Caterpillar Cat 926E WHEEL LOADER (Prefix 8NB) Service Repair Manual (8NB02452 and up).pdf

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 926 WHEEL LOADER 8NB
Configuration: 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGINE
Disassembly and Assembly
3204 VEHICULAR ENGINES
Media Number -SENR3230-00 Publication Date -01/10/1985 Date Updated -30/11/2001
Cylinder Head Assembly
SMCS - 1100-011; 1100-012; 1100-015; 1100-016
Remove Cylinder Head Assembly
START BY:
a. remove exhaust manifold
b. remove rocker shaft assembly and push rods
c. remove fuel injection nozzles *
1. Loosen hose clamp (2), and remove tube assembly (1) between the cylinder head assembly and
the timing gear cover.
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926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN...
2021/2/20
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

2. Remove 22 bolts (3) that hold the cylinder head assembly to the cylinder block.
3. Fasten tool (A) and a hoist to the cylinder head assembly. Remove the cylinder head assembly
from the cylinder block. Weight of the cylinder head assembly is 57 kg (125 lb.).
4. Remove the cylinder head gasket, water ferrule and seal from the cylinder block.
*
The fuel injection nozzles do not have to be removed from the cylinder head assembly when the
cylinder head assembly is removed from the cylinder block. If the fuel injection nozzles are not
removed, do not put the cylinder head assembly down on a flat surface. This can cause damage to
the fuel injection nozzles.
Install Cylinder Head Assembly
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NOTE: Check the cylinder head and block for top deck flatness. The flatness of the cylinder head
and block should be within 0.15 mm (.006") total, and a maximum of 0.08 mm (.003") for any
152.4 mm (6.00") span.
1. Check the condition of the water ferrule and seal (4). Make a replacement if needed. Put the
water ferrule and seal (4) in position with the adjusting screw of hose clamp (2) toward the top and
approximately 45° to the right of vertical line as seen from the front of the engine. Make sure the
seal is installed all the way into the counterbore.
2. Clean the surfaces of the cylinder head assembly and the cylinder block that make contact with
each other. Make sure the surfaces are clean and dry. Install a new, dry cylinder head gasket (3) on
the cylinder block.
NOTE: If the plugs in the oil passages in the cylinder head were removed, put 5P3413 Pipe
Sealant with Teflon on the threads, and install the plugs in the head.
3. Fasten tool (A) and a hoist to the cylinder head assembly. Put cylinder head assembly (1) in
position on the cylinder block.
4. Put 5P960 Multipurpose Type Grease on the threads of all the cylinder head bolts.
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5. Install the cylinder head bolts, and tighten them as follows:
a. Tighten bolts 1 through 18 in the number sequence shown to a torque of 81.5 ± 13 N·m (60 ±
10 lb.ft.).
b. Tighten bolts 1 through 18 in number sequence to a torque of 149 ± 6.5 N·m (110 ± 5 lb.ft.).
c. Tighten bolts 1 through 18 again in number sequence to a torque of 149 ± 6.5 N·m (110 ± 5
lb.ft.).
d. Tighten bolts 19 through 22 in number sequence to a torque of 43.5 ± 6.5 N·m (32 ± 5 lb.ft.).
6. Install tube assembly (5) between the cylinder head assembly and the timing gear cover.
Tighten hose clamp (6).
END BY:
a. install fuel injection nozzles
b. install rocker shaft assembly and push rods
c. install exhaust manifold
Disassemble Cylinder Head Assembly
START BY:
4/8
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a. remove cylinder head assembly
1. If necessary, remove plugs (1) with a punch and hammer.
2. Fasten a hoist to the cylinder head, and put it in position on tooling (A). Use adapter plates (2)
from tooling (A) to hold the head in place.
3. Put the valve springs under compression with tool (C).
4. Remove the locks from the valves.
5. Remove tool (C), the retainer, spring, washer and valve from the cylinder head. Put
identification marks on the valve as to its location in the cylinder head.
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6. Check the valve spring force with tool (B). The spring force must be 222 ± 22 N (50 ± 5 lb.)
when the length of the spring is 42.04 mm (1.655 in.). For additional information, see Guidelines
For Reusable Parts - Valve And Valve Springs Form Nos. SEBF8034 and SEBF8002.
7. Do Steps 2 through 5 for the remainder of the valves.
8. Remove the valve seat inserts with tooling (D).
9. Clean and remove any burrs from the valve seat bores.
NOTE: The valve guides are part of the cylinder head. Meaure the bore diameter of the guides at
a location which is 19.0 mm (.75 in.) in from both ends of each valve guide. The bore must be a
diameter of 9.512 ± 0.013 mm (.3745 ± .0005 in.). The maximum permissible bore diameter must
not be more than 9.550 mm (.3760 in.). Valve guides worn more than the maximum specification
can be made to the original size by knurling. Use the 4.5" Bore V8 DI Engine Reconditioning
Procedures, Form No. SENR2031 as guide for knurling valve guides. For reconditioning
information of the cylinder head, see Service Training Meeting Guide, Form No. SESV1202.
Assemble Cylinder Head Assembly
1. Clean and remove burrs and all foreign material from the valve seat bores.
2. Lower the temperature of the valve seat inserts, and install them with tooling (A).
6/8
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3. Grind the valve inserts according to specifications given in Specifications.
4. Put clean engine oil on the valve stem. Install the valve, washer (3), spring (2) and retainer (1)
in the cylinder head.
5. Put the valve spring under compression with tool (C).
6. Install the locks on the valve stem with tool (B).
The locks can be thrown from the valve when the spring compressor is
released if they are not in their correct position on the valve stem. To
prevent possible personal injury, be sure to stay away from in front of
the valve retainer and springs.
7. Remove tool (C), and hit the valve with a rubber hammer to be sure the locks are in their correct
position.
7/8
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8. Do Steps 4 through 7 for the remainder of the valves.
9. If plugs (5) were removed from the cylinder head assembly, install them with tool (A) until they
are 1.0 ± 0.5 mm (0.04 ± 0.02) from the bottom of the chamfer.
END BY:
a. install cylinder head assembly
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sat Feb 20 20:06:12 UTC+0800 2021
8/8
2021/2/20

Shutdown SIS
Previous Screen
Valve Lifters
SMCS - 1209-010
Remove And Install Valve Lifters
START BY:
NOTICE
Put identification marks on the lifters as to their location in the
cylinder block.
1. Remove valve lifters (1) from the cylinder block with a magnet. Put identification marks on the
lifters for installation purposes if the old lifters are to be used again.
1/2
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2. Check the diameter of the valve lifter. The diameter of the valve lifter (new) must be 29.436 ±
0.010 mm (1.1589 ± .0004 in.). The bore in the block for new valve lifters must be 29.525 ± 0.025
mm (1.1624 ± .0010 in.). The maximum permissible clearance between the lifter and the bore for
the valve lifter (worn) is 0.20 mm (.008 in.).
NOTICE
Install the lifters in their respective bores in the cylinder block. Failure
to do this can result in an increased rate of wear or failure.
3. Put 2P2506 Thread Lubricant on the lifter face that makes contact with the camshaft.
4. Install valve lifters (1) in their original positions in the cylinder block.
END BY:
Sat Feb 20 20:07:09 UTC+0800 2021
2/2
2021/2/20

Shutdown SIS
Previous Screen
Oil Pump And Relief Valve
SMCS - 1304-011; 1304-012
Remove Oil Pump And Relief Valve
START BY:
a. remove timing gear cover
1. Remove the bolt and retainer (1) that hold guide (2) for the relief valve. Remove guide (2), the
spring and the plunger from the timing gear cover.
2. Remove bolts (3) and oil pump cover (4).
3. Remove inner rotor (5) and outer rotor (6) from the timing gear cover.
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4. Remove bearing (7) and shaft (8) from the timing gear cover if a replacement is necessary.
Install Oil Pump And Relief Valve
2/4
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1. Install shaft (2) in the timing gear cover until dimension (Y) is 21.84 ± 0.25 mm (.860 ± .010
in.).
2. Use tooling (B) to install bearing (1) in the timing gear cover until dimension (X) is 8.74 ± 0.25
mm (.344 ± .010 in.). Also, the bearing joint must be located 45° ± 30° from centerline (Z).
3. After installation of the bearing in the timing gear cover, check the inside diameter. The inside
diameter (W) of the bearing must be 71.22 ± 0.05 (2.804 ± .002 in.).
NOTICE
When the outer and inner rotors are replaced, they must be replaced
as a set.
4. Install outer rotor (4) and inner rotor (3) in the timing gear cover.
3/4
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5. Check the clearance between the inner and outer rotors with feeler gauge (5) as shown. The
clearance must be 0.05 to 0.20 mm (.002 to .008 in.). The maximum permissible clearance must
not be more than 0.28 mm (.011 in.).
6. Put cover (6) in position on the timing gear cover, and install the bolts that hold it in place.
7. Check the oil pump end clearance with feeler gauge (5). The maximum permissible end
clearance must not be more than 0.120 mm (.0047 in.). If the end clearance is more, replace the
inner and outer rotors as a set.
8. Install plunger (9), spring (8) and guide (7) in the timing gear cover. Use tooling (C) to tighten
guide (7) to a torque of 41 ± 7 N·m (30 ± 5 lb.ft.).
9. Install the retainer and bolt that holds the guide in the timing gear cover.
END BY:
a. install timing gear cover
Sat Feb 20 20:08:06 UTC+0800 2021
4/4
2021/2/20

Shutdown SIS
Previous Screen
Timing Gears And Plate
SMCS - 1162-011; 1162-012; 1206
Remove Timing Gears And Plate
START BY:
a. remove timing gear cover
1. Loosen bolt and washer (1) that hold fuel injection pump drive gear (2) to the fuel injection
pump camshaft until the washer is approximately 3.20 mm (.125 in.) from the gear. Do not
remove the bolt and washer at this time.
2. Install tooling (A) on the drive gear. Tighten the screw in tooling (A) until the drive gear is
loose. Remove tooling (A), bolt and washer (1) and drive gear (2).
1/5
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3. Remove bolt (3), the lock and washer and idler gear (4).
4. Remove bearing (5) from the idler gear with tooling (B).
5. Turn the crankshaft until "C" marks (7) on crankshaft drive gear (8) and camshaft drive gear (6)
are in alignment with each other.
NOTICE
Do not turn the crankshaft after the camshaft drive gear has been
removed. Damage to pistons or valves or both can result.
6. Remove bolts (9) and camshaft drive gear (6) from the camshaft.
2/5
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7. Remove three nuts (10) from the studs that hold the fuel injection pump housing to the timing
gear plate.
8. Remove bolts (12) and timing gear plate (11) from the cylinder block.
Install Timing Gears And Plate
1. Clean the old gasket from the contact surfaces of the timing gear plate and the cylinder block.
Install a new gasket on the cylinder block. Cut the gasket even with the bottom face of the
cylinder block. Put 5H2471 Cement on the bottom of the gasket where the gasket makes contact
with the gasket for the oil pan.
2. Be sure O-ring seals (1) are in position on the end of the fuel injection pump housing.
3. Put timing gear plate (2) in position on the cylinder block. Install the four bolts that hold the
plate in place. Install the three nuts that hold the fuel injection pump housing to the back of the
timing gear plate.
3/5
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4. Install camshaft drive gear (4) on the camshaft so the "C" marks on both camshaft drive gear (4)
and crankshaft drive gear (3) are in alignment. Install the bolts that hold camshaft gear drive (4) on
the camshaft. Tighten them to a torque of 55 ± 7 N·m (41 ± 5 lb.ft.).
5. Install the bearing in idler gear (5) with tooling (A). The end of the bearing must be 1.5 ± 0.5
mm (.06 ± .02 in.) below the surface of the gear hub.
6. Be sure the oil hole in shaft (6) for idler gear (7) is open. Put idler gear (7) in position on the
shaft, and install the washer, lock and bolt that hold the gear on the shaft.
7. Put fuel injection pump drive gear (8) in position on the fuel injection pump camshaft. Install
the washer and bolt that hold the gear in place, but do not tighten the bolt at this time. The flat side
4/5
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of the washer must face away from the gear. For correct installation of the fuel injection pump
drive gear and timing of the engine, see Install Fuel Injection Pump Housing And Governor.
END BY:
Sat Feb 20 20:09:03 UTC+0800 2021
5/5
2021/2/20

Shutdown SIS
Previous Screen
Connecting Rod Bearings
SMCS - 1219-010
Remove And Install Connecting Rod Bearings
START BY:
a. remove oil pan
1. Turn the crankshaft until two pistons are at the bottom center. Remove connecting rod caps (2)
from the two connecting rods. Remove the lower half of the rod bearing from the rod bearing cap.
NOTICE
The connecting rod bolts are loose on the connecting rods and can fall
out when the nuts are removed.
2. Push connecting rods (1) away from the crankshaft. Remove the upper half of the rod bearing
from the connecting rod.
1/4
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NOTE: Install the connecting rod bearings dry when the clearance checks are made. Put clean
engine oil on the connecting rod bearings for final assembly.
NOTICE
Be sure the tabs in the back of the connecting rod bearings are in the
tab grooves of the connecting rod and cap.
3. Install the upper half of the rod bearing in the connecting rod, and put the connecting rod in
position on the crankshaft.
4. Install the lower half of the rod bearing in the connecting rod cap.
The serviceman must be very careful to use Plastigage correctly. The following points must be
remembered:
...Make sure that the backs of the bearings and the bores are clean and dry.
...Make sure that the bearing locking tabs are properly seated in their slots.
...The crankshaft must be free of oil where the Plastigage touches it.
...Put a piece of Plastigage on the crown of the bearing half that is in the cap. Do not allow the
Plastigage to extend over the edge of the bearing.
...Install the bearing cap using the correct torque-turn specifications. Do not use an impact wrench.
Be careful not to dislodge the bearing when the cap is installed.
...Do not turn the crankshaft with the Plastigage installed.
...Carefully remove the cap, but do not remove the Plastigage. Measure the width of the Plastigage
while it is in the bearing cap or on the crankshaft journal. Do this by using the correct scale on the
package. Record the measurements.
...Remove the Plastigage before installing the cap.
When using Plastigage, the readings can sometimes be unclear. For example, all parts of the
Plastigage are not the same width. Measure the major widths to make sure that they are within the
specification range. Also, experience has shown that when checking clearances tighter than 0.10
mm (.004") the readings may be low by 0.013 to 0.025 mm (.0005 to .0010"). Out-of-round
2/4
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journals can give faulty readings. Also, journal taper may be indicated when one end of the
Plastigage is wider than the other.
For complete details concerning measuring bearing clearances, see Engine Bearings And
Crankshafts, Form No. SEBD0531.
5. Use Plastigage (A) to check the connecting rod bearing clearance.
6. Put Plastigage (A) on the connecting rod bearing.
7. Put 2P2506 Thread Lubricant on the threads of the rod bolts and seat surfaces of the nuts.
NOTICE
When connecting rod caps are installed, make sure the number on the
side of the cap is next to and respective with the number on the side of
the connecting rod.
8. Install connecting rod cap (2). Install the nuts. Tighten the nuts to a torque of 41 ± 4 N·m (30 ±
3 lb.ft.). Put a mark on each nut and the end of each bolt. Tighten the nuts 60° ± 5° more.
9. Remove the connecting rod caps. Measure the thickness of the Plastigage. The connecting rod
bearing clearance must be 0.043 ± 0.140 mm (.0017 to .0055 in.) for new bearings. The maximum
clearance with used bearings is 0.15 mm (.006 in.).
10. Install the connecting rod caps, and tighten the nuts as in Step 8.
11. Do Steps 1 through 9 for the remainder of the connecting rod bearings.
END BY:
a. install oil pan
3/4
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Sat Feb 20 20:09:59 UTC+0800 2021
4/4
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Shutdown SIS
Previous Screen
Pistons And Connecting Rods
SMCS - 1225-011; 1225-012; 1225-015; 1225-016
Remove Pistons And Connecting Rods
START BY:
b. remove oil pan
1. Put the engine in position on tooling (A) as shown.
1/7
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2. Remove the carbon ridge from the top inside surface of the cylinders with tool (B).
3. Turn the crankshaft until the two center pistons are in the down position.
4. Remove nuts (1) and rod cap (2). Put pieces of rubber hose or tape on the threads of the
connecting rod bolts as protection for the crankshaft.
NOTICE
Do not let the connecting rods hit the crankshaft or the bottom edge of
the cylinder bore when the pistons are removed.
5. Push the piston and connecting rod away from the crankshaft until the piston rings are above the
cylinder block. Remove piston (3) and connecting rod (4) as a unit.
6. Keep each connecting rod cap with its respective connecting rod and piston. Put identification
marks on each piston as to its location in the cylinder block.
NOTICE
2/7
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Do not turn the crankshaft while any of the connecting rods are in the
engine without the connecting rod caps installed.
7. Repeat Steps 3 through 6 for the remainder of the pistons.
Install Pistons And Connecting Rods
1. Put the engine in position on tooling (A).
2. Put clean engine oil on the piston rings, connecting rod bearings, cylinder walls and crankshaft
journals.
3. Make sure the piston ring gaps are at least 120° apart on the piston.
4. Use tool (B), and install the piston and connecting rod in the same cylinder bore of the engine
from which it was removed. The hole (crater) in the top of the piston must be toward the camshaft
side of the engine.
3/7
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NOTE: For more detail concerning the installation of connecting rod bearings, see Remove And
Install Connecting Rod Bearings.
5. Check the bearing clearances with tool (C). For complete details concerning measuring bearing
clearances, see Engine Bearing And Crankshafts, Form No. SEBD0531.
6. Put clean engine oil on the threads of the bolts and contact surfaces of the nuts for the
connecting rod caps.
NOTICE
When the connecting rod caps are installed, make sure that the
number on the side of cap (1) is next to and respective with the number
on the side of connecting rod (2).
7. Put cap (1) in position on the connecting rod, and install the nuts. Tighten the nuts to a torque of
41 ± 4 N·m (30 ± 3 lb.ft.). Put a mark on each nut and the end of each bolt. Tighten the nuts 60 ±
5° more.
8. Repeat Steps 1 through 7 for the remainder of the pistons.
END BY:
4/7
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b. install oil pan
Disassemble Pistons And Connecting Rods
START BY:
a. remove pistons and connecting rods
1. Remove the rings from the piston with tool (A).
2. Remove the bearings from the connecting rod and connecting rod cap.
3. Remove snap rings (3), pin (1) and connecting rod (2) from the piston.
5/7
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4. See Use Of Piston Pin Bearing Removal And Installation Tools, Special Instructions, Form No.
SMHS7295 for more information concerning removal and installation of piston pin bearings.
5. Heat the connecting rod to a temperature of 176° to 260°C (350° to 500°F). Put 5P8654 Spacer
(11) in the base plate. Put the connecting rod on the base plate of tooling (B).
6. Put the connecting rod piston pin bearing end in the center of the port assembly of tooling (B).
Install pin (6) in the center of the bore for the connecting rod bearings.
7. Install 5P8653 Adapter (9). Put the hole in the adapter in alignment with the hole in the base
plate of tooling (B).
8. Install clamp bar (10) and clamp pin (7).
9. Install new piston bearing (5) on adapter (9).
NOTE: The old bearing is pushed out by tooling (B) as the new bearing is installed.
10. Put 5P8645 Adapter (8) in position as shown with the taper side down. The piston pin bearing
joint must be in alignment with the hole in adapter (9) and the base plate of tooling (B).
11. Put pusher (4) on adapter (8).
12. Use tooling (B) to push the new piston pin bearing into the connecting rod until adapter (8) of
tooling (B) makes full contact with the connecting rod surface.
13. Remove the connecting rod and the old piston pin bearing from tooling (B).
14. Check the piston pin bearing bore diameter after the bearing is installed. The correct
dimension is 38.125 ± 0.008 mm (1.5010 ± .0003 in.).
Assemble Pistons And Connecting Rods
6/7
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1. Install connecting rod (1) in the piston with the bearing tab groove (slot) on the same side as the
hole (crater) in the top of the piston.
2. Install piston pin (2) and snap ring (3).
3. When old pistons are to be used again, clean and measure the pistons according to Guideline
For Reusable Parts Pistons And Liners, Form No. SEBF8001.
4. Install the spring for the oil ring. Install the oil ring with tool (A). The gap in the ring must be
approximately 180° from the oil ring spring connections.
5. Install the compression ring with tool (A). The side of the ring that has the identification "TOP"
must be toward the top of the piston. The gaps in the rings must be approximately 120° apart.
NOTE: Compression rings that do not have identification must be installed with the edge that has
the bevel toward the top of the pistons.
6. Install connecting rod bearings.
END BY:
a. install pistons and connecting rods
Sat Feb 20 20:10:56 UTC+0800 2021
7/7
2021/2/20

Shutdown SIS
Previous Screen
Camshaft
SMCS - 1210-011; 1210-012
Remove Camshaft
START BY:
a. remove valve lifters
b. remove timing gear cover
1. Put the engine in position on tooling (A) as shown.
NOTE: To keep the engine timing correct during removal and installation of the camshaft, put a
mark on the teeth of the idler gear and camshaft drive gear at location (X). Put a mark on the teeth
of the camshaft drive gear and crankshaft drive gear at location (Y).
2. Remove bolts (2) and gear (1) from the camshaft.
1/3
2021/2/20

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3. Bend the tabs of lock (3) away from bolts (5). Remove bolts (5), lock (3) and washer (4) that
hold the camshaft in place.
NOTICE
Use extra care not to damage the camshaft bearings as the camshaft is
removed.
4. Carefully remove camshaft (6) from the cylinder block.
Install Camshaft
2/3
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1. Put the engine in position on tooling (A).
2. Put clean engine oil on the bearing journals and 2P2506 Thread Lubricant on the cam lobes of
the camshaft.
3. Carefully install camshaft (1) in the cylinder block. Hold the camshaft up during installation so
the camshaft bearings will not be damaged.
4. Install washer (3), lock (2) and the bolts that hold the camshaft in place. Bend the tabs of the
lock against one of the flats of each bolt head.
5. Install two 3/8"-16 NC guide bolts (4) in the end of the camshaft.
6. Put camshaft drive gear (5) in position on the guide bolts. Make sure the marks on the idler gear
and the crankshaft drive gear are in alignment with the marks on the camshaft drive gear.
7. Turn the camshaft, and make sure the "C" mark on the camshaft drive gear is in alignment with
the "C" mark on the crankshaft drive gear.
NOTE: If a new gear has been installed, it will be necessary to check the engine timing to make
sure the timing is correct. See Remove And Install Fuel Injection Pump Housing And Governor.
8. Install two bolts in the camshaft gear, and remove the guide bolts. Install the remaining bolts in
the camshaft drive gear. Tighten the bolts to a torque of 55 ± 7 N·m (41 ± 5 lb.ft.).
END BY:
b. install valve lifters
Sat Feb 20 20:11:53 UTC+0800 2021
3/3
2021/2/20

Shutdown SIS
Previous Screen
Camshaft Bearings
SMCS - 1211-011; 1211-012
Remove Camshaft Bearings
START BY:
a. remove camshaft
b. remove timing gears and plate
c. remove flywheel housing
NOTE: The camshaft bearings may be pulled toward the inside or the outside of the cylinder
block for removal.
1. Use tooling (A), and remove the rear camshaft bearing.
2. Remove the remainder of the camshaft bearings with tool (A).
1/3
2021/2/20

Caterpillar Cat 926E WHEEL LOADER (Prefix 8NB) Service Repair Manual (8NB02452 and up).pdf

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Caterpillar Cat 926E WHEEL LOADER (Prefix 8NB) Service Repair Manual (8NB02452 and up).pdf