988b wheel loader s/n 50w1 & up...caterpillar 988b wheel loader service manual ct-s-988b w/l{83273},...

Serv

ice

Man

ual

Service Manual

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF CATERPILLAR OR IT’S SUCCESSORS. CATERPILLAR AND IT’S SUCCESSORS ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

988B Wheel Loader S/n 50W1 & Up

CT-S-988B W/L

http://www.jensales.com/products/caterpillar-988b-wheel-loader-service-manual-sn-50w1-and-up.html

3408 VEHICULAR ENGINE FOR 9888 WHEEL LOADER

SPECIFICATIONS

INTRODUCTION

The specifications given in this book are on the basis of information available at the time the book was written. These specifications give the torques, operating pressure, measurements of new parts, adjustments and other items that will affect the service of the product.

When the words "use again" are in the description, the specification given can be used to determine if a part can be used again. If the part is equal to or within the specification given, use the part again.

When the word "permissible" is in the description,

~!;~n~~;ec~~l~~~~~~ gi;:~m\Stt~~e '~~f~~~m~~u~~:ei~~~ @@ repair and/or new parts are needed.

A comparison can be made between the measure-ments of a worn part, and the specifications of a new part to find the amount of wear. A part that is worn can be safe to use if an estimate of the re-mainder of its service life is good. If a short service life is expected, replace the part.

NOTE: The specifications given for "use again" and "permissible" are in-tended for guidance only and Caterpillar Tractor Co. hereby expressly denies and excludes any representation, warranty or implied warranty of the reuse of any component. 77200Xl

ENGINE DESIGN

Bore ....................................................................................................................... 5.40 in. (137.2 mm)

Stroke .................................................................................................................... 6.00 in. (152.4 mm)

Number and Arrangement of Cylinders ........................................................................................... V-8

Firing Order (Injection Sequence) ......................................................................... 1, 8, 4, 3, 6, 5, 7, 2

Rotation of Crankshaft (when seen from flywheel end) .... ...... ... ... ....... ................. ...... ...... .... ... ...... ........ counterclockwise

Rotation of Fuel Pump Camshaft (when seen from pump drive end) ..... ............. ... ........ .............. ........... ... ........... counterclockwise

NOTE: Front end of engine is opposite to flywheel end. Left side and right side of engine are as seen from flywheel end. No.1 cylinder is the front cylinder on the left side. No.2 cylinder is the front cylinder on the right side.

NOTE: For System Operation and Testing and Adjusting, make reference to 3408 VEHICULAR ENGINE FOR 988B WHEEL LOADER, Form No. SENR7392.

INDEX

Air-Fuel Ratio Control.................................................................. 9 Governor ...................................................................................... 8 Alternator ............................................ ........................................ 30 Oil Bypass Valves .......... ............................................................ 19 Automatic Timing Unit (Drive for the Injection Pump) ............. .... 9 Oil Filter ...................................................................................... 19 Belt Tightener ............................................................................. 22 Oil Pan ....................................................................................... 18 Camshaft ............................................ ........................................ 16 Oil Pump .................................................................................... 18 Connecting Rod ........... ...................................... ............ ............ 25 Piston and Rings ............................ ............................................ 25 Crankshaft .......................................... ........................................ 26 Pressure Cap, Cooling System ................................................. 20 Cylinder Block .......... .......... .................................... .... ................ 23 Primary Fuel Filter ....................................................................... 6 Cylinder Heads .................................... ...................................... 15 Radiator ...................................................................................... 20 Cylinder Liner .................... .......... ............... .................. .......... .... 24 Rear Gear Group ....................................................................... 10 Cylinder Liner Projection ............ .......................................... ...... 24 Service Meter, Drive For ............................................................ 11 Drive and Oil Pump for the Governor ...................... ............ ...... 10 Starter Solenoid ......................................................................... 31 Engine Design ......................................... ............. .... .................... 2 Starting Motors (Electric) ............................................... ............ 30 Exhaust Manifold .................................... ................................... 16 Tachometer, Drive for ....... ......................................................... 11 Flywheel..................................................................................... 29 Timing Gears ..... ...... ... ..... ............ .............................................. 11 Flywheel Housing ........... ....... .............. ............. ..... ........ ............. 27 Timing Gear Housing ................... ............ ..... ............................. 27 Flywheel Housing Bore .. .............. .............................................. 28 Turbocharger .................. ................................................. ........... 17 Fuel Filter ..................................................................................... 6 V-Belt Tension Chart ................................................................. 22 Fuel Injection ......... ......... ..... .......... .................... ............ ............... 4 Valves ........................................................................................ 12 Fuel Injection Housing ................................................................. 5 Valve Covers .............................................................................. 14 Fuel Injection Pump, Drive for .......................... ....... .... ................ 9 Valve Rocker Anns, Lifters and Bridges ................................... 13 Fuel Transfer Pump ............ ............................ ............ ............ ..... 7 Fuel Transfer Pump, Drive for .................................... ................. 7

Water Pump ....... ...... ..... .... ........ .... .......... ........ ........................... 21 Water Temperature Regulator ................................................... 21

2


l' ~ \., "

C,>


SPECIFICATIONS

GENERAL TIGHTENING TORQUE FOR BOLTS, NUTS AND TAPERLOCK STUDS

The following charts give the standard torque values for bolts, nuts and taperlock studs of SAE Grade 5 or better quality. Exceptions are given in other sections of the Service Manual where needed.

THREAD DIAMETER

inches millimeters lb. ft.

Standard thread

STANDARD TORQUE

N'm*

~ [illi[[(D Use these torques for bolts and nuts with stan-

1/4

5/16

3/8

7/16

1/2

9/16

5/8

3/4

7/8

1 1 1/8 1 1/4 1 3/8 1 1/2

5/16

3/8

7/16

1/2

5/8

,

Tlperlock stud

6.35 7.94 9.53

11.11 12.70 14.29 15.88 19.05 22.23 25.40 28.58 31.75 34.93 38.10

7.94 9.53

11.11 12.70 15.88

dard threads (conversions are approximate).

9±3 12 ± 4 18 ± 5 25 ± 7 32 ±5 45 ± 7 50 ± 10 70'± 15 75 ± 10 100 ± 15

110 ± 15 150 ± 20 150 ± 20 200 ± 25 265 ± 35 360 ± 50 420 ± 60 570 ± 80 640 ± 80 875 ± 100 800 ± 100 1100 ± 150

1000 ± 120 1350 ± 175 1200 ± 150 1600 ± 200 1500 ± 200 2000 ± 275

Use these torques for bolts and nuts on hydraulic valve bodies.

13 ± 2 20± 3 24 ±2 35 ± 3 39 ±2 50 ± 3 60 ±3 80±4

118 ±4 160 ± 6

CDIID Use these torques for studs with Taperlock threads. 1/4 6.35 5±2 7±3 5/16 7.94 10 ± 3 15 ± 5 3/8 9.53 20 ±3 30±5 7/16 11.11 30 ±5 40 ± 10 1/2 12.70 40 ±5 55 ± 10 9/16 14.29 60 ± 10 80 ± 15 5/8 15.88 75 ± 10 100 ± 15 3/4 19.05 110±15 150 ± 20 7/8 22.23 170 ± 20 230 ± 30

1 25.40 260 ±30 350 ± 40 1 1/8 28.58 320 ±30 400 ± 40 1 1/4 31.75 400 ±40 550 ± 50 13/8 34.93 480 ±40 650 ± 50 11/2 38.10 550 ± 50 750 ± 70

*1 newton meter (N·m) is approximately the same as 0.1 mkg. T95416-7

3



FUEL INJECTION

Firing order (injection sequence) ... .... .. ... .. .. ... .. .... ... .. .... . 1.8.4.3.6.5.7.2

Injection timing before TC (top center) ........ .... ....... .. .... .... .. ....... ... .. 11 0

(1) Torque for bushing .......... ......... .. 150 ± 10 Ib.ft. (204 ± 14 N·m)

(2) S8634 Spring:

Length under test force ..... .. ... ..... ... .... .... ... .. ... .321 in. (8 .15 mm)

Test force ..... ... ... ....... .... ... ... . .190 ± .010 lb. (0.086 ± 0.005 kg)

Free length after test .... ... ..... ... ...... ... ........ .... .418 in. (10.62 mm)

Outside diameter .. ... ...... ............. .. ..... .. ...... .. ... .388 in. (9.86 mm)

(3) Thickness of spacers:

5M2697 Spacer ......... ... .. ... ........... .... ...... ........ . 170 in. (4.32 mm)

2M4208 Spacer ... ..... ........ ....... ... .. .... .... ..... .. .... 174 in . (4.42 mm)

2M4209 Spacer .. .. ....... .. ... ....... ...... ... ... ..... ....... 178 in. (4 .52 mm)

2M4210 Spacer .... ....... .. ... .. ... ... ............ ..... .... . . 182 in. (4.62 mm)

2M4211 Spacer ..... ......... ........ .... ... ...... .. ... .... .. . 186 in. (4.72 mm)

2M4212 Spacer ... .... ..... .. ... .. ...... ... .... ... ... .. ..... . . 190 in. (4.83 mm)

5M2691 Spacer .... .. ...... .. ........ .. .......... .. .. .... .. .. . 194 in. (4.93 mm)

5S7189 Spacer .. .. .. .. .... .. .. .. ...... .... .. .. .... .. .... .. .... 198 in. (5.03 mm)

(4) lS7592 Spring:

Length under test force .... .... .. .. .. ...... .. .... .... 1..522 in. (38.66 mm)

Test force .. .. .. .... : ...... .... ...... .. 22.6 ± 1.1 lb. (10.250 ± 0.500 kg)

Free length after test .. .. .. .... .. .......... .. .......... 1.751 in. (44.48 mm)

Outside diameter .. .. .. .... .. ...... .. .... .. .... .. ...... .... .. 1.00 in. (25.4 mm)

(5) Length of pump plunger (new) .... .......... .... .. .. .... 2.7212 ± .0015 in. (69.118 ± 0.038 mm)

Minimum permissible length (wom) .. .. ........ ........ ...... .. ...... .. .. .... .......... .. 2.7147 in. (68.953 mm)

(6) Bores for the racks:

Bore in housing. at the rear (new) .. .... .. .... ...... .. ......... 5023 ± .0015 in. (12.758 ± 0.038 mm)

Bearing at the front (new) .. .... .. ..................... 5023 ± .0013 in. (12.758 ± 0.033 mm)

Diameter of fuel racks (new) .... .. .. .. .... .... .. .... .. .. .4985 ± .0002 in. (12.662 ± 0.005 mm)

Maximum permissible clearance between rack and bearings (wom) .. ............ .. .... .......... .... .. .... . 007 in. (0.18 mm)

(7) Bore in bearings for the camshaft (new) .. .. ...... 2.1255 ± .0010 in. (53.988 ± 0.025 mm)

Diameter of bearing surfaces of the camshaft (new) .... .... .. 2.1220 ± .0005 in. (53.899 ± 0.013 mm)

Maximum permissible clearance between the bearings and the camshaft ...... .. .. ...... .... .... .... . . 010 in. (0.25 mm)

(8) Timing dimension for the fuel injection pumps. with 8S7167 Gauge (A) :

On engine .... .. ........ .. ........ 4.343 ± .002 in. (110.31 ± 0.05 mm)

Off engine .. .... ...... .. .... .. .... 4.394 ± .002 in. (111 .61 ± 0.05 mm)

(9) Torque for all nuts that hold the fuel lines ....................................... 30 ± 5 Ib.ft. (41 ± 7 N·m)

(10) Torque for the nuts that hold the nozzles .. .. .... .. .... ...... .. .. .. .. .. .... .. .. .. . 55 ± 5 Ib.ft. (75 ± 7 N·m)

SPECIFICATIONS

A - 857167 GAUGE

13

(11) Body.

(12) Nozzle. Tighten nozzle finger tight on body (11).

(13) Torque for glow plug .... .... .... .... 120 ± 24 Ib.in. (13.6 ± 2.7 N·m) (

(14) Torque for precombustion chamber .. .... .. .... .......... .. .. .. ...... .. .. 150 ± 10 Ib.ft. (204 ± 14 N.m)

4 NOTE : FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES



GOVERNOR

NOTE: Any adjustment to the governor must be made only by a person approved by Caterpillar or by a Caterpillar Dealer.

(1) Torque for nut ....................................... 9 ± 3 Ib.ft. (12 ± 4 N·m)

(2) 2S7235 Spring for the collar:

Length under test force .. ............. ........... ........ .375 in. (9.53 mm)

Test force .................................. 39 ± .03 lb. (0.177 ± 0.014 kg)

Free length after test ......................................... 68 in. (17.3 mm)

Outside diameter .............................................. .43 in. (10.9 mm)

(3) 9L6448 Spring for the governor:

Color code ............................ one green stripe, one yellow stripe

Put force on spring of ..................................... 4.00 lb. (1.814 kg)

Then add more force to make spring shorter by.............. ........... .......... ....... ... ......... .900 in. (22.86 mm)

Total test force ....................... 16.6 ± .30 lb. (7.530 ± 0.136 kg)

Free length after test ..................................... 2.24 ± .03 in. (56.9 ± 0.8 mm)

Outside diameter ............................................ 1.39 in. (35.3 mm)

(4) 9M6303 Spring:

Length under test force .................................. .180 in. (4.57 mm)

Test force ...................................... 10.0 ± 5 lb. (4.54 ± 0.23 kg)

Free length after test ....................................... 344 in. (8.74 mm)

Outside diameter ........................................... 480 in. (12.19 mm)

(5) Diameter of the outer surface of the cylinder (new) .......................... 1.5000 ± .0005 in. (38.100 ± 0.013 mm)

Bore in the gear (new) .......................... 1.5020 ± .0005 in. (38.151 ± 0.013 mm)

(6) Note: Put marks in alignment on pinion-stop-and gear before instal-ling dowel.

(7) Bore in the bearings (new) ........................... .8765 ± .0015 in. (22.263 ± 0.038 mm)

Diameter of the gear, at the hub (new) ........ ................... .8735 ± .0005 in. (22.187 ± 0.013 mm)

(8) Distance from the face of the housing to the end of the bearing for the governor control shaft ......................... 998 ± .005 in. (25.35 ± 0.13 mm)

(9) Distance between the bearings for the governor control shaft ...................... 2.385 ± .005 in. (60.58 ± 0.13 mm)

(10) Distance from the face of the housing to the end of the bearing for the governor control shaft ...................... 1.708 ± .004 in. (43.38 ± 0.10 mm)

(11) Torque for plug .................................. 27 ± 5 Ib.ft. (37 ± 7 N·m)

(12) 1S9312 Spring for speed limiter:

Length under test force ................................. .86 in. (21.84 mm)

Test force .............................. 2.38 ± .19 lb. (1.080 ± 0.086 kg)

Free length after test ..................................... 2.62 in. (66.5 mm)

Outside diameter ......................................... .671 in. (17.04 mm) A.2250",X,

8 NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES

SPECIFICATIONS

A324t6X4

11



AIR-FUEL RATIO CONTROL (4N8256)

(1) On Precombustion Chamber Engines the valve has "P.C." on this surface.

(2) 6N515 Spring:

Length under test force .................................. 1.81 in. (46.0 mm)

Test force ............................... 6.84 ± .40 lb. (3.100 ± 0.180 kg)

Free length after test ...................................... 2.95 in. (74.9 mm)

Outside diameter ........................................... 810 in. (20.57 mm)

(3) 9N2140 Spring:

Length under test force .............................. 1.210 in. (30.73 mm)

Test force ..................................... 32.0 ± 2.9 lb. (14.5 ± 1.3 kg)


Outside diameter ........ " ................................ 1.780 in. (45.2 mm)

(4) 9N2141 Spring:

Length under test force ................................. 600 in. (15.24 mm)

Test force ..................................... 32.0 ± 2.9 lb. (14.5 ± 1.3 kg)



DRIVE FOR THE FUEL INJECTION PUMP (4N677)

(1) Weight (two).

(2) 6N5164 Outer Spring:

Length under test force ................................ 2.64 in. (67.41 mm)

Test force ............................. 11.25 ± .56 lb. (5.103 ± 0.254 kg)

Free length after test ............................................. 3.40 ± .03 in. (86.4 ± 0.8 mm)


(3) 6N5165 Medium Spring:

Length under test force .............................. 2.654 in. (67.41 mm)

Test force ............................... 8.57 ± .43 lb. (3.887 ± 0.195 kg)

Free length after test ............................................. 3.40 ± .03 in. (86.4 ± 0.8 mm)

Outside diameter ..................... : ......................... 79 in. (20.1 mm)

(4) 6N5163 Inner Spring:

Free length ................................. 1.63 ± .03 in. (41.4 ± 0.8 mm)

Outside diameter ............................................... 59 in. (15.0 mm)

(5) Torque for the four bolts ................. 100 ± 5 Ib.ft. (136 ± 7 N.m)

SPECIFICATIONS

88250X5 4

4

5 A22493X1

9


988b wheel loader s/n 50w1 & up...caterpillar 988b wheel loader service manual ct-s-988b w/l{83273},...

Documents