Testing & Adjusting 926e Wheel Loader 8NB01542-02451

926E WHEEL LOADER 8NB01542-02451 (MACHINE) POWERED BY 3204 ENGINE(XMBP9855 - 00) - Documentation
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Product: WHEEL LOADER

Model: 926 WHEEL LOADER 8NB
Configuration: 926E WHEEL LOADER 8NB01542-02451 (MACHINE)
POWERED BY 3204 ENGINE
Testing and Adjusting

926 & 926E WHEEL LOADER HYDRAULIC SYSTEM
Media Number -SENR3071-01 Publication Date -01/11/1988 Date Updated -11/10/2001
Testing And Adjusting
Introduction
NOTE: For Specifications with illustrations make reference to the Specifications for 926 AND 926E Wheel Loaders
Hydraulic System, Form No. SENR3070. If the Specifications given in Form SENR3070 are not the same as listed in
the Systems Operation and the Testing and Adjusting, look at the printing date on the back cover of each book. Use the
Specifications listed in the book with the latest date.
Hydraulic System
Sudden movement of the machine or release of oil under pressure can

cause injury to persons on or near the machine. To prevent possible
injury, do the procedure that follows before testing and adjusting the
hydraulic system:
1. Move the machine to a smooth horizontal location. Move away from working machines and personnel.
2. Permit only one operator on the machine. Keep all other personnel either away from the machine or in view of the
operator.
3. Activate the parking brake. With the engine running, lower the bucket to the ground. When the bucket is raised for
tests or adjustments, be sure that the bucket has correct support and the bucket is fully in the DUMP position. The lift
circuit has high oil pressure when the lift arms raise the front of the machine. Do not stop the engine with the front of
the machine off of the ground. Lower machine to the ground and stop the engine.
4. Install the anti-pivot link.
5. Move the hydraulic control levers to all positions to release the pressure in the hydraulic system.
6. Carefully loosen the filler cap on the hydraulic tank to release the pressure in the tank.
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7. Make sure all hydraulic pressure is released before any fitting, hose or component is loosened, tightened, removed or
adjusted.
8. Tighten the filler cap on the hydraulic tank.
9. The pressure in the system has now been released and lines or components can be removed.
During a diagnosis of the hydraulic system, remember that correct oil flow and pressure are necessary for correct
operation. The output of the pump (oil flow) increases with an increase in engine speed (rpm) and decreases when
engine speed (rpm) is decreased. Oil pressure is caused by resistance to the flow of oil.
Visual checks and measurements are the first step when troubleshooting a possible problem. Then do the Operation
Checks and last the Instrument Tests.
Use the 5S5123 and 6V4161 Hydraulic Test Groups, a stop watch, a magnet, a thermometer and a mm (inch) ruler for
basic tests to measure:
1. The pressure of the oil to open the main relief valve and the relief valves force the tilt and attachment circuits. Relief
valve pressures that are too low will cause a decrease in the performance of the machine. Pressures that are too high will
cause a decrease in the life of hoses and components.
2. Drift rates in the lift and tilt circuits: Circuit drift is caused by leakage past cylinder pistons, O-ring seals in the
control valves, check valves or makeup valves that do not seat correctly or poor adjustment or fit in the control valves.
3. Cycle times in the lift and tilt circuits: Cycle times that are longer than those shown are the result of leakage, pump
wear and/or pump speed (rpm).
If the basic tests give an indication of circuit leakage, install a flow meter and do a system test. This procedure will find
the source of the leakage.
Visual Checks
A visual inspection of the hydraulic system and its components is the first step when identifying a problem. Stop the
engine and lower the implements to the ground. To remove the tank filler cap, slowly turn the filler cap until it is loose.
If oil comes out, let the tank pressure lower before the filler cap is removed. Make the following inspections:
Do not check for leaks with your hands. Pin hole (very small) leaks can
result in a high velocity oil stream that will be invisible close to the hose.
This oil can penetrate the skin and cause personal injury. Use
cardboard or paper to locate pin hole leaks.
1. Check all implement oil line connections for damage and leaks.
2. Follow all implement oil lines from the implement connections to valve connections. Check the lines and connections
for damage and leaks.
3. Check the control valves for leaks.

4. Check the pump and connections for damage and leaks.
5. Follow the pump lines to the tank and valves. Check the lines and tank for damage and leaks.
6. Check tank oil level.
7. Use a clear bottle or container to get an oil sample from the tank immediately after the machine is stopped. Check for
air bubbles in the oil sample.
8. Remove the filter element and check for particles removed from the oil by the filter elements. A magnet will separate
ferrous particles from nonferrous particles (piston rings, O-rings, seals, etc.).
9. Inspect control linkage for bent, broken or damaged components.
Troubleshooting
Problem 1: Pump makes noise, the cylinder rods do not move smoothly and there are air
bubbles in the oil.
Probable Cause:
1. The viscosity of the oil is wrong.

2. The relief valve opens at low oil pressure.
3. Loose connection of the oil line on the inlet side of the pump.
4. The pump has too much wear.
Problem 2: The temperature of the oil is too hot.
Probable Cause:

4. There is a restriction in an oil passage.
5. The load of the system is too high.
6. Low oil level.
7. Air in the hydraulic oil.
NOTE: If the problem is because of air in the oil, it must be corrected before the system will operate at normal
temperatures. There are two things that cause air in the oil (aeration).
a. Return oil to the tank goes in above the level of the oil in the tank.
b. Air leaks in the oil suction line between the pump and the tank.
Problem 3: The output of the pump is low.
Probable Cause:
1. Low level of oil in the tank.


Problem 4: The pressure of the oil is low.
Probable Cause:

3. The failure of an O-ring seal in the system.
4. The control valve and valve spool have a large amount of wear.
Problem 5: Implement moves with control lever in HOLD position.
Probable Cause:
1. The control valve and valve spool have a large amount of wear.
2. A piston seal in a cylinder has a large amount of wear.
3. A leak in a connection between the control valve and the cylinders.
4. A leak check valve not closing because of dirt or a worn seat.
Problem 6: Implement droops when control lever is shifted from HOLD to LIFT.
Probable Cause:
1. Load check valve not closing.
a. Weak or broken spring.

b. Dirt or debris in valve.
Operation Checks
The control valves have a parallel circuit arrangement. The hydraulic pump and the pressure relief valve are common to
all circuits. Each valve section has a check valve to help prevent cylinder drift when the valve spool is first moved.
Relief valves help give protection to system components from too much pressure. The main relief valve is also a
makeup valve. Makeup valves let extra oil go to the cylinders when needed.
The operation checks can be used to find leakage in the system. They can also be used to find a bad valve or pump.
The oil in the hydraulic system must be at operating temperature of 38 to 54°C (100 to 130°F).
Extend and retract each implement cylinder several times.
1. Watch the cylinder as it is extended and retracted. Movement must be smooth and regular.
2. Listen for noise from the pump.
3. Listen for the sound of the relief valve. It must not open except when the cylinders are fully extended or retracted.
The pressure setting of the relief valve can lower the performance of the machine. A too high pressure setting will cause
a reduction in the life of hoses and other parts of the system.
4. Allow the implement cylinders to travel full stroke in each direction.
5. Put each control valve in HOLD while implement is off the ground. Watch for excessive cylinder rod drift.

Implement cylinder drift is caused by leakage past cylinder piston seals, control valve seals, check or make-up valves
and/or too much spool to valve body clearance.
Lift And Tilt Cylinder Drift Tests

The drift rates will change with different conditions of the hydraulic components as well as with the operation, the type
of bucket (empty or loaded), hydraulic oil temperature, etc.
The values shown are for an empty bucket. Before measuring drift on the cylinder rod, the cylinders must be extended at
least five times. Check the oil temperature.
To check the lift circuit, lift the bucket to maximum height and move the lift control lever to the HOLD position.
Measure the distance (and check the time) that the lift cylinders retract, with the chart.
NOTE: The drift distances in the charts are for new machines.
To check the tilt circuit, lift the bucket to maximum height, and move the lift control lever to the HOLD position.
Activate the tilt circuit until the bucket is at the angle to dig (almost level) and move the tilt control lever to the HOLD
position. Measure the distance (and check the time) that the tilt cylinder retracts, with the chart.
NOTE: The drift distances in the charts are for new machines.
If the cylinder drift is too much:
1. Check the makeup valves in the lift and tilt control valves.
2. Check the condition of the valve spools in the lift and tilt control valves.

3. Check the piston seals in the cylinders.
Lift And Tilt Cylinder Speed Tests

Start and run the engine at high idle rpm. Lift and lower the lift arms again and again to increase the temperature of the
hydraulic oil.
The oil in the system must be SAE 10 and at a temperature of 65 ± 3°C (150 ± 5°F) to get accurate test results. All speed
tests are made with the engine at high idle. The speeds in the chart are those of machines equipped with a general
purpose bucket.
If the travel times are not correct:
1. Check the pump efficiency.
2. Check the setting of the relief valves.
3. Check the makeup valves in the lift and tilt control valves.
4. Check the valve spools in the lift and tilt control valves.
5. Check the piston seals in the cylinders.
Checking Pump Efficiency

For any pump test, the pump flow, measured in U.S. gpm (liter/min) at 100 psi (690 kPa) will be larger than the pump
flow at 1000 psi (6900 kPa) at the same rpm.
The difference between the pump flow of two operating pressures is the flow loss.
Method of finding flow loss:

Flow loss when expressed as a percent of pump flow is used as a measure of pump performance.
Example of finding percent of flow loss:
If the percent of flow loss is more than 10%, pump performance is not good enough.
*Numbers in examples are for illustration and are not values for any specific pump or pump condition, See
specifications for 926 And 926E Wheel Loaders Hydraulic System, Form SENR3070, for pump flow of a new pump at
100 psi and 1000 psi.
Test On The Machine
Install a flow meter. Run the engine at high idle. Measure the pump flow at 100 psi (690 kPa) and at 1000 psi (6900
kPa). Use these values in Formula I.
Formula I:
Test On The Bench
If the test bench can be run at 1000 psi and at full pump rpm, find the percent of flow loss using Formula I.
If the test bench can not be run at 1000 psi at full pump rpm, run the pump shaft at 1000 rpm. Measure the pump flow at
100 psi (690 kPa) and at 1000 psi (6900 kPa). Use these values in the top part of Formula II. For the bottom part of the
formula, run the pump shaft at 2000 rpm. Measure the pump flow at 100 psi.
Formula II:

Relief Valve Tests
Make reference to WARNING on first page of Hydraulic System

Testing And Adjusting section.
Main Relief Valve
6V4161 Hydraulic Test Group.
Right Side Of Machine (Under Cab)

(1) Pressure tap for main oil pressure. (2) Main relief valve.
1. Lower the bucket so it is on the ground and can not be tilted. Remove the shroud from under the right side of the cab.
2. Connect a 6V3081 Hose to pressure tap (1) with a 6V4143 Coupler. Install a 28 000 kPa (4000 psi) pressure gauge.
3. Start the engine and raise the lift arms to the top of their travel.

Main Relief Valve

(3) Nut. (4) Retainer.
4. Increase the engine rpm to high idle. Look at the test gauge and move the lift control lever to the RAISE position. The
high reading on the gauge is the pressure setting of the main relief valve (do not keep the control lever in RAISE
position, at the relief valve setting, more than 5 seconds). The correct pressure setting of the main relief valve is 17 300
± 300 kPa (2500 ± 45 psi).
5. If a pressure change is needed, lower the bucket to the ground and stop the engine. Loosen nut (3) on the main relief
valve. Turn retainer (4) clockwise for an increase or counterclockwise for a decrease in the pressure setting of main
relief valve (2).
6. When the pressure setting is correct, tighten nut (3) to a torque of:
7. Remove the test equipment.
NOTE: If the line relief valves are to be tested, do not install the shroud.
Relief Valve For Rod End Of Tilt Cylinder

6V4161 Hydraulic Test Group.
1. Connect a 6V3081 Hose to pressure tap (5) with a 6V4143 Coupler. Install a 28 000 kPa (4000 psi) pressure gauge.
2. Start the engine and lift the lift arms until they are parallel with the ground. Move the tilt control lever to DUMP

position until the bucket is fully dumped. Release the tilt control lever.
Right Side Of Tilt Cylinder

(5) Pressure tap for rod end of tilt cylinder.
Right Side Of Machine

(6) Relief valve for the rod end of the tilt cylinder.
3. Increase engine rpm to high idle. Look at the test gauge and move the lift control lever to RAISE position. The high
reading on the test gauge is the pressure setting of the relief valve. The high reading on the test gauge must be 15 500 ±
300 kPa (2250 ± 45 psi).
Relief Valve For Rod End Of Tilt Cylinder

4. If it is necessary to change the pressure setting of relief valve (6), lower the bucket to the ground and stop the engine.
5. Loosen nut (7) and turn retainer (8) either clockwise for an increase or counterclockwise for a decrease in the pressure
setting of relief valve (6).

6. When the pressure setting is correct, tighten nut (7) to a torque of:
7. Remove the test equipment.
NOTE: If a test is to be made for the relief valve for the head end of the tilt cylinder, do not install the shroud.
Relief Valve For Head End Of Tilt Cylinder

6V4161 Hydraulic Test Group.3S6224 Electric Hydraulic Pump.5H4019 Cover.Miscellaneous Fittings.
Left Side Of Tilt Cylinder

(9) Pressure tap for head end of tilt cylinder. (10) Hose assembly to head end of tilt cylinder.
The relief valve for the head end of the tilt cylinder has a higher pressure setting than the main relief valve. Because of
this high pressure setting an 3S6224 Electric Hydraulic Pump is used to test the relief valve.
1. Stop the engine with the bucket on the ground. Move the tilt control lever to all positions to release the pressure in the
tilt circuit.
2. Disconnect hose assembly (10) and install a 5H4019 Cover in the line. Connect hose assembly (10).
3. Connect a 6V3081 Hose to pressure tap (9) with a 6V4143 Coupler.

Right Side Of Machine

(11) Relief valve for the head end of the tilt cylinder.
4. Install tee (17) and a 28 000 kPa (4000 psi) pressure gauge (12) with the correct fittings to the 6V3081 Hose. Connect
the 3S6224 Electric Hydraulic Pump to the tee.
Typical Gauge And Fittings

(12) Pressure gauge. (13) 1P2375 Coupler. (14) Coupler. (15) Adapter. (16) Nipple. (17) Tee. (18) Nipple.
5. Look at the test gauge and operate the electric hydraulic pump. The gauge reading must be 19 300 ± 300 kPa (2800 ±
45 psi).
6. If relief valve (11) needs an adjustment, loosen nut (7) and turn retainer (8) either clockwise for an increase or
counterclockwise for a decrease in the pressure setting of relief valve (11).
Relief Valve For Head End Of Tilt Cylinder

7. When the pressure setting is correct, tighten nut (7) to a torque of 24 ± 2 N·m (18 ± 1 lb ft). Remove the test
equipment. Install the shroud.
Relief Valves For Attachment Cylinders
Use the same basic procedures to test these line relief valves as is given for the tilt relief valves. The method to read the
pressure settings will change according to the optional equipment on the machine.

Location Of Pressure Taps For Front Attachments (Typical Example)
Location Of Relief Valves For Attachment Cylinders (Typical Example)
Hydraulic Oil Temperature (Too Hot)

When the temperature of the hydraulic oil gets over 98.8°C (210°F), polyurethane seals in the system start to fail. High
oil temperature causes seal failure to become more rapid. There are many reasons why the temperature of the oil will get
this hot.
1. Hydraulic pump is badly worn.

2. Heavy hydraulic loads that cause the main relief valve to open.
3. The setting on the main relief valve is too low.
4. Too many restrictions in the system.
5. Hydraulic oil level in the tank is too low.
6. High pressure oil leak in one or more circuits.
7. Very dirty oil.
8. Air flow through the optional oil cooler core is too low.
9. Oil flow through the optional oil cooler is too low.
10. Air in the hydraulic oil.
NOTE: If the problem is because of air in the oil, it must be corrected before the system will operate at normal
temperatures. There are two things that cause air in the oil (aeration).
a. Return oil to the tank goes in above the level of the oil in the tank.
b. Air leaks in the oil suction line between the pump and the tank.
Bucket Positioner Adjustment Procedure


Bucket Positioner Adjustment

(1) Tube assembly. (2) Magnet assembly. (3) Switch assembly (under cover). (4) Screw. (5) Bolt (two). (A) Dimension 5 ± 1 mm (.20 ± .04 in).
1. With the engine running, move the tilt control lever to put the bucket at the correct angle to dig. Move the tilt control
lever to the HOLD position. Lower the bucket to the ground and stop the engine.
2. Make sure that magnet assembly (2) has its longer length perpendicular (in a vertical position) to tube assembly (1).
Tighten the set screws in the magnet assembly.
3. Measure dimension (A) between magnet assembly (2) and switch assembly (3). The correct dimension is 5 ± 1 mm
(.20 ± .04 in).
4. To change dimension (A), loosen bolts (5) then tighten screw (4) just enough to move tube assembly (1) and the
switch away from magnet assembly (2). Switch assembly (3) must be vertically centered with magnet assembly (2).
5. Move tube assembly (1) until the front edge of switch assembly (3) is even (flush) with the front edge of magnet
assembly (2).
6. Loosen screw (5) and tighten two bolts (6).
7. Start and run the engine. Put the lift arm assembly parallel to the ground with the bucket in a full DUMP position. Put
the tilt control lever in the TILT BACK (detent) position. The action of the bucket positioner moves the control lever
from TILT BACK to HOLD position when the bucket is at the correct angle to dig.
NOTE: If the til control lever does not move to the HOLD position at all, check the kickout solenoid adjustment.
8. If the bucket angle to dig was too flat, move tube assembly (1) and the switch toward the bucket. If the angle to dig
was too much, move tube assembly (1) and switch toward the tilt cylinder.
Lift Kickout Adjustment Procedure


Lift Kickout
(1) Magnet assembly. (2) Switch assembly. (3) Lift arm.
1. Lift the bucket to the desired height.
2. Adjust magnet assembly (1) on lift arm (3) so that the lower edge of the magnet is even with the center of switch
assembly (2).
3. Adjust switch assembly (2) to get a clearance between the switch and magnet assembly (1) of 5 ± 1 mm (.20 ± .04 in).
4. Tighten the bolts that hold the magnet assembly in place.
5. Start and run the engine. The lift kickout switch action must move the lift control lever from RAISE to HOLD
position before the lift arm assembly gets to the top of its travel.
NOTE: If the tilt control lever does not move to the HOLD position at all, check the kickout solenoid adjustment.
6. If the kickout was too soon, move magnet assembly (1) away from switch assembly (2). If the kickout was not soon
enough (cylinder pistons hit the heads inside the lift cylinders), move magnet assembly (1) toward switch assembly (2).
Kickout Solenoid Adjustment Procedure


Lift And Tilt Control Linkage

(1) Kickout solenoid. (2) Solenoid plunger. (3) Locknut. (4) Threaded rod. (5) Detent. (6) Roller.
1. Be sure the lift kickout and bucket positioner are correctly located.
2. Raise the bucket as high as it will go and tilt it back to the limit of its travel. This is to make sure that kickout
solenoids (1) will be energized (have electrical power to pull solenoid plunger (2) in) when the key switch is on. Use
blocks or jack stands to support the lift arms and bucket in this position.
3. Be sure the key switch is on to energized kickout solenoids (1). Each solenoid plunger (2) should be pulled into its
solenoid body. Measure the distance between the top of solenoid plunger (2) and the solenoid mounting surface,
distance X.
4. Turn the key switch off to remove the electrical power from the solenoids.
5. Move the lift control lever to the RAISE detent position. Move the tilt control lever to the TILT BACK detent
position. Roller (6) should be in detent (5).

6. Distance Y is the distance from the top of the extended solenoid plunger to the solenoid plunger mounting surface.
Measure distance with all slack removed from the linkage. It must equal distance X + 13 mm (.05 in). If not, loosen
locknut (3) on threaded rod (4) and turn solenoid plunger (2) on threaded rod (4) until distance Y is correct.
7. Turn the key switch on to energize the kickout solenoids. The solenoid plungers must be pulled in and the lift and tilt
control levers must release from the detent position.
8. Repeat Steps 4, 5 and 7 several times to check the operation of the kickout solenoids.
9. Repeat Steps 4, 5 and 6 to check dimension Y.
10. Tighten locknut (3) on threaded rod (4).
Copyright 1993 - 2020 Caterpillar Inc. Tue Sep 22 01:39:15 UTC+0200 2020
All Rights Reserved.
Private Network For SIS Licensees.

Testing & Adjusting 926e Wheel Loader 8NB01542-02451

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926E WHEEL LOADER 8NB01542-02451 (MACHINE) POWERED BY 3204 ENGINE(XMBP9855 - 00) - Documentation

Product: WHEEL LOADER

Testing and Adjusting

Testing And Adjusting

Sudden movement of the machine or release of oil under pressure can

4. Install the anti-pivot link.

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8. Tighten the filler cap on the hydraulic tank.

3. Check the control valves for leaks.

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4. Check the pump and connections for damage and leaks.

6. Check tank oil level.

9. Inspect control linkage for bent, broken or damaged components.

1. The viscosity of the oil is wrong.

Problem 2: The temperature of the oil is too hot.

1. The viscosity of the oil is wrong.

Problem 3: The output of the pump is low.

1. Low level of oil in the tank.

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Problem 4: The pressure of the oil is low.

1. The relief valve opens at low oil pressure.

Problem 5: Implement moves with control lever in HOLD position.

1. Load check valve not closing.

a. Weak or broken spring.

Extend and retract each implement cylinder several times.

2. Listen for noise from the pump.

4. Allow the implement cylinders to travel full stroke in each direction.

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Lift And Tilt Cylinder Drift Tests

If the cylinder drift is too much:

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3. Check the piston seals in the cylinders.

Lift And Tilt Cylinder Speed Tests

If the travel times are not correct:

1. Check the pump efficiency.

2. Check the setting of the relief valves.

5. Check the piston seals in the cylinders.

Checking Pump Efficiency

Method of finding flow loss:

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Example of finding percent of flow loss:

Test On The Machine

Test On The Bench

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Relief Valve Tests

Make reference to WARNING on first page of Hydraulic System

Main Relief Valve

6V4161 Hydraulic Test Group.

Right Side Of Machine (Under Cab)

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Main Relief Valve

7. Remove the test equipment.

Relief Valve For Rod End Of Tilt Cylinder

Make reference to WARNING on first page of Hydraulic System

6V4161 Hydraulic Test Group.

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Right Side Of Tilt Cylinder

Right Side Of Machine

Relief Valve For Rod End Of Tilt Cylinder

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7. Remove the test equipment.

Relief Valve For Head End Of Tilt Cylinder

Make reference to WARNING on first page of Hydraulic System