Caterpillar Cat 988K Wheel Loader (Prefix T8E) Service Repair Manual (T8E00001 and up).pdf

Service Repair Manual
Models
988K Wheel Loader

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 988K WHEEL LOADER T8E
Configuration: 988K Wheel Loader T8E00001-UP (MACHINE) POWERED BY C18 Engine
Disassembly and Assembly
836K Landfill Compactor, 834K Wheel Dozer and 988K Wheel Loader Power Train
Media Number -KENR6490-06 Publication Date -01/09/2015 Date Updated -05/12/2017
i02719081
Torque Converter (Lockup) - Assemble
SMCS - 3101-016-L7
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
138-7573 Link Bracket 1
138-7575 Link Bracket 2
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
G 1P-1863 Retaining Ring Pliers 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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988K Wheel Loader T8E00001-UP (MACHINE) POWERED BY C18 Engine(M0087...
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Illustration 1 g00674989
2. Install five O-ring seals (96) and three plugs (97).
3. Install block (95) and four bolts (94).
4. Install ring (93) and two bearings (92) to idler gear assembly (91).
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5. Install idler gear assembly (91).
6. Install idler gear shaft (90).
7. Install bolt (89) and the washer.
8. Install O-ring seal (88) to cover (87).
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9. Install three bolts (86) and cover 87.
10. Use the proper equipment in order to handle bearing cup (85).
11. Lower the temperature of bearing cup (85).
12. Install bearing cup (85) into the housing.
13. Use the proper equipment to handle bearing (83).
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14. Heat bearing (83) to a maximum temperature of 135 °C (275 °F).
15. Install bearing (83) onto gear assembly (77).
16. Install plate (82) onto adapter (80).
17. Install retaining ring (81).
18. Install adapter assembly (80) into gear assembly (77).
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20. Use the proper equipment in order to handle bearing (78).
22. Install bearing (78) onto gear assembly (77).
Note: Allow the bearing and the gear assembly to reach a uniform temperature.
23. 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.
24. Install gear assembly (77) and entire shim pack (84).
25. If both pump drives were removed, repeat Steps 10 through 24 for the remaining pump
drive.
26. 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.
27. 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).
28. Install seven bolts (72) and six bolts (78). The torque for bolts (72) and (78) is
240 ± 40 N·m (177 ± 30 lb ft).
29. When possible, rotate either the torque converter or the outer housing in order to ensure that
the bearings are properly seated.
30. 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.
31. Remove the pump adapters from the torque converter housing.
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32. Use Tooling (B) in order to install seal (76) into adapter (73).
33. Lightly lubricate seal (76) with oil.
34. Install two O-ring seals (74) on adapter (73).
35. Lubricate the O-ring seals (74) prior to assembly.
36. Install two O-ring seals and one lip seal on the remaining adapter.
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37. Install the correct amount of shims (84) to the torque converter housing. The correct shim
thickness was determined in the above steps.
38. 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).
39. Install seven bolts (72) and six bolts (78). The torque for bolts (72) and (78) is
240 ± 40 N·m (177 ± 30 lb ft).
40. When possible, rotate either the torque converter or the outer housing in order to ensure that
the bearings are properly seated.
41. Use Tooling (F) in order to recheck the bearing end play. If necessary, repeat the above
procedure.
42. Install seal (71) onto piston (70).
43. Install piston (70).
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44. Install two wear plates (68) and two friction discs (69).
45. Install plate (67) and retaining ring (66).
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46. Install clutch adapter (65) and hub (63) to turbine (64).
47. Install 24 bolts (62). The torque for bolts (62) is 105 ± 15 N·m (77 ± 11 lb ft).
48. Install bearing (61).
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49. Install O-ring seal (59) and two plugs (60).
50. Use the appropriate equipment in order to turn the housing assembly onto the opposite side,
as shown.
51. Install turbine assembly (64) into housing assembly.
52. Install the ring and the plate below bearing (58).
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56. Install bearing (57) onto the outer shaft.
Note: Allow the bearing and the shaft to reach a uniform temperature.
57. 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.
58. Use the proper equipment in order to handle seal carrier (56).
Note: Allow the ring and the shaft to reach a uniform temperature.
59. Heat seal carrier (56) to a maximum temperature of 135 °C (275 °F).
60. Install seal carrier (56) onto the outer shaft.
61. Use a hammer and a suitable punch in order to install pin (55).
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62. Install seal (52).
63. Install two seals (53).
65. Install seal (51) to sleeve (50).
66. Install sleeve (50) and eight bolts (49). The torque for bolts (49) is 30 ± 5 N·m (22 ± 4 lb ft).
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67. Use the proper equipment to handle race (48).
68. Lower the temperature of race (48).
69. Install race (48) in drive gear (47).
70. Install drive gear (47) onto housing assembly (45).
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72. Install Tooling (E) in order to housing assembly (45).
73. Attach a suitable hoist and lifting slings to housing assembly (45).
74. Use a 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).
75. Install seal (44) onto piston (43).
76. Install piston (43).
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77. Install two friction discs (42) and one wear plate.
78. Install plate (41).
79. Install two bolts (22) on the underside of plate (41).
80. 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).
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81. Use the proper equipment in order to handle race (37).
82. Lower the temperature of race (37).
83. Install race (37) in impeller (36).
86. Install the plate above bearing (40).
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87. 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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91. Install spacer (33).
92. Install race (32) and retaining ring (31).
Note: Inspect the splines on the stator. If the splines were damaged during disassembly,
replace the stator with a new part.
Typical Example
93. Use proper equipment in order to handle stator (24).
94. Heat stator (24) to a maximum temperature of 121 °C (250 °F) for one hour.
95. Install stator (24) onto cam (30).
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97. Install plate (28) and retaining ring (27) onto stator (24). Repeat this procedure for the
opposite side.
98. Install 13 springs (25) and 13 rollers (26).
99. Install springs (25) in the deepest part of the groove. Assemble the springs so that the
maximum number of loops face toward the outside of the cam.
100. Install rollers (26) in the narrowest part of the groove.
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101. Install stator (24) to carrier assembly (23).
102. Carefully rotate carrier assembly into the upright position. The springs and the rollers will
hold the stator in place.
103. Install Tooling (D) to carrier assembly (23).
104. Attach a suitable lifting device and slings to carrier assembly (23).
105. Use a 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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107. Use the proper equipment in order to handle seal carrier (20).
108. Heat seal carrier (20) to a maximum temperature of 135 °C (275 °F).
109. Install seal carrier (20) onto inner shaft (18).
112. Install bearing (19) onto inner shaft (18).
Note: Allow the bearing and the shaft to reach a uniform temperature.
113. 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.
114. Install Tooling (C) to shaft assembly (18).
115. Attach a suitable lifting device and a suitable lifting sling to Tooling (C).
116. Use the suitable lifting device in order to install shaft assembly (18). The weight of shaft
assembly (18) is 17 kg (38 lb).
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117. Carefully position the torque converter onto the side, as shown.
118. Install washer (17), retainer (16), and two bolts (15). The torque for bolts (15) is
105 ± 15 N·m (77 ± 11 lb ft).
119. 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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120. Position the torque converter upright.
121. Install gasket (10).
122. Install O-ring seals (11) and (12).
123. Use Tooling (B) in order to install seal (9) into retainer (8).
124. Install retainer (8) and eight bolts (7). The torque for bolts (7) is 60 ± 7 N·m (45 ± 5 lb ft).
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Note: It is necessary to install the torque converter into the torque converter housing prior to
installation of the idler gear.
125. Install Tooling (A) to the torque converter housing.
126. Attach a suitable lifting device and lifting chains to Tooling (A), as shown.
127. 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).
128. Install eleven bolts (6) and the washers.
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129. Install yoke (5).
130. Install O-ring seal (4).
131. Install bolt (2) and retainer (3). The torque for bolt (2) is 240 ± 25 N·m (175 ± 20 lb ft).
132. Install speed sensor (1).
End By:
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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
machine that is being serviced.
e. Install the torque converter. Refer to Disassembly and Assembly, "Torque Converter -
Install" for the machine that is being serviced.
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All Rights Reserved.
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Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 988K WHEEL LOADER T8E
Configuration: 988K Wheel Loader T8E00001-UP (MACHINE) POWERED BY C18 Engine
Disassembly and Assembly
836K Landfill Compactor, 834K Wheel Dozer and 988K Wheel Loader Power Train
Media Number -KENR6490-06 Publication Date -01/09/2015 Date Updated -05/12/2017
i05590451
Modulating Valve (Torque Converter Lockup Clutch) -
Remove and Install
SMCS - 3139-010-VC
Removal Procedure
Start By:
a. Connect the steering frame lock.
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, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to local regulations and mandates.
Personal injury can result from hot oil spray.
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Make sure all attachments have been lowered, oil is cool and the
pressure has been released from the hydraulic system before removing
any components or lines.
Be sure there is no pressure in the tubing before it is disconnected from
the fitting.
Do not allow hot oil or components to contact skin.
Note: The modulating valve for the torque converter lockup clutch is mounted on the torque
converter below the steering pump.
1. Disconnect harness assembly (2). Remove two bolts (3) and modulating valve (1).
2. Remove seal (4) from modulating valve (1).
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3. Remove nut (5) and coil assembly (6).
Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
4. Remove cartridge assembly (7) from valve body (8).
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Caterpillar Cat 988K Wheel Loader (Prefix T8E) Service Repair Manual (T8E00001 and up).pdf

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