Caterpillar Cat 988G Wheel Loader (Prefix BNH) Service Repair Manual Instant Download.pdf

Service Repair Manual
Models
988G Wheel Loader

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 988G WHEEL LOADER BNH
Configuration: 988G Wheel Loader BNH00001-UP (MACHINE) POWERED BY 3456 Engine
Disassembly and Assembly
988G Wheel Loader Power Train
Media Number -RENR3096-11 Publication Date -01/05/2011 Date Updated -25/05/2011
i02112056
Torque Converter - Assemble
SMCS - 3101-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
138-7573 Link Bracket 1
B 1P-0520 Driver Gp 1
C 188-1456 Metric Eyebolt 1
D 138-7575 Link Bracket 2
E 138-7575 Link Bracket 3
F
1P-0520 Driver Gp 1
8T-5096 Dial Indicator Gp 1
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are
worn or damaged, use new parts for replacement.
Note: Apply oil to all of the bearings before assembly.
1. Check the condition of the O-ring seals that are used in the torque converter and torque
converter housing. If any of the seals are damaged, use new parts for replacement.
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https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

Illustration 1 g00674989
2. Install five O-ring seals (96) and three plugs (97) .
3. Install block (95) and four bolts (94) .
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4. Install seal (71) onto piston (70) .
5. Install piston (70) .
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6. Install two wear plates (68) and two friction discs (69) .
7. Install plate (67) and retaining ring (66) .
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8. Install clutch adapter (65) and hub (63) to turbine (64) .
9. Install 24 bolts (62). The torque for bolts (62) is 105 ± 15 N·m (77 ± 11 lb ft).
10. Install bearing (61) .
11. Install O-ring seal (59) and two plugs (60) .
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12. Use the appropriate equipment in order to turn the housing assembly onto the opposite side,
as shown.
13. Install turbine assembly (64) into housing assembly.
14. Install the ring and the plate below bearing (58) .
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16. Use the proper equipment in order to handle bearing (57) .
17. Heat bearing (57) to a maximum temperature of 135 °C (275 °F).
18. Install bearing (57) onto the outer shaft.
Note: Allow the bearing and the shaft to reach a uniform temperature.
19. Use a hammer and a punch in order to reset the bearing around the inside race of the
bearing. This will ensure that the bearing is seated correctly.
20. Use the proper equipment in order to handle seal carrier (56) .
Note: Allow the ring and the shaft to reach a uniform temperature.
21. Heat seal carrier (56) to a maximum temperature of 135 °C (275 °F).
22. Install seal carrier (56) onto the outer shaft.
23. Use a hammer and a suitable punch in order to install pin (55) .
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24. Install seal (52) .
25. Install two seals (53) .
26. Install retaining ring (54) .
27. Install seal (51) to sleeve (50) .
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28. Install sleeve (50) and eight bolts (49). The torque for bolts (49) is 30 ± 5 N·m (22 ± 4 lb ft).
29. Use the proper equipment to handle race (48) .
30. Lower the temperature of race (48) .
31. Install race (48) in drive gear (47) .
32. Install drive gear (47) onto housing assembly (45) .
33. Install 12 bolts (46). The torque for bolts (46) is 105 ± 15 N·m (77 ± 11 lb ft).
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34. Install Tooling (E) in order to housing assembly (45) .
35. Attach a suitable lifting device and lifting slings to housing assembly (45) .
36. Use the suitable lifting device in order to install housing assembly (45) to outer shaft
assembly. The weight of housing assembly (45) is 45 kg (100 lb).
37. Install seal (44) onto piston (43) .
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988G Wheel Loader BNH00001-UP (MACHINE) POWERED BY 3456 Engine(SE...
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38. Install piston (43) .
39. Install two friction discs (42) and one wear plate.
40. Install plate (41) .
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41. Install two bolts (25) on the underside of plate (41) .
42. Install 12 bolts (38) and impeller (36) to adapter assembly (39). The torque for bolts (38) is
105 ± 15 N·m (77 ± 11 lb ft).
43. Use the proper equipment in order to handle race (37) .
44. Lower the temperature of race (37) .
45. Install race (37) in impeller (36) .
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48. Install the plate above bearing (40) .
49. Use two persons in order to install the impeller (36) onto the shaft assembly. The weight of
impeller (36) is 29 kg (65 lb).
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53. Install spacer (33) .
54. Use proper equipment in order to handle stator (24) .
55. Use a suitable press in order to install adapter (30) into stator (24) .
56. Install plate (28) and retaining ring (29) onto stator (24). Install plate (27) (not shown), and
retaining ring (26) (not shown) in the opposite side of stator (24) .
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57. Install stator (24) to carrier assembly (23) .
58. Carefully rotate carrier assembly into the upright position. The springs and the rollers will
hold the stator in place.
59. Install Tooling (D) to carrier assembly (23) .
60. Attach a suitable lifting device and lifting slings to carrier assembly (23) .
61. Use the suitable lifting device in order to install carrier assembly (23) to the torque
converter housing. The weight of carrier assembly (23) is 132 kg (290 lb).
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62. Install 36 bolts (21) and washers (22). The torque for bolts (21) is 60 ± 7 N·m (45 ± 5 lb ft).
63. Use the proper equipment in order to handle seal carrier (20) .
64. Heat seal carrier (20) to a maximum temperature of 135 °C (275 °F).
65. Install seal carrier (20) onto inner shaft (18) .
68. Install bearing (19) onto inner shaft (18) .
Note: Allow the bearing and the shaft to reach a uniform temperature.
69. Use a hammer and a suitable punch in order to reset the bearing around the inside race of
the bearing. This will ensure that the bearing is seated correctly.
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70. Install Tooling (C) to shaft assembly (18) .
71. Attach a suitable lifting device and a suitable lifting sling to Tooling (C) .
72. Use the suitable lifting device in order to install shaft assembly (18). The weight of shaft
assembly (18) is 17 kg (38 lb).
73. Carefully position the torque converter onto the side, as shown.
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74. Install washer (17), retainer (16), and two bolts (15). The torque for bolts (15) is 105 ± 15
N·m (77 ± 11 lb ft).
75. Install cover (14) and six bolts (13). The torque for bolts (13) is 60 ± 7 N·m (44 ± 5 lb ft).
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76. Position the torque converter upright.
77. Install gasket (10) .
78. Install O-ring seals (11) and (12) .
79. Use Tooling (B) in order to install seal (9) into retainer (8) .
80. Install retainer (8) and eight bolts (7). The torque for bolts (7) is 60 ± 7 N·m (45 ± 5 lb ft).
Note: It is necessary to install the torque converter into the torque converter housing prior to
installation of the idler gear.
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81. Install Tooling (A) to the torque converter housing.
82. Attach a suitable lifting device and lifting chains to Tooling (A), as shown.
83. Use the suitable lifting device in order to install the torque converter housing to the torque
converter. The weight of the torque converter housing is 270 kg (600 lb).
84. Install eleven bolts (6) and the washers.
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85. Install yoke (5) .
86. Install O-ring seal (4) .
87. Install bolt (2) and retainer (3). The torque for bolt (2) is 240 ± 25 N·m (175 ± 20 lb ft).
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88. Install two bearings (92) and ring (93) to idler gear assembly (91) .
89. Install idler gear assembly (91) .
90. Install idler gear shaft (90) .
91. Install bolt (89) and the washer.
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92. Install O-ring seal (88) to cover (87) .
93. Install three bolts (86) and cover 87.
94. Use the proper equipment in order to handle bearing cup (85) .
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95. Lower the temperature of bearing cup (85) .
96. Install bearing cup (85) into the housing.
97. Use the proper equipment to handle bearing (83) .
99. Install bearing (83) onto gear assembly (77) .
100. Install plate (82) onto adapter (80) .
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102. Install adapter assembly (80) into gear assembly (77) .
106. Install bearing (78) onto gear assembly (77) .
Note: Allow the bearing and the gear assembly to reach a uniform temperature.
107. Use a hammer and a suitable punch in order to reset the bearing around the inside race of
the bearing. This will ensure that the bearing is seated correctly.
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108. Install gear assembly (77) and entire shim pack (84) .
109. If both pump drives were removed, repeat Steps 94 through 108 for the remaining pump
drive.
110. Lower temperature of bearing cup (75). Install bearing cup (75) into adapter (73). Ensure
that the bearing cup (75) is seated.
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Note: DO NOT install the seals to the adapters at this time.
111. Use two persons in order to install adapters (73) and (77) on the torque converter housing.
The weight of adapter (73) is 30 kg (65 lb).
112. Install seven bolts (72) and six bolts (78). The torque for bolts (72) and (78) is 240 ± 40
N·m (177 ± 30 lb ft).
113. When possible, rotate either the torque converter or the outer housing in order to ensure that
the bearings are properly seated.
114. Use Tooling (F) in order to check bearing end play. The bearing end play must be 0.15 ±
0.05 mm (.006 ± .002 inch). Remove shims (84) in order to attain the correct bearing end
play.
115. Remove the pump adapters from the torque converter housing.
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116. Use Tooling (B) in order to install seal (76) into adapter (73) .
117. Lightly lubricate seal (76) with oil.
118. Install two O-ring seals (74) on adapter (73) .
119. Lubricate the O-ring seals (74) prior to assembly.
120. Install two O-ring seals and one lip seal on the remaining adapter.
121. Install the correct amount of shims (84) to the torque converter housing. The correct shim
thickness was determined in the above steps.
122. Use two persons in order to install adapters (73) and (77) on the torque converter housing.
The weight of adapter (73) is 30 kg (65 lb).
123. Install seven bolts (72) and six bolts (78). The torque for bolts (72) and (78) is 240 ± 40
N·m (177 ± 30 lb ft).
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124. When possible, rotate either the torque converter or the outer housing in order to ensure that
the bearings are properly seated.
125. Use Tooling (F) in order to recheck the bearing end play. If necessary, repeat the above
procedure.
126. Install speed sensor (1) .
End By:
a. Install the transmission oil pump. Refer to Disassembly and Assembly, "Transmission Oil
Pump - Install" for the machine that is being serviced.
b. Install the torque converter outlet relief valve. Refer to Disassembly and Assembly, "Relief
Valve (Torque Converter Outlet) - Install" for the machine that is being serviced.
c. Install the modulating valve for the torque converter impeller clutch. Refer to Disassembly
and Assembly, "Modulating Valve (Torque Converter Impeller Clutch) - Install" for the
machine that is being serviced.
d. Install the modulating valve for the torque converter lockup clutch. Refer to Disassembly
and Assembly, "Modulating Valve (Torque Converter Lockup Clutch) - Install" for the
e. Install the torque converter. Refer to Disassembly and Assembly, "Torque Converter -
Install" for the machine that is being serviced.
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Tue Feb 23 15:11:59 UTC+0800 2021
30/30
2021/2/23

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 988G WHEEL LOADER BNH
Configuration: 988G Wheel Loader BNH00001-UP (MACHINE) POWERED BY 3456 Engine
Disassembly and Assembly
988G Wheel Loader Power Train
Media Number -RENR3096-11 Publication Date -01/05/2011 Date Updated -25/05/2011
i02071477
Torque Converter (Lockup) - Disassemble
SMCS - 3101-015-L7
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
B
5F-7366 Screw 1
3H-0465 Plate 2
1P-5546 Crossblock 1
5H-7369 Puller Leg 2
6B-6682 3/4" - 16 NF Nut 2
1P-0520 Driver Gp 1
4C-5653 Threaded Adapter 2
C 188-1456 Metric Eyebolt 1
D 138-7575 Link Bracket 2
E 138-7575 Link Bracket 3
F 5F-7366 Screw 1
3H-0465 Plate 2
1/27
2021/2/23

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5H-7369 Puller Leg 2
8B-7551 Bearing Puller 1
6B-6682 3/4" - 16 NF Nut 2
1P-0520 Driver Gp 1
G
5F-7366 Screw 1
3H-0465 Plate 2
8B-7549 Puller Leg 2
5F-7343 Bearing Puller 1
6B-6682 3/4" - 16 NF Nut 2
1P-0520 Driver Gp 1
5F-7342 Adapter 2
H 1P-0520 Driver Gp 1
J 138-7574 Link Bracket 2
Start By:
a. Remove the torque converter. Refer to Disassembly and Assembly, "Torque Converter -
Remove" for the machine that is being serviced.
b. Remove the transmission oil pump. Refer to Disassembly and Assembly, "Transmission Oil
Pump - Remove" for the machine that is being serviced.
c. Remove the torque converter outlet relief valve. Refer to Disassembly and Assembly,
"Relief Valve (Torque Converter Outlet) - Remove" for the machine that is being serviced.
d. Remove the modulating valve for the torque converter impeller clutch. Refer to
Disassembly and Assembly, "Modulating Valve (Torque Converter Impeller Clutch) -
Remove" for the machine that is being serviced.
e. Remove the modulating valve for the torque converter lockup clutch. Refer to Disassembly
and Assembly, "Modulating Valve (Torque Converter Lockup Clutch) - Remove" for the
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Caterpillar Cat 988G Wheel Loader (Prefix BNH) Service Repair Manual Instant Download.pdf

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