Service Manual

Service Manual

988B
Wheel Loader
S/n 50W1 & Up

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.

CT-S-988B W/L
3408 VEHICULAR ENGINE FOR SPECIFICATIONS
9888 WHEEL LOADER

INTRODUCTION
The specifications given in this book are on the When the word "permissible" is in the description,
basis of information available at the time the book
was written. These specifications give the torques, ~!;~n~~;ec~~l~~~~~~ gi;:~m\Stt~~e '~~f~~~m~~u~~:ei~~~ @@
operating pressure, measurements of new parts, repair and/or new parts are needed.
adjustments and other items that will affect the A comparison can be made between the measure-
service of the product. ments of a worn part, and the specifications of a
When the words "use again" are in the description, new part to find the amount of wear. A part that is
the specification given can be used to determine if worn can be safe to use if an estimate of the re-
a part can be used again. If the part is equal to or mainder of its service life is good. If a short service
within the specification given, use the part again. 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
Alternator ............................................ ........................................ 30
Automatic Timing Unit (Drive for the Injection Pump) ............. .... 9
Belt Tightener ............................................................................. 22
Camshaft ............................................ ........................................ 16
Connecting Rod ........... ...................................... ............ ............ 25
Crankshaft .......................................... ........................................ 26
Cylinder Block .......... .......... .................................... .... ................ 23
Cylinder Heads .................................... ...................................... 15
Cylinder Liner .................... .......... ............... .................. .......... .... 24
Cylinder Liner Projection ............ .......................................... ...... 24
Drive and Oil Pump for the Governor ...................... ............ ...... 10
Engine Design ......................................... ............. .... .................... 2
Exhaust Manifold .................................... ................................... 16
Flywheel..................................................................................... 29
Flywheel Housing ........... ....... .............. ............. ..... ........ ............. 27
Flywheel Housing Bore .. .............. .............................................. 28
Fuel Filter ..................................................................................... 6
Fuel Injection ......... ......... ..... .......... .................... ............ ............... 4
Fuel Injection Housing ................................................................. 5
Fuel Injection Pump, Drive for .......................... ....... .... ................ 9
Fuel Transfer Pump ............ ............................ ............ ............ ..... 7
Fuel Transfer Pump, Drive for .................................... ................. 7
Governor ...................................................................................... 8
Oil Bypass Valves .......... ............................................................ 19
Oil Filter ...................................................................................... 19
Oil Pan ....................................................................................... 18
Oil Pump .................................................................................... 18
Piston and Rings ............................ ............................................ 25
Pressure Cap, Cooling System ................................................. 20
Primary Fuel Filter ....................................................................... 6
Radiator ...................................................................................... 20
Rear Gear Group ....................................................................... 10
Service Meter, Drive For ............................................................ 11
Starter Solenoid ......................................................................... 31
Starting Motors (Electric) ............................................... ............ 30
Tachometer, Drive for ....... ......................................................... 11
Timing Gears ..... ...... ... ..... ............ .............................................. 11
Timing Gear Housing ................... ............ ..... ............................. 27
Turbocharger .................. ................................................. ........... 17
V-Belt Tension Chart ................................................................. 22
Valves ........................................................................................ 12
Valve Covers .............................................................................. 14
Valve Rocker Anns, Lifters and Bridges ................................... 13
Water Pump ....... ...... ..... .... ........ .... .......... ........ ........................... 21
Water Temperature Regulator ................................................... 21

2
 3408 VEHICULAR ENGINE FOR SPECIFICATIONS
9888 WHEEL LOADER

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 STANDARD TORQUE

inches millimeters lb. ft. N'm*

Standard thread
Use these torques for bolts and nuts with stan-
~ [illi[[(D dard threads (conversions are approximate).

1/4 6.35 9±3 12 ± 4

5/16 7.94 18 ± 5 25 ± 7
3/8 9.53 32 ±5 45 ± 7
7/16 11.11 50 ± 10 70'± 15
1/2 12.70 75 ± 10 100 ± 15
9/16 14.29 110 ± 15 150 ± 20
5/8 15.88 150 ± 20 200 ± 25
3/4 19.05 265 ± 35 360 ± 50
7/8 22.23 420 ± 60 570 ± 80
1 25.40 640 ± 80 875 ± 100
1 1/8 28.58 800 ± 100 1100 ± 150
1 1/4 31.75 1000 ± 120 1350 ± 175
1 3/8 34.93 1200 ± 150 1600 ± 200
1 1/2 38.10 1500 ± 200 2000 ± 275
l' ,
~
\., " Use these torques for bolts and nuts on
hydraulic valve bodies.

5/16 7.94 13 ±2 20± 3

3/8 9.53 24 ±2 35 ± 3
7/16 11.11 39 ±2 50 ± 3
1/2 12.70 60 ±3 80±4
5/8 15.88 118 ±4 160 ± 6

Tlperlock stud

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

C,> 11/2 38.10

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

550 ± 50 750 ± 70

T95416-7

3
 3408 VEHICULAR ENGINE FOR SPECIFICATIONS
9888 WHEEL LOADER

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) A - 857167 GAUGE

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)
13
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)
(11) Body.
Off engine .. ............ .... .. .... 4.394 ± .002 in. (111 .61 ± 0.05 mm)
(12) Nozzle. Tighten nozzle finger tight on body (11).
(9) Torque for all nuts that hold
the fuel lines ....................................... 30 ± 5 Ib.ft. (41 ± 7 N·m) (13) Torque for glow plug ........ ........ 120 ± 24 Ib.in. (13.6 ± 2.7 N·m) (
(10) Torque for the nuts that hold (14) Torque for precombustion
the nozzles .. .. .... .. .... ........ .. .. .. .. .... .. .. .. . 55 ± 5 Ib.ft. (75 ± 7 N·m) chamber .. .... .. .............. .. .. .. ........ .. 150 ± 10 Ib.ft. (204 ± 14 N.m)

NOTE : FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST

4 PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
3408 VEHICULAR ENGINE FOR SPECIFICATIONS
9888 WHEEL LOADER

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 A324t6X4
(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, 11

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST

8 PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
3408 VEHICULAR ENGINE FOR SPECIFICATIONS
9888 WHEEL LOADER

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) 88250X5 4
Free length after test ...................................... 1.49 in. (37.8 mm)
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)
Free length after test ...................................... 1.22 in. (31.0 mm)
Outside diameter ............................................ 1.28 in. (32.5 mm)

DRIVE FOR THE FUEL INJECTION PUMP

(4N677) 4

(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)
Outside diameter ............................................ 1.00 in. (25.4 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: 5 A22493X1

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)