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

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

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  1. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 1/8 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  2. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 2/8 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 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  3. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 3/8 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  4. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 4/8 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: https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  5. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 5/8 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  6. https://www.aservicemanualpdf.com/ My Dear Friend! Thank you very much for visiting. Full manual if required, please enter the following URL into your browser. https://www.aservicemanualpdf.com/

  7. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 6/8 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  8. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 7/8 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  9. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 8/8 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. Sat Feb 20 20:06:12 UTC+0800 2021 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  10. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 1/2 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 Valve Lifters SMCS - 1209-010 Remove And Install Valve Lifters START BY: a. remove cylinder head assembly 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  11. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 2/2 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: a. install cylinder head assembly Copyright 1993 - 2021 Caterpillar Inc. Sat Feb 20 20:07:09 UTC+0800 2021 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  12. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 1/4 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 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  13. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 2/4 4. Remove bearing (7) and shaft (8) from the timing gear cover if a replacement is necessary. Install Oil Pump And Relief Valve https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  14. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 3/4 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  15. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 4/4 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 Copyright 1993 - 2021 Caterpillar Inc. Sat Feb 20 20:08:06 UTC+0800 2021 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  16. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 1/5 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 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  17. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 2/5 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  18. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 3/5 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  19. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 4/5 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 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  20. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 5/5 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: a. install timing gear cover Copyright 1993 - 2021 Caterpillar Inc. Sat Feb 20 20:09:03 UTC+0800 2021 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  21. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 1/4 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 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  22. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 2/4 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 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  23. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 3/4 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 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  24. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 4/4 Copyright 1993 - 2021 Caterpillar Inc. Sat Feb 20 20:09:59 UTC+0800 2021 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  25. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 1/7 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 Pistons And Connecting Rods SMCS - 1225-011; 1225-012; 1225-015; 1225-016 Remove Pistons And Connecting Rods START BY: a. remove cylinder head assembly b. remove oil pan 1. Put the engine in position on tooling (A) as shown. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  26. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 2/7 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 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  27. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 3/7 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  28. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 4/7 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: a. install cylinder head assembly https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  29. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 5/7 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  30. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 6/7 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 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  31. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 7/7 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 Copyright 1993 - 2021 Caterpillar Inc. Sat Feb 20 20:10:56 UTC+0800 2021 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  32. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 1/3 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 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

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  35. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 2/3 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 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  36. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 3/3 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: a. install timing gear cover b. install valve lifters Copyright 1993 - 2021 Caterpillar Inc. Sat Feb 20 20:11:53 UTC+0800 2021 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

  37. 926E WHEEL LOADER 8NB02452-UP (MACHINE) POWERED BY 3204 ENGIN... 1/3 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 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2021/2/20

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