CAT + Caterpillar 988B Wheel Loader Service Repair Manual by Heavy Equipment Manual

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Product: WHEEL LOADER

Model: 988B WHEEL LOADER 50W

Configuration: 988B Wheel Loader 50W06041-UP (MACHINE) POWERED BY 3408 Engine

Disassembly and Assembly

3408E and 3412E Engines for Caterpillar Built Machines Media Number -SENR1013-11

Aftercooler - Install

SMCS - 1063-012

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: There are several possible configurations of the aftercooler. The following procedure illustrates a typical example.

Note: The following procedure wasperformed on a 3408E engine. However, the process for the 3412E engine is very similar.

Note: Check the condition of the gaskets and the O-rings. If the gaskets or the O-rings are worn or damaged, use new parts for replacement.

i01101057

Illustration 1

Typicalexample

1. Install gasket (25) for the aftercooler housing, if the gasket was removed .

Illustration 2

Typicalexample

g00579413

2. Install aftercooler housing (23), if the housing was removed.

3. Install bolts (24) and the washers.

g00579418

Illustration 3

Typicalexample

4. Install O-ring seals (22).

g00579412

5. Lightly lubricate the boresof the aftercooler housing and O-rings (22) with glycerin.

6. Install aftercooler core (21). Use the lifting brackets on the aftercooler core and a suitable lifting device.

The weight of the aftercooler core assembly is approximately 26 kg (57 lb).

Illustration 4

Typicalexample

7. Install adapters (16) and O-ring seal (17).

8. Install adapters (18) and the O-ring seal.

9. Install elbow (19) with bolts(20).

g00579409

Illustration 5

g00579407

Typicalexample

10. Install bolts (15) and the washers.

Illustration 6

Typicalexample

11. Install aftercooler cover (14).

g00579404

12. Install clips (12), bracket (11), and bolts (13).

13. Install elbow (10) with bolts(9) and the O-ring seals.

Illustration 7

Typicalexample

g00579403

14. Install relief valve housing (6) with bolts(7).

15. Connect fuel line (8).

Illustration 8 g00579401

Typicalexample

16. Install elbow (4) with bolts(3).

17. Connect fuel line (1).

18. Install bolt (2) and the washer in the clip.

19. Install bolt (5), the washer, and the spacer.

Product: WHEEL LOADER

Model: 988B WHEEL LOADER 50W

Configuration: 988B Wheel Loader 50W06041-UP (MACHINE) POWERED BY 3408 Engine

Disassembly and Assembly

3408E and 3412E Engines for Caterpillar Built Machines Media Number -SENR1013-11

Aftercooler - Remove

SMCS - 1063-011

Removal Procedure

NOTICE

Care must be taken to ensure that fluidsare contained during performance of inspection, maintenance, testing, adjusting, andrepair 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, "Dealer Service Tool Catalog" for tools andsupplies suitable to collect andcontainfluids on Cat products.

Dispose of all fluids according to local regulationsand mandates.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

i01100860

Note: There are several possible configurations of the aftercooler. The following procedure illustrates a typical example.

Note: The following procedure wasperformed on a 3408E engine. However, the process for the 3412E engine is very similar.

1. Drain the coolant from the aftercooler core and the water lines into a suitable container for storage or disposal.

Illustration 1

Typicalexample

2. Remove bolt (5), the washer, and the spacer.

3. Remove bolt (2) and the washer from the clip.

4. Disconnect fuel line (1). Cap all male openings and plug all female openings immediately.

5. Remove bolts (3). Remove elbow (4).

Illustration 2

Typicalexample

g00579403

6. Disconnect fuel line (8). Cap all male openings and plug all female openings immediately.

g00579401

7. Remove bolts (7). Remove relief valve housing (6).

Typicalexample

8. Remove bolts (9). Remove elbow (10) and the O-ring seals.

9. Remove bolts (13) and the washers.

10. Remove clips (12) and bracket (11).

11. Remove aftercooler cover (14) and the gasket.

Illustration 4

Typicalexample

12. Remove bolts (15) and the washers.

Illustration

g00579404

g00579407

Illustration 5

Typicalexample

g00579409

13. Remove bolts (20), elbow (19), and the O-ring seal.

14. Remove two adapters(16) and O-ring seal (17).

15. Remove two adapters(18) and the O-ring seal.

Illustration 6

Typicalexample

g00579412

16. Attach a suitable lifting device to the lifting brackets on aftercooler core (21).

17. Remove the aftercooler core from the housing.

The weight of the aftercooler core is approximately 26 kg (57 lb).

18. Remove O-ring seals (22).

Illustration 7

Typicalexample

g00579413

19. If necessary, remove bolts(24) and the washers. Remove aftercooler housing (23).

Illustration 8

Typicalexample

g00579418

20. Remove gasket (25) for the aftercooler housing.

Product: WHEEL LOADER

Model: 988B WHEEL LOADER 50W

Configuration: 988B Wheel Loader 50W06041-UP (MACHINE) POWERED BY 3408 Engine

Disassembly and Assembly

3408E and 3412E Engines for Caterpillar Built Machines Media Number -SENR1013-11

i01055901

Atmospheric Pressure Sensor - Remove and Install

SMCS - 1923-010

Removal Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1 g00548090

1. Disconnect atmospheric pressure sensor connector (1).

2. Remove nut (3) and the washer.

3. Remove clamp (2).

4. Remove atmospheric pressure sensor (4).

Installation Procedure NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 2

1. Install atmospheric pressure sensor (4).

2. Install clamp (2).

3. Install the washer and nut (3).

g00548090

4. Connect atmospheric pressure sensor connector (1) to the engine wiring harness.

Product: WHEEL LOADER

Model: 988B WHEEL LOADER 50W

Configuration: 988B Wheel Loader 50W06041-UP (MACHINE) POWERED BY 3408 Engine

Disassembly and Assembly

3408E and 3412E Engines for Caterpillar Built Machines

Bearing Clearance - Check

SMCS - 1203-535; 1219-535

Measurement Procedure

Table 1 Required Tools

Plastic Gauge (Green)

to 0.076 mm

to 0.003 inch)

Plastic Gauge (Red)

to 0.152 mm

to 0.006 inch)

Plastic Gauge (Blue)

to 0.229 mm (0.004 to 0.009 inch)

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

i05977048

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 clearancesparticularly on small engines. Thisisbecause 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 journalswith small diametersif clearancesare 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 pointsof 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 isinstalled.

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

TypicalExample

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 SpecificationsManual, "Connecting Rod Bearing Journal" and Specifications Manual, "Main Bearing Journal" for the correct clearances.

Product: WHEEL LOADER

Model: 988B WHEEL LOADER 50W

Configuration: 988B Wheel Loader 50W06041-UP (MACHINE) POWERED BY 3408 Engine

Disassembly and Assembly

3408E and 3412E Engines for Caterpillar Built Machines

i06177964

Camshaft - Remove and Install

SMCS - 1210-010

Removal Procedure

Start By:

a. Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove".

b. Remove the lifter group. Refer to Disassembly and Assembly, "Lifter Group - Remove and Install".

c. Remove the flywheel housing. Refer to Disassembly and Assembly, " Flywheel HousingRemove and Install".

NOTICE

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

NOTICE

Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools andsupplies suitable to collect andcontainfluids on Cat products.

Dispose of all fluids according to local regulationsand mandates.

1. Remove four bolts (1) and plate (2) from the rear of the camshaft. Remove gear (3) from the camshaft.

Illustration 1

g00572086

Illustration 2

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2. Rotate the engine until the “V” marks on the front of the timing gears are in alignment.

Illustration 3

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3. Remove two bolts (5) and plate (4) from the camshaft.

Illustration 4

g00572105

4. Remove camshaft (6) from the cylinder block.

Illustration 5 g00572214

5. If necessary, remove camshaft gear (7) with Tool (A) and press.

Installation Procedure NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 6

g00572220

Note: The key for gear (7) must be in position on the camshaft (6) before gear (7) is installed.

1. Do not use a torch to heat camshaft gear (7). Raise the temperature of camshaft gear (7) by one of the following methods.

Use a suitable oven to raise the temperature of camshaft gear (7). Do not exceed 150° C (302° F) for more than four hours.

Use a suitable induction heater to raise the temperature of the hub of camshaft gear (7). Do not exceed 150° C (302°F) at bottom of gear teeth root radius.

2. Install camshaft gear (7) to camshaft (6).

3. Put 8T-2998 Lubricant on the camshaft lobesand the rollers for the valve lifter. Put clean engine oil on the bearing journalsof the camshaft.

Illustration 7

g00572105

4. Install camshaft (6) until the rear of the camshaft is even with the rear of the cylinder block.

Illustration 8

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5. Make an alignment of the “V” markson the camshaft gear and the idler gear.

Illustration 9

6. Install plate (4) on the cylinder block.

g00572221

7. Install gear (3) and plate (2) on the rear of the camshaft.

End

By:

a. Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel HousingRemove and Install".

b. Install the lifter group. Refer to Disassembly and Assembly, "Lifter Group - Remove and Install".

c. Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install".

Product: WHEEL LOADER

Model: 988B WHEEL LOADER 50W

Configuration: 988B Wheel Loader 50W06041-UP (MACHINE) POWERED BY 3408 Engine

Disassembly and Assembly

3408E and 3412E Engines for Caterpillar Built Machines

Camshaft Bearings - Remove and Install

SMCS - 1211-010

Removal Procedure

Table 1

Required Tools

i01519738

Start By:

A. Remove the flywheel housing. Refer to Disassembly and Assembly, "Flywheel HousingRemove and Install".

B. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove and Install".

C. Remove the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods- Remove".

NOTICE

Keep all parts clean from contaminants.

Contaminants

cause rapid wear and shortened component life.

NOTICE

Care must be taken to ensure that fluidsare 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 Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulationsand mandates.

Illustration 1

g00569925

1. Remove the rear camshaft bearing with Tool (A) .

2. Remove the remainder of the camshaft bearings with Tool (A) through the rear of the engine block. Start from the rear of the cylinder block and move toward the front.

Installation Procedure

Table 2 Required Tools Tool Part

A 8S-2241 Camshaft Bearing Tool Group 1

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