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928G WHEEL LOADER

Printed by Heavy Equipment Manuals v2.20

Printed in U.S.A

Heavy Equipment Manuals













 



 



 



























































































































































































































































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

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



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

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

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

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









  Product: WHEEL LOADER Model: 928G WHEEL LOADER WLG Configuration: 928G Wheel Loader and IT28G Integrated Toolcarrier WLG00001-UP (MACHINE) POWERED BY 3056E Engine

Disassembly and Assembly 3056E Engine for Caterpillar Built Machines Media Number -RENR2400-06

Publication Date -01/02/2006

Date Updated -03/05/2017

i01844640

Alternator - Install SMCS - 1405-012

Installation Procedure

Illustration 1

g00999586

1. Put the alternator in position on the alternator bracket on the engine. 2. Install the fasteners for the pivot (1) and tighten finger tight.

This is the sample of the manual click on the download link for complete manual

DOWNLOAD LINK For some reason if link does not work download this pdf and then click

3. Install the adjustment link and the fasteners (2) for the adjustment link. Tighten the fasteners (2) finger tight. 4. Install the V-belts in position on the pulley. Adjust the tension on the V-belts by moving the alternator away from the engine. Tighten the fasteners (2) for the adjustment link after the correct belt tension has been set. Refer to the Systems Operation/Testing and Adjusting Manual, "V-Belt Test" for the correct tension of the V-belts. Tighten fasteners (2) for the adjustment link to a torque of 78 N·m (58 lb ft). 5. Tighten the fasteners for the pivot (1) in order to secure the alternator in position on the engine to a torque of 22 N·m (16 lb ft). 6. Reconnect the electrical wires to the alternator. Refer to the Specifications Manual, "Alternator" for the correct torques for the terminal nuts. Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.

Mon Sep 27 11:52:31 UTC+0530 2021

Disassembly and Assembly 3056E Engine for Caterpillar Built Machines Media Number -RENR2400-06

Publication Date -01/02/2006

Date Updated -03/05/2017

i01776356

Alternator - Install SMCS - 1405-012

Installation Procedure

Illustration 1

g00908147

1. Put alternator (3) in position on the engine. 2. Install bolts (2) and the washers. 3. Install nuts (1) that fasten the alternator to the alternator bracket. Tighten nuts (1) finger tight.

Illustration 2

g00907181

4. Install tension adjustment bolt (5) and the washer through the adjustment bracket and into the alternator. Do not tighten tension adjustment bolt (5) at this time. 5. Install V-belts (4) in position on the pulley. Adjust the tension on V-belts (4) by moving alternator (3) away from the engine. Tighten tension adjustment bolt (5) after the proper belt tension is made. Refer to Specifications, "Belt Tension Chart" for the correct tension of the Vbelts.

Illustration 3

g00907180

Mon Sep 27 11:52:06 UTC+0530 2021

Disassembly and Assembly 3056E Engine for Caterpillar Built Machines Media Number -RENR2400-06

Publication Date -01/02/2006

Date Updated -03/05/2017

i01895190

Alternator - Remove SMCS - 1405-011

Removal Procedure 1. Disconnect the electrical wires from the alternator.

Illustration 1

g00999586

2. Loosen the fasteners for the pivot (1) from the alternator bracket. 3. Loosen the fasteners for the adjustment link (2) and slide the alternator toward the engine in order to slacken the V-belts. Remove the V-belts from the pulley.

4. Remove the fasteners for the adjustment link (2) and remove the adjustment link from the alternator. 5. Support the alternator. Remove the fasteners for the pivot (1) and remove the alternator from the engine. Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.

Mon Sep 27 11:51:45 UTC+0530 2021

Disassembly and Assembly 3056E Engine for Caterpillar Built Machines Media Number -RENR2400-06

Publication Date -01/02/2006

Date Updated -03/05/2017

i01774077

Alternator - Remove SMCS - 1405-011

Removal Procedure 1. Place an index mark on all of the electrical wires that are connected to the alternator. Disconnect the electrical wires from the alternator.

Illustration 1

g00907180

2. Loosen nuts (1) and bolts (2) from the alternator bracket.

Illustration 2

g00907181

3. Loosen tension adjustment bolt (5) and slide alternator (3) toward the engine. Remove V-belts (4) from the pulley. 4. Remove tension adjustment bolt (5) and the washer from alternator (3).

Illustration 3

g00908147

5. Remove nuts (1) and the washers. 6. Remove bolts (2) from the alternator bracket. 7. Remove alternator (3) from the engine. Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.

Mon Sep 27 11:51:22 UTC+0530 2021

Disassembly and Assembly 3056E Engine for Caterpillar Built Machines Media Number -RENR2400-06

Publication Date -01/02/2006

Date Updated -03/05/2017

i01773087

Atmospheric Pressure Sensor - Remove and Install SMCS - 1923-010

Removal Procedure

Illustration 1

g00906557

1. Cut cable strap (1) and disconnect harness assembly (2).

Illustration 2

g00906558

2. Remove atmospheric pressure sensor (3).

Installation Procedure

Illustration 3

1. Install atmospheric pressure sensor (3).

g00906558

Illustration 4

g00906557

Mon Sep 27 11:48:05 UTC+0530 2021

Disassembly and Assembly 3056E Engine for Caterpillar Built Machines Media Number -RENR2400-06

Publication Date -01/02/2006

Date Updated -03/05/2017

i05977048

Bearing Clearance - Check SMCS - 1203-535; 1219-535

Measurement Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

198-9142

Plastic Gauge (Green) 0.025 to 0.076 mm (0.001 to 0.003 inch)

198-9143

Plastic Gauge (Red) 0.051 to 0.152 mm (0.002 to 0.006 inch)

198-9144

Plastic Gauge (Blue) 0.102 to 0.229 mm (0.004 to 0.009 inch)

198-9145

Plastic Gauge (Yellow) 0.230 to 0.510 mm (0.009 to 0.020 inch)

Note: Plastic gauge may not be necessary when the engine is in the chassis.

NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Note: Cat does not recommend the checking of the actual bearing clearances particularly on small engines. This is because of the possibility of obtaining inaccurate results and the possibility of damaging the bearing or the journal surfaces. Each Cat engine bearing is quality checked for specific wall thickness. Note: The measurements should be within specifications and the correct bearings should be used. If the crankshaft journals and the bores for the block and the rods were measured during disassembly, no further checks are necessary. However, if the technician still wants to measure the bearing clearances, Tooling (A) is an acceptable method. Tooling (A) is less accurate on journals with small diameters if clearances are less than 0.10 mm (0.004 inch).

NOTICE Lead wire, shim stock or a dial bore gauge can damage the bearing surfaces.

The technician must be very careful to use Tooling (A) correctly. The following points must be remembered: • Ensure that the backs of the bearings and the bores are clean and dry. • Ensure that the bearing locking tabs are properly seated in the tab grooves. • The crankshaft must be free of oil at the contact points of Tooling (A). 1. Put a piece of Tooling (A) on the crown of the bearing that is in the cap. Note: Do not allow Tooling (A) to extend over the edge of the bearing. 2. Use the correct torque-turn specifications in order to install the bearing cap. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed. Note: Do not turn the crankshaft when Tooling (A) is installed. 3. Carefully remove the cap, but do not remove Tooling (A). Measure the width of Tooling (A) while Tooling (A) is in the bearing cap or on the crankshaft journal. Refer to Illustration 1.

Illustration 1

g01152855

Typical Example

4. Remove all of Tooling (A) before you install the bearing cap. Note: When Tooling (A) is used, the readings can sometimes be unclear. For example, all parts of Tooling (A) are not the same width. Measure the major width in order to ensure that the parts are within the specification range. Refer to Specifications Manual, "Connecting Rod Bearing Journal" and Specifications Manual, "Main Bearing Journal" for the correct clearances. Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.

Mon Sep 27 11:47:43 UTC+0530 2021

Disassembly and Assembly 3056E Engine for Caterpillar Built Machines Media Number -RENR2400-06

Publication Date -01/02/2006

Date Updated -03/05/2017

i01755583

Camshaft - Remove and Install SMCS - 1210-010

Removal Procedure Start By: a. Remove the rocker shaft assembly and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Remove". b. Remove the fuel transfer pump. Refer to Disassembly and Assembly, "Fuel Transfer Pump Remove". c. Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove". d. Remove the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install".

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

1. Turn the engine upside-down so the valve lifters are held in a position away from the camshaft.

Illustration 1

g00546803

2. Remove thrust washer (1). Make a note of the location of the hollow dowel (X) for installation purposes.

Illustration 2

g00546869

NOTICE Do not damage the lobes or the bearings when the camshaft is removed or installed.

3. Carefully remove camshaft (2) from the engine.

Installation Procedure

Illustration 3

g00546869

Note: Ensure that camshaft (2) is clean. Lubricate camshaft (2) with clean engine oil prior to installation. 1. Carefully install camshaft (2) in the engine.

Illustration 4

g00546803

2. Put thrust washer (1) in position. Make sure that thrust washer (1) is aligned with hollow Dowel (X). End By: a. Install the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install". b. Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install". c. Install the fuel transfer pump. Refer to Disassembly and Assembly, "Fuel Transfer Pump Install". d. Install the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrods - Install". Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.

Mon Sep 27 11:41:00 UTC+0530 2021

Disassembly and Assembly 3056E Engine for Caterpillar Built Machines Media Number -RENR2400-06

Publication Date -01/02/2006

Date Updated -03/05/2017

i01778792

Camshaft Bearings - Remove and Install SMCS - 1211-010

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

8S-2241

Camshaft Bearing Tool Group

8H-0684

Ratchet Wrench

Start By: A. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove and Install".

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g00546238

1. Use Tooling (A). Apply 4C-5591 Anti-Seize Compound to the threads of Tooling (A) .

Illustration 2

g00546333

2. Remove camshaft bearings (1) from the cylinder block.

Installation Procedure Table 2 Required Tools Tool

Part Number

Part Description

Qty

8S-2241

Camshaft Bearing Tool Group

8H-0684

Ratchet Wrench

NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 3

g00546238

Illustration 4

g00546333

1. Use Tooling (A) in order to install camshaft bearings (1). Apply 4C-5591 Anti-Seize Compound to the threads of Tooling (A) . End By: Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove and Install". Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.

Mon Sep 27 11:41:40 UTC+0530 2021

Disassembly and Assembly 3056E Engine for Caterpillar Built Machines Media Number -RENR2400-06

Publication Date -01/02/2006

Date Updated -03/05/2017

i03140046

Camshaft Gear - Remove and Install SMCS - 1210-010-GE

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Name

Qty

1U-6671

Puller Gp

8S-4712

Bolt

1P-0510

Driver Group

Start By: a. Remove the fan. Refer to Disassembly and Assembly, "Fan - Remove and Install". b. Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove".

Illustration 1

g00541128

1. Rotate the crankshaft until the timing marks on the crankshaft gear, the camshaft gear, and the fuel injection pump gear are aligned, as shown. Note: The timing marks on the idler gear may not be aligned. This is caused by the difference in the speed of the rotation of the idler gear.

Illustration 2

g00541130

2. Remove bolt (1) and the washer from the camshaft gear (2).

Illustration 3

g00541131

3. Install Tooling (A) and remove camshaft gear. Note: Do not lose the key from the camshaft gear. 4. Inspect the camshaft gear for wear and damage. Replace the gear, if necessary.

Installation Procedure

Illustration 4

g00541130

1. Install camshaft gear (2) in the front housing. Note: When you install the camshaft gear, ensure that the teeth that have the timing marks are facing toward the front. Also, ensure that the key is aligned properly in the keyway. If necessary, tap the gear with a soft hammer in order to seat the key in the keyway. 2. If necessary, remove the idler gear in order to align the gear teeth correctly. 3. Install the washer and bolt (1) on the camshaft gear. Tighten bolt (1) to a torque of 95 N·m (70 lb ft).

Note: Ensure that the timing marks on the camshaft gear, the crankshaft gear, and the fuel injection pump gear are aligned. 4. If a new camshaft gear is used, check the backlash of the camshaft gear. The minimum backlash for a new gear is 0.08 mm (0.003 inch). End By: a. Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Install". b. Install the fan. Refer to Disassembly and Assembly, "Fan - Remove and Install". Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.

Mon Sep 27 11:41:19 UTC+0530 2021

This is the sample of the manual click on the download link for complete manual

DOWNLOAD LINK For some reason if link does not work download this pdf and then click

CAT Caterpillar 928G Service Repair Manual PDF Download