the Kickout Valve
   • Inspect the kickout valve for proper operation. Ensure that it is correctly calibrated and replace it if necessary.
     
5. Step 5: Inspect the Electrical System
   • Check the electrical components, including the wiring, fuses, and connections. Replace any damaged components and test the system to ensure proper electrical flow.
     
6. Step 6: Test the Control Lever or Joystick
   • Test the control lever or joystick for proper function. If the lever is not responding correctly, recalibrate or replace it as necessary.
     
7. Step 7: Use a Diagnostic Tool
   • If the issue persists, use a diagnostic tool to check for any fault codes related to the electronic control system or ECM. Reset or recalibrate the ECM if required.
     

Conclusion
The bucket lift kickout feature on the CAT 924G is an essential function that improves productivity and ease of use. When it stops working, it can lead to inefficiencies and frustration for operators. By following the troubleshooting steps outlined in this article, you can identify the cause of the issue and take the necessary actions to restore proper functionality. Regular maintenance and timely repairs will ensure that your loader continues to perform at its best, minimizing downtime and improving overall operational efficiency.