988 G
988 G
988 G
2010 Caterpillar
All Rights Reserved
SEBU7198-07
June 2005
Operation and
Maintenance
Manual
988G Wheel Loader
BNH1-Up (Machine)
2TW1-Up (Machine)
86
Maintenance Section
Maintenance Interval Schedule
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When Required
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Maintenance Section
Maintenance Interval Schedule
88
Maintenance Section
Alternator - Inspect
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Alternator - Inspect
SMCS Code: 1405-040
Illustration 133
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Illustration 134
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A pressure hazard is present. Severe personal injury or death can result from removing hoses or
fittings that are under pressure. Relieve the pressure in the system before you remove hoses or
fittings.
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Bulk Fill
1. In order to fill the reservoir, remove the lower and
upper plugs from the side of the reservoir.
2. Attach the appropriate pump to the lower inlet.
3. Fill the reservoir until visual indicator on the lid
of the tank indicates FULL or until the grease
appears at the top vent port.
Reference: For the correct type of grease, refer
to Operation and Maintenance Manual, Lubricant
Viscosities.
89
Maintenance Section
Axle Oil Cooler Filter - Replace
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Illustration 135
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Front Filter
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Rear Filter
90
Maintenance Section
Axle Oscillation Bearings - Lubricate
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Illustration 137
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Illustration 138
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Illustration 139
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Maintenance Section
Battery - Clean
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Battery - Clean
SMCS Code: 1401-070
Illustration 142
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Battery - Recycle
SMCS Code: 1401-561
Always recycle a battery. Never discard a battery.
Always return used batteries to one of the following
locations:
A battery supplier
Illustration 141
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92
Maintenance Section
Battery Hold-Down - Tighten
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Belts - Inspect/Adjust/Replace
SMCS Code: 1397-025; 1397-040; 1397-510
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Illustration 144
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Illustration 145
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93
Maintenance Section
Brake Accumulator - Check
94
Maintenance Section
Bucket Cutting Edges - Inspect/Replace
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95
Maintenance Section
Bucket Lift and Bucket Tilt Control - Inspect/Clean
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Illustration 147
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Illustration 148
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96
Maintenance Section
Bucket Tips - Inspect/Replace
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Bucket Tips
Illustration 151
Illustration 149
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(1) Usable
(2) Replace
(3) Replace
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(6) Retainer
(7) Retaining washer
(8) Adapter
Check the bucket tips for wear. If the bucket tip has a
hole, replace the bucket tip.
1. Remove the pin from the bucket tip. The pin can
be removed by one of the following methods.
Illustration 152
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5. Drive the pin through the bucket tip. The pin can
be installed by using one of the following methods:
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Maintenance Section
Bucket Wear Plates - Inspect/Replace
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Illustration 155
6. After you drive the pin, make sure that the retainer
fits snugly into the pin groove.
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Illustration 154
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98
Maintenance Section
Case Drain Oil Filters - Replace
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Illustration 157
Illustration 156
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(1) Case drain filter for the steering pump. (2) Case drain filter for
the implement pump. (3) Case drain filter for the fan motor.
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99
Maintenance Section
Cooling System Coolant (ELC) - Change
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Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve
the pressure.
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, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Illustration 158
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Illustration 159
The drain valve is located at the rear of the machine under the
engine compartment.
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Maintenance Section
Cooling System Coolant Extender (ELC) - Add
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NOTICE
Topping off or mixing Cat ELC with other products that
do not meet Caterpillar EC-1 specifications reduces
the effectiveness of the coolant and shortens coolant
service life.
Use only Caterpillar products or commercial products
that have passed the Caterpillar EC-1 specification for
pre-mixed or concentrate coolants. Use only Extender
with Cat ELC.
Failure to follow these recommendations can result in
shortened cooling system component life.
When a Caterpillar Extended Life Coolant (ELC) is
used, an Extender must be added to the cooling
system.
Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve
the pressure.
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.
Illustration 160
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Illustration 161
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101
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
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Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
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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, 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 regulations and
mandates.
Illustration 163
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Illustration 164
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Illustration 165
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Illustration 166
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103
Maintenance Section
Cooling System Water Temperature Regulator - Replace
NOTICE
Topping off or mixing Cat ELC with other products that
do not meet Caterpillar EC-1 specifications reduces
the effectiveness of the coolant and shortens coolant
service life.
Use only Caterpillar products or commercial products
that have passed the Caterpillar EC-1 specification for
pre-mixed or concentrate coolants. Use only Extender
with Cat ELC.
Failure to follow these recommendations can result in
shortened cooling system component life.
2. If the coolant level is low, slowly remove the
cooling system pressure cap on the top left side
of the machine and add the required coolant in
order to maintain the coolant level within the sight
gauge.
Illustration 167
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Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve
the pressure.
Replace the water temperature regulator on a regular
basis in order to reduce the chance of unscheduled
downtime and the chance of problems with the
cooling system.
Illustration 168
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104
Maintenance Section
Crankshaft Vibration Damper - Inspect
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NOTICE
Caterpillar engines incorporate a shunt design cooling
system and require operating the engine with a thermostat installed.
If the thermostat is installed wrong, it will cause the
engine to overheat. Inspect gaskets before assembly
and replace if worn or damaged.
3. Install a new gasket on the regulator housing.
Install a new water temperature regulator.
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Illustration 170
Final Drive
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105
Maintenance Section
Differential and Final Drive Oil Level - Check
Illustration 171
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Front Differential
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Illustration 173
Illustration 172
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106
Maintenance Section
Differential and Final Drive Oil Sample - Obtain
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Illustration 174
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Front Differential
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, 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 regulations and
mandates.
Illustration 175
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Rear Differential
Illustration 176
Differential Filler Plug
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Maintenance Section
Drive Shaft Support Bearing - Lubricate
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Illustration 178
Center Drive Shaft
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108
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
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NOTICE
Caterpillar recommends certified air filter cleaning services that are available at Caterpillar dealers. The
Caterpillar cleaning process uses proven procedures
to assure consistent quality and sufficient filter life.
Observe the following guidelines if you attempt to
clean the filter element:
Do not tap or strike the filter element in order to remove dust.
Do not wash the filter element.
Use low pressure compressed air in order to remove
the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
to the pleats.
Do not use air filters with damaged pleats, gaskets, or
seals. Dirt entering the engine will cause damage to
engine components.
NOTICE
Service the air filter only with the engine stopped. Engine damage could result.
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Illustration 181
Illustration 179
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Maintenance Section
Engine Air Filter Secondary Element - Replace
12. Clean the cover for the air cleaner housing. Align
the slot on the cover with the pin on the air cleaner
housing. Install the cover.
13. Close the engine.
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Illustration 182
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Illustration 183
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Maintenance Section
Engine Air Filter Service Indicator - Inspect
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Illustration 186
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Maintenance Section
Engine Air Filter Service Indicator - Inspect/Replace
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Illustration 189
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Maintenance Section
Engine Crankcase Breather - Clean
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S/N: 2TW1-Up
Note: The engine crankcase breather on the
988G(S/N: BNH1-Up) is located inside the valve
cover. This breather does not require a maintenance
interval. Caterpillar recommends replacing the
crankcase breather during an engine overhaul. In
order to replace the breather element, the valve
cover will need to be replaced.
NOTICE
Attempts to clean the engine crankcase breather on
the 988G(S/N: BNH1-Up) may cause damage to the
element.
Illustration 192
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Illustration 191
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113
Maintenance Section
Engine Oil (High Speed) and Oil Filter - Change
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Table 10
Fuel
Sulfur
from
0.3% to
0.5%
Altitude
above
1830 m
(6000 ft)
(4)
Cat DEO
Preferred
500 hr
500 hr
500 hr
250 hr(6)
Cat ECF-1
11.0
minimum
TBN(4)
Preferred
500 hr
500 hr
500 hr
250 hr(6)
Cat ECF-1
TBN(4)
below 11.0
500 hr
500 hr
250 hr(5)
250 hr(6)
API CG-4
250 hr
250 hr(5)
250 hr(5)
250 hr(6)
High
Load
Factor(3)
above
69 L (17
US gal)
per hr
of fuel
(1)
(2)
(3)
(4)
(5)
(6)
The traditional oil change interval for engines is 250 hours. The
standard oil change interval in this machine is 500 hours, if the
operating conditions and recommended oil types that are listed
in this table are met. Improvements in the engine allow this
engine oil change interval. This new standard interval is not
permitted for other machines. Refer to the applicable Operation
and Maintenance Manuals for the other machines.
Normal conditions include these factors: Fuel sulfur below
0.3%, altitude below 1830 m (6000 ft), and good air filter and
fuel filter maintenance. Normal conditions do not include high
load factor, harsh operating cycles, or harsh environments.
High load factors can shorten the service life of your engine oil.
Continuous heavy load cycles and very little idle time result
in increased fuel consumption and oil contamination. These
factors deplete the oil additives more rapidly. If the average
fuel consumption of your machine exceeds 69 L (17 US gal)
per hour, follow the High Load Factor recommendations in
Table 10. To determine average fuel consumption, measure
average fuel consumption for a period of 50 to 100 hours. If
the application of the machine is changed, the average fuel
consumption may change.
For sulfur content above 0.5%, refer to Operation and
Maintenance Manual, SEBU6250, Total Base Number (TBN)
and Fuel Sulfur Levels for Direct Injection (DI) Diesel Engines.
In order to verify an oil change interval of 500 hours, refer to
Program A below.
Use Program B below to determine an appropriate interval.
114
Maintenance Section
Engine Oil (High Speed) and Oil Filter - Change
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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.
Illustration 193
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Illustration 194
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115
Maintenance Section
Engine Oil Level - Check
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Illustration 196
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Maintenance Section
Engine Oil Sample - Obtain
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Illustration 198
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Illustration 199
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Illustration 200
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Maintenance Section
Engine Oil and Filter - Change
Table 11
High
Load
Factor(3)
above
69 L (17
US gal)
per hr
of fuel
Fuel
Sulfur
from
0.3%
to
0.5%
Altitude
above
1830 m
(6000
ft)
(4)
Cat DEO
Preferred
500 hr
500 hr
500 hr
250 hr(6)
Cat ECF-1
11.0
minimum
TBN(4)
Preferred
500 hr
500 hr
500 hr
250 hr(6)
Cat ECF-1
TBN(4) below
11.0
500 hr
500 hr
250
hr(5)
250 hr(6)
API CG-4
250 hr
250 hr(5)
250
hr(5)
250 hr(6)
(1)
(2)
(3)
(4)
(5)
(6)
The traditional oil change interval for engines is 250 hours. The
standard oil change interval in this machine is 500 hours, if the
operating conditions and recommended oil types that are listed
in this table are met. Improvements in the engine allow this
engine oil change interval. This new standard interval is not
permitted for other machines. Refer to the applicable Operation
and Maintenance Manuals for the other machines.
Normal conditions include these factors: Fuel sulfur below
0.3%, altitude below 1830 m (6000 ft), and good air filter and
fuel filter maintenance. Normal conditions do not include high
load factor, harsh operating cycles, or harsh environments.
High load factors can shorten the service life of your engine oil.
Continuous heavy load cycles and very little idle time result
in increased fuel consumption and oil contamination. These
factors deplete the oil additives more rapidly. If the average
fuel consumption of your machine exceeds 69 L (17 US gal)
per hour, follow the High Load Factor recommendations in
Table 11. To determine average fuel consumption, measure
average fuel consumption for a period of 50 to 100 hours. If
the application of the machine is changed, the average fuel
consumption may change.
For sulfur content above 0.5%, refer to Operation and
Maintenance Manual, SEBU6250, Total Base Number (TBN)
and Fuel Sulfur Levels for Direct Injection (DI) Diesel Engines.
In order to verify an oil change interval of 500 hours, refer to
Program A below.
Use Program B below to determine an appropriate interval.
118
Maintenance Section
Engine Oil and Filter - Change
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Program B
Optimizing Oil Change Intervals
Begin with a 250 hour oil change interval. The oil
change intervals are adjusted by increments. Each
increment is an additional 50 hours. Periodic oil
sampling and analysis is done during each interval.
The analysis includes oil viscosity and infrared (IR)
analysis of the oil. Repeat Program B if you change
the application of the machine.
If an oil sample does not pass the analysis, shorten
the oil change interval, or change to a preferred
multigrade oil type in the listing above.
Illustration 202
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Illustration 203
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References
Reference: Form, PEDP7035, Optimizing Oil
Change Intervals
Reference: Form, PEDP7036, SOS Fluid Analysis
Reference: Form, PEDP7076, Understanding the
SOS Oil Analysis Tests
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Maintenance Section
Engine Oil and Filter - Change
Illustration 204
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Illustration 205
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Illustration 207
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8. Remove the engine oil filler cap (1) and fill the
engine crankcase with oil.
Reference: Refer to Operation and Maintenance
Manual, Capacities (Refill) for the proper
amount of oil.
9. Clean the oil filler cap and install the oil filler cap.
10. Start the engine and allow the oil to circulate.
Check for leaks.
11. Check the engine oil level on dipstick (2).
Illustration 206
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120
Maintenance Section
Engine Valve Lash - Check
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Illustration 208
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Start the engine and run the engine at low idle. Watch
the top surface of each valve rotator. Whenever an
inlet valve closes or an exhaust valve closes, each
valve rotator should turn.
If a valve rotator fails to turn, consult your Caterpillar
dealer for service.
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121
Maintenance Section
Ether Starting Aid Cylinder - Replace
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Illustration 211
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122
Maintenance Section
Fuel System Primary Filter (Water Separator) - Check/Drain
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Illustration 212
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Illustration 213
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123
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
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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.
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Illustration 214
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124
Maintenance Section
Fuel System Secondary Filter - Replace
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Illustration 217
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NOTICE
Do not fill fuel filters with fuel before installing them.
The fuel will not be filtered and could be contaminated.
Contaminated fuel will cause accelerated wear to fuel
system parts. The fuel system should be primed prior
to starting the engine.
Illustration 218
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125
Maintenance Section
Fuel Tank Cap and Strainer - Clean
Illustration 221
Illustration 219
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Illustration 220
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126
Maintenance Section
Fuses - Replace
Illustration 222
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Illustration 223
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Open the fuel tank drain valve. Allow the water and
sediment to drain into a suitable container. Close the
fuel tank drain valve.
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Fuses - Replace
Illustration 224
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Illustration 225
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127
Maintenance Section
Hydraulic System Oil - Change
Oil Filters
Oil
The 4000 hour interval for changing the oil is for the
following oil types.
Payload Control System (9) 10 amp
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Measured Data
128
Maintenance Section
Hydraulic System Oil - Change
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Illustration 226
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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, 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 regulations and
mandates.
1. Operate the machine in order to warm the
hydraulic oil.
2. Park the machine on level ground. Lower the
attachment to the ground and apply slight
downward pressure. Engage the parking brake
and stop the engine.
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Maintenance Section
Hydraulic System Oil Filter - Replace
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130
Maintenance Section
Hydraulic System Oil Level - Check
Illustration 228
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Illustration 230
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Illustration 229
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Maintenance Section
Hydraulic System Oil Sample - Obtain
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Illustration 231
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Illustration 233
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Illustration 234
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132
Maintenance Section
Lift Cylinder Pin Oil - Change
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Illustration 236
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, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
g01094056
2. Remove the drain plug for pin joint (K). The drain
plug is located on the right side of the machine.
Allow the oil to drain into a suitable container.
3. Remove the filler plug for pin joint (K). The filler
plug is located on the right side of the machine.
4. After the oil has drained, clean the drain plug and
install the drain plug.
Illustration 237
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Illustration 235
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5. Fill the pin joint with SAE 80W90 oil until oil
escapes from the filler opening.
6. Clean the filler plug and install the filler plug.
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Illustration 238
133
Maintenance Section
Lift Cylinder Pin Oil Level - Check
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Illustration 241
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8. Remove the filler plug for pin joint (Y). The filler
plug is located on the inside of the left front loader
frame.
9. After the oil has drained, clean the drain plug and
install the drain plug.
10. Fill the pin joint with SAE 80W90 oil until oil
escapes from the filler opening.
Note: It will be necessary to use a funnel and a hose
to fill the pin joint through the filler opening.
Illustration 239
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11. Clean the filler plug and install the filler plug.
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Illustration 240
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Illustration 242
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134
Maintenance Section
Loader Boom Pin Oil - Change
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Illustration 243
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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.
2. Clean the area around the filler plug for pin joint
(K). Slowly loosen the filler plug.
Illustration 244
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Illustration 246
The A-pin joints (1) do not have drain plugs.
Illustration 245
Pin Joint (Y)
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135
Maintenance Section
Loader Boom Pin Oil Level - Check
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Illustration 247
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A-Pin Joint
Illustration 248
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Illustration 249
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A-Pin Joint
136
Maintenance Section
Loader Boom Pin and Lift Cylinder Pin - Inspect
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Illustration 252
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B-Pin Joint
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C-Pin Joints
Illustration 254
Illustration 251
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E-Pin Joints
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Maintenance Section
Oil Filter - Inspect
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Illustration 255
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Illustration 258
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Illustration 256
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Illustration 257
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G-Pin Joint
138
Maintenance Section
Radiator Core - Clean
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Illustration 259
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Illustration 260
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NOTICE
If the refrigerant system has been open to the outside
air (without being plugged) for more than 30 minutes,
the receiver-dryer must be replaced. Moisture will enter an open refrigerant system and cause corrosion
which will lead to component failure.
Refer to Service Manual, SENR5664, Air
Conditioning and Heating System with R-134a
Refrigerant for All Caterpillar Machines for the proper
procedure to change the receiver-dryer assembly
and for the procedure to reclaim the refrigerant gas.
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139
Maintenance Section
Rollover Protective Structure (ROPS) - Inspect
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Illustration 262
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Typical example
Illustration 261
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140
Maintenance Section
Seat Side Rails - Adjust
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of installation (retractor)
of installation (buckle)
of manufacture (tag) (fully extended web)
of manufacture (underside) (buckle)
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Illustration 265
Illustration 264
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Maintenance Section
Tire Inflation - Check
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Illustration 267
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Illustration 268
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142
Maintenance Section
Transmission Oil - Change
Illustration 269
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Illustration 271
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Illustration 270
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143
Maintenance Section
Transmission Oil Filter - Replace
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Transmission Breather
13. Start the engine and run the engine at low idle.
14. Slowly operate the transmission control in order
to circulate the oil. Return the transmission to
neutral.
15. Stop the engine. Inspect the entire transmission
for leaks.
Illustration 274
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144
Maintenance Section
Transmission Oil Filter - Replace
Illustration 275
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Illustration 277
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Illustration 276
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Illustration 278
145
Maintenance Section
Transmission Oil Level - Check
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Illustration 280
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Illustration 279
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The sight gauge is located on the left side of the machine near
the articulation joint.
Illustration 281
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146
Maintenance Section
Turbocharger - Inspect
SEBU7198-07
Turbocharger - Inspect
Walk-Around Inspection
SMCS Code: 7000-040
Note: Inspect the machine for leaks. If leaks are
observed, find the source of the leak and correct the
leak. If leaks are suspected, check the fluid levels
more frequently than the recommended intervals.
SEBU7198-07
147
Maintenance Section
Window Washer Reservoir - Fill
i02161333
i00037755
Windows - Clean
SMCS Code: 7310-070
Illustration 284
g00038949
g01095908
Illustration 283
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