Caterpillar Cat 926E WHEEL LOADER (Prefix 8NB) Service Repair Manual (8NB01542-02451)

1
Service Repair Manual
Models 926 and 926E WHEEL LOADER
2
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Product WHEEL LOADER Model 926 WHEEL LOADER
8NB Configuration 926E WHEEL LOADER
8NB01542-02451 (MACHINE) POWERED BY 3204 ENGINE
Disassembly and Assembly 926 WHEEL LOADER VEHICLE
SYSTEMS Media Number -SENR3073-00 Publication
Date -01/06/1985
Date Updated -11/10/2001
Hydraulic Pump SMCS - 5055-010 5055-015
5055-016 Remove And Install Hydraulic Pump START
BY a. remove cab right side lower shroud
To prevent personal injury, release the pressure
from the hydraulic system before any hoses are
disconnected or removed.

1. Drain the oil from the hydraulic tank. The
   capacity of the hydraulic tank is 53 liter (14
   U.S. gal.).
2. Remove right side rear fender.

1. Disconnect clip (1) that holds the wiring harness
   to the support.
2. Remove strip (2).
3. Remove tubes (3).

3

1. Thoroughly clean the tube connections at the
   hydraulic pump to prevent dirt entry into the
   hydraulic pump.
2. Disconnect tubes (4), (5) and (6) at the
   hydraulic pump.

• Remove the bolts that hold hydraulic pump (7) to
  the engine. Use two persons, and remove the
  pump. The weight of the pump is 30 kg (66 lb.).
• Put protective covers in the hydraulic openings.
• NOTE The following steps are for installation of
  the hydraulic pump.
• Remove the protective covers, and install a new
  O-ring seal on the hydraulic pump.
• Be sure the O-ring seals are in place in tubes
  (4), (5) and (6).
• Install the hydraulic pump.
• Install the right side rear fender.
• Fill the hydraulic system with oil to the correct
  level. See the Maintenance Guide. END BY
• a. install cab right side lower shroud

Disassemble Hydraulic Pump
START BY
4
a. remove hydraulic pump 1. For correct assembly
of the parts, the pump rotation is in a clockwise
direction as seen from the shaft end (drive end)
of the hydraulic pump. Mark the relative position
of the pump sections before disassembly. NOTE
The pictures that follow show a pump with
different orientation and rotation from the one
used on 926 Wheel Loaders. However, the service
procedure is the same.
2. Remove four bolts (1) that hold cover (2) to
cover (3). Remove cover (2) and the cartridge
assembly from the pump as a unit.
NOTE Make a note of the direction of the arrows
at locations (X) and (Y) and the location of
bolts (4) for assembly purposes. Arrows at
locations (X) and (Y) show the direction of pump
rotation. 3. Remove cartridge assembly (5) and
O-ring seal (6) from cover (2).

1. Remove seal ring (8) from the cartridge assembly.
2. Remove O-ring seal (7) and the back-up ring from
   the cartridge assembly.

5
6. Remove bolts (4) and cover (9) from the
cartridge.
7. Remove seals (10) and the retainers from cover
(9).
8. Remove plate (11) from the cartridge.
9. Remove ring (13) and rotor assembly (12) from
plate (14) as a unit.
10. Remove rotor assembly (12) from ring (13).
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11. Remove vanes (16) and inserts (15) from the
rotor.

1. Remove plate (17) from end plate (14).
2. Remove seals (18) and the retainers from the end
   cover.

14. Remove bolts (19) and cover (20) from body
assembly (21).

• Remove cartridge assembly (22) and O-ring seal
  (25) from body assembly (21).
• NOTE Make a note of the direction of the arrows
  (23) nearest the bolts and the direction of the
  arrow (24) on the ring for assembly purposes.
• Do Steps 4 through 13 again for the disassembly
  of cartridge (22).

17. Remove spiral snap ring (27), and remove the
shaft assembly from the body.
8
18. Remove snap ring (28) from shaft (26).
19. Use tooling (A) and a press to remove shaft
(26) from bearing (27).

1. Remove washer (29) and two lip-type seals (30)
   from the body.
2. Inspect all parts for wear or damage, and make
   replacements if necessary. If any parts with
   alignment marks are replaced, put new marks in
   the same location on the new parts.

Assemble Hydraulic Pump
1. Put clean oil on all parts at assembly. NOTE
For correct assembly of all parts, the pump
rotation is in a clockwise direction as seen
from the shaft end (drive end) of the hydraulic
pump.
2. Use tooling (A), and install lip-type seal in
body (1). Install the seal with the lip down as
shown.
9
3. Turn body (1) over, and install the lip-type
seal with tooling (A). Install the seal with the
lip up toward the cartridge assembly as shown.
4. Use tooling (B) and a press to install bearing
(3) on shaft (2).

1. Install snap ring (4) that holds bearing (3) on
   the shaft.
2. Protect the seal lip with shim stock or plastic,
   and put washer (6) and shaft assembly (5) in
   position in body (1). Remove the shim stock or
   plastic.

7. Install spiral ring (7) that holds shaft
assembly (5) in body (1).
10
8. Put O-ring seals (8) in position in plastic
retainers (9). Install seal assemblies on end
plate (10) with the O-ring seal toward the end
plate.
9. Put plate (11) in position on the end plate
with the brass side up toward the rotor.

• NOTE When vanes (15) are installed correctly,
  the rear edge of each vane is next to the balance
  opening (slot) in the rotor. The leading edge of
  each vane faces the direction of pump rotation
  (arrow).
• Install inserts (14) and vanes (15) in rotor
  (13). The sharp edge of the vanes must be in the
  same direction as the arrow on the chamfer of
  ring (12). Each vane (15) must move freely in its
  slot in the rotor. Each insert (14) must move
  freely in its vane (15).
• Put a large rubber band around rotor (13) to hold
  the vanes and inserts in the rotor.

11

1. Put rotor assembly (17) in position on plate (11)
   as shown. Be sure the sharp edge of the vanes
   and the arrow on the chamfer of the ring are in
   the same direction.
2. Put ring (12) in position on plate (11) and end
   plate (10) as shown. The arrow on the chamfer of
   ring (12) must be in the same direction as the
   rotation of the rotor.
3. Put plate (16) in position on the cartridge
   assembly. Make sure the brass side of the plate
   is toward the rotor assembly. Also, make sure
   the notches on the outside diameter of plate (16)
   are in alignment with the notches on plate (11)
   and the chamfers on ring (12).

1. Put O-ring seals (18) in position in plastic
   retainers (20). Install seal assemblies on plate
   (19) with the O-ring seal toward plate (16).
2. Put plate (19) in position on the cartridge
   assembly as shown.

17. Install bolts (21) that hold plate (19) on
the cartridge assembly. Install the bolts in the
holes nearest to the arrows on the plate that
show the direction of pump rotation.

1. Install O-ring seal (24) then back-up ring (25)
   on the end plate of cartridge assembly (22).
2. Install seal ring (23) on the end plate of
   cartridge assembly (22).
3. Install cartridge assembly (22) on the shaft
   assembly.

12

• Install O-ring seal (28) in body assembly (1).
• NOTE Dowels (27) in the cartridge assembly must
  be aligned with the holes in cover (26).
• Install cover (26) on body assembly (1). Use the
  original marks for alignment.
• Install the bolts that hold the cover to the
  body, and tighten them to a torque of 95 14 Nm
  (70 10 lb.ft.).

1. Do Steps 8 through 16 again for the assembly of
   cartridge (30).
2. Install cartridge assembly (30) in cover (29).

• Install O-ring seal (32) in cover (29).
• NOTE Dowels (31) in the cartridge assembly must
  be aligned with the holes in cover (26).
• Put cartridge assembly (30) and cover (29) in
  position on cover (26) as a unit. Use the
  original marks for alignment.

13
28. Install bolts (33) that hold cover (29) to
the cover, and tighten them to a torque of 61 7
Nm (45 4 lb.ft.). END BY a. install
hydraulic pump
Copyright 1993 - 2021 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Sat Feb 20 171134 UTC0800 2021
14
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Product WHEEL LOADER Model 926 WHEEL LOADER
8NB Configuration 926E WHEEL LOADER
8NB01542-02451 (MACHINE) POWERED BY 3204 ENGINE
Disassembly and Assembly 926 WHEEL LOADER VEHICLE
SYSTEMS Media Number -SENR3073-00 Publication
Date -01/06/1985
Date Updated -11/10/2001
Hydraulic Tank SMCS - 5056-011 5056-017 Remove
And Install Hydraulic Tank

1. Remove the hood.
2. Remove the engine compartment doors.

To prevent personal injury, stop the engine,
lower the bucket to the ground, move the control
levers backward and forward to release the
pressure in the hydraulic system. Slowly loosen
the cap to release any pressure in the hydraulic
tank. Let the hydraulic oil become cool before
any lines are disconnected in the hydraulic
system.
3. Drain the oil from the hydraulic tank. The
capacity of the hydraulic tank is 53 liter (14
U.S. gal.).
15

1. Disconnect wire harness (1) from the hydraulic
   tank.
2. Remove the bolts and nuts that hold plate (2) to
   the hydraulic tank. Move plate (2) off the studs.

6. Disconnect hoses (3), (4) and (5) at the
fittings on the hydraulic tank.

1. Fasten tooling (A), and a hoist to the hydraulic
   tank. The weight of the hydraulic tank is 104 kg
   (230 lb.).
2. Remove support (6).

9. Disconnect tube assemblies (7) at the fittings
on the hydraulic tank.
10. Remove bolts (8) that hold the hydraulic tank
to the support.
16

• Lift hydraulic tank (9) straight up. Be careful
  not to damage the cab while removing the
  hydraulic tank.
• Put protective covers over the hydraulic
  openings.
• Remove the protective plugs, and install the
  hydraulic tank in the reverse order of removal.
  Tighten bolts (8) that hold the hydraulic tank to
  the support to a torque of 135 15 Nm (100 11
  lb.ft.).
• Fill the hydraulic tank to the correct level. See
  the Maintenance Guide.
• Install the engine compartment doors.
• Install the hood.
• Disassemble And Assemble Hydraulic Tank
• START BY
• a. remove hydraulic tank

1. Remove elbows (1), (2), (3) and (4) from the
hydraulic tank.
2. Remove plate (5).
17

• Remove cover (6) and filter element (7).
• Remove oil filter bypass valve (8).
• Remove strainer (9) and strainer (10).
• Inspect all parts, and replace as necessary. See
  Wheel Loader Hydraulic System Specifications for
  filter bypass valve spring data.
• NOTE The sight glass can be removed if
  necessary. Tighten the screws to a torque of 24
  3 Nm (18 2 lb.ft.).
• Tighten the filter element bolt to a torque of 56
  3 Nm (41 2 lb.ft.).
• Thoroughly clean the mating surfaces of the
  hydraulic tank and plate (5).
• Assemble the hydraulic tank components in the
  reverse order as disassemble.

1. Peel the tape from a 300 cm (118 in.) piece of
   3G4090 Sealant. Apply the sealant, adhesive side
   down to the hydraulic tank. Apply sealant (11) to
   the area of the tank flange between the inside
   edge of the flange and the holes. Overlap the
   ends of the sealant bead around a bolt hole as
   shown.
2. Install plate (5) on the hydraulic tank.

18
12. Install elbows (1), (2), (3) and (4) with new
O-ring seals. END BY a. install hydraulic tank
Copyright 1993 - 2021 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Sat Feb 20 171230 UTC0800 2021
19
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Product WHEEL LOADER Model 926 WHEEL LOADER
8NB Configuration 926E WHEEL LOADER
8NB01542-02451 (MACHINE) POWERED BY 3204 ENGINE
Disassembly and Assembly 926 WHEEL LOADER VEHICLE
SYSTEMS Media Number -SENR3073-00 Publication
Date -01/06/1985
Date Updated -11/10/2001
Air Dryer SMCS - 4285-010 4285-015
4285-016 Remove And Install Air Dryer
To prevent possible personal injury, make sure
all the pressure is released from the air system
before any lines are disconnected.

• Disconnect two tube assemblies (1) and hose
  assembly (2).
• Disconnect wire assembly (3).
• Remove the two U-bolts, and remove air dryer (4).
• NOTE The following steps are for the
  installation of the air dryer.
• Put the air dryer in position, and install two
  U-bolts (5). Tighten the nuts on the U-bolts to a
  torque of 25 7 Nm (18 5 lb.ft.).
• Connect wire assembly (3). Tighten the nut
  holding the wire to 0.50 0.05 Nm (4 0.4
  lb.in.).
• Connect hose assembly (2) and two tube assemblies
  (1).

20
Disassemble Air Dryer START BY a. remove air
dryer
1. Remove two nuts (1), washer (2) and purge cap
(3). Pull the cap off with a twisting, upward
motion.

1. Unscrew center shaft (5). The shaft has a heavy
   spring load and will release as the shaft is
   removed.
2. Remove two seal washers (4), shaft (5), purge
   plate (6) and desiccant spring (7) from the
   filter cartridge.
3. Remove desiccant canister (8) from the housing.
   If necessary, pry the canister out of the
   housing by inserting a screw driver in the groove
   at the top of the canister.

21
5. With the desiccant canister in an upright
position, remove spiral lockring (9), retainer
screen (10) and cloth filter pad (11) from the
desiccant canister. 6. Tip the open canister
over, and pour out the desiccant.

1. Remove spiral lockring (14) from the bottom of
   canister (8), and remove deflector plate (15)
   and oil separator pad (16).
2. Remove retaining ring (19), tube assembly (12)
   and retaining ring (18) from the canister.
3. Remove filter pad (17) and retainer screen (20)
   from the tube assembly.
4. Remove O-ring seal (13) from the canister.

NOTICE The threads on purge valve assembly (21)
are left hand threads. The valve assembly must
be rotated clockwise for removal.
NOTE The entire purge valve assembly does not
have to be removed for service. Center post
(26), spring (24) and purge valve (25) can be
removed out the top of housing (22). 11. Rotate
purge valve assembly (21) clockwise, and remove
it from housing (22). NOTICE
22
Do not use a collapsible wrench such as a pipe
wrench to loosen center port (26) from the valve
body. Damage to the internal thread port will
occur.
NOTICE Do not apply a sideload to center port
(26) during removal. The post may bend.

• Use a wrench on the flats on center port (26),
  and remove it from the valve body. Be careful
  not to apply a sideload which may bend the post.
• Remove spring (24) and purge valve (25) from the
  valve body. If necessary, use a screwdriver
  inserter through the purge hole to remove the
  purge valve from the valve body.
• Remove U-cup seal (23) from the valve.
• Assemble Air Dryer
• Inspect all seals and parts for wear or damage.
  Make replacements if necessary.
• Make sure all parts are clean and free of dirt
  and foreign material. Lubricate all seals with
  clean oil during assembly.

NOTICE Do not use a collapsible wrench such as a
pipe wrench to tighten center post (4). Damage
to the internal thread port will occur.
NOTICE Do not apply a sideload to center post
(4). The post may bend.
23

1. Install seal (1) on valve body (5). Install seal
   (3) on center post (4). Install seal (7) and
   U-cup seal (6) on purge valve (2). Make sure the
   "U" of the seal is facing down against the valve
   body shoulder.
2. Install purge valve (2), spring (8) and center
   port (4) into valve body (5).
3. Use a wrench on the flats on center post (4) to
   tighten it. Do not apply a sideload which may
   bend the post.

NOTICE The threads on purge valve assembly (9)
are left hand threads. The valve assembly must
be rotated counterclockwise for installation.
6. Install purge valve assembly (9) into housing
(10). Install seal (11).

1. Install seal (13). Install retaining ring (18) in
   the groove closest to the top of canister (21).
2. Install retainer screen (20) and filter pad (17)
   on tube assembly (12). The filter pad must be
   facing the desiccant.
3. Install tube assembly (12) into the canister, and
   fasten it in position with retaining ring (19).
4. Install oil separator (16) and deflector plate
   (15). Fasten them to the tube assembly with
   spiral lockring (14).

24

• NOTE Both filter pads must face the desiccant
  and completely cover their respective retainer
  screws to prevent the desiccant from rubbing
  against the rough retainer screens.
• Set canister (21) upright, and pour new,
  premeasured desiccant into the canister.
• Jar the canister and tamp down the desiccant
  until the entire package is added to the
  canister.
• Install filter pad (24) and retainer screen (23).
  Push the retainer screen down until spiral
  lockring (22) can be installed.

14. Install the canister assembly into housing
(10). Rotate the canister while installing, and
be sure that O-ring seal (13) seats below the
housing shoulder.
15. Install two seals (28) on purge plate (26).
Install desiccant spring (25), purge plate (26),
seal washer (29), center shaft (27) and seal
washer (29).
25

• Install purge cap (32) with a downward twisting
  motion.
• Install washer (30) and two nuts (31). END BY
• a. install air dryer

Copyright 1993 - 2021 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Sat Feb 20 171327 UTC0800 2021
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Product WHEEL LOADER Model 926 WHEEL LOADER
8NB Configuration 926E WHEEL LOADER
8NB01542-02451 (MACHINE) POWERED BY 3204 ENGINE
Disassembly and Assembly 926 WHEEL LOADER VEHICLE
SYSTEMS Media Number -SENR3073-00 Publication
Date -01/06/1985
Date Updated -11/10/2001
Air Tank SMCS - 4272-010 Remove And Install Air
Tank
To prevent personal injury, release the pressure
in the air tank before any lines are
disconnected.
1. Turn the valve on the bottom of the air tank
to the "OPEN" position to release the air
pressure from the air tank.
2. Disocnnect air supply hose (1) to the air tank
at the air compressor. Disconnect the two clips
that hold it.
27
3. Remove hose (1). Remove hose (2) to the air
compressor governor.

1. Remove tube (3) to the brake control valves.
2. Remove the clamps that hold air tank (4), and
   remove the tank.
3. Install the air tank in the reverse order of
   removal.
4. Check the operation of the air compressor
   governor and the air relief valve. See the
   respective topics in Systems Operation Testing
   And Adjusting Air System And Brakes.

Copyright 1993 - 2021 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Sat Feb 20 171424 UTC0800 2021
28
Shutdown SIS
Previous Screen
Product WHEEL LOADER Model 926 WHEEL LOADER
8NB Configuration 926E WHEEL LOADER
8NB01542-02451 (MACHINE) POWERED BY 3204 ENGINE
Disassembly and Assembly 926 WHEEL LOADER VEHICLE
SYSTEMS Media Number -SENR3073-00 Publication
Date -01/06/1985
Date Updated -11/10/2001
Brake Foot Control Valves SMCS - 4265-016
4265-011 4265-012 4265-015
29

• Remove Brake Foot Control Valves
• START BY
• remove lower cab shrouds
• remove windshield washer reservoir (only for
  removal of left brake foot control valve)
• remove brake pedal
• If only removing the left brake valve, remove
  only the front left hand shroud and the front
  shroud. If only removing the right brake valve,
  remove only the right hand shroud and the front
  shroud.

30
To prevent personal injury, release the pressure
from the air reservoir before any lines are
disconnected.
NOTE The procedure to remove the right brake
valve and the left brake valve is the same,
except there are two less hose assemblies
connected to the right brake valve. The left
brake valve is shown.

1. Put identification marks on hose assemblies for
   correct installation.
2. Disconnect hose assemblies (1), (2), (3) and (4)
   from the brake valve.

1. Put identification marks on wire assemblies (7)
   for correct installation. Disconnect wire
   assemblies (7) from the brake valve.
2. Disconnect tube assembly (8) and hose assembly
   (6) from brake valve (5).

5. Remove three bolts (9) located inside the cab,
and remove brake valve (5) from the
machine. This operation is in the Operator's
Station, Disassembly And Assembly section.
31
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Install Brake Foot Control Valves
1. Put brake valve (1) in position under the cab,
and install the three bolts inside the cab that
hold it in place.

1. Connect tube assembly (4) and hose assembly (2)
   to brake valve (1).
2. Connect wire assemblies (3) to the brake valve.

• Connect hose assemblies (5), (6), (7) and (8) to
  the brake valve.
• END BY
• install brake pedal
• install windshield washer reservoir (if only the
  left brake foot control valve was removed)
• install lower cab shrouds
• This operation is in the Operator's Station,
  Disassembly And Assembly section.
• If only the left brake valve was removed,
  install the front left hand shroud and the front
  shroud. If only the right brake valve was
  removed, install the right hand shroud and the
  front shroud.

33
Disassemble Brake Foot Control Valves
START BY a. remove brake foot control valve
Retainer (3) holds spring (1) under compression.
To prevent personal injury, carefully remove the
retainer.
1. Remove retainer (3), piston assembly (2) and
spring (1) from the valve body.

1. Remove O-ring seal (5) from the piston.
2. Remove bolt (8) and the washer. Remove seat (7)
   and spring (6) from piston (4).

4. Use tool (A) to remove snap ring (9) and the
washer.
34
5. Remove valve assembly (10) from the valve
body. Remove the O-ring seal from the valve.

1. Remove screw (18) and the washer, diaphragm (17)
   and spring (16) from seat (15).
2. Remove valve (11) and spring (14) from the seat.
3. Remove O-ring seal (13) and retainer (12) from
   the valve.

Assemble Brake Foot Control Valves

1. Install the O-ring seal, retainer (4) and spring
   (2) on valve (3).
2. Put seat (1) in position on the valve. Install
   the spring, diaphragm, washer and bolt in the
   seat.
3. Install the O-ring seal in the valve body.

4. Install valve assembly (6), washer (7) and
snap ring (8) in valve body (5). Use tool (A) to
install the snap ring.
35
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