988G Wheel Loader Engine Supplement Caterpillar

Installation Procedure

1. Check the condition of the mount assemblies that are used at the front and at the rear of the engine. If any component of the mount assemblies are worn or damaged, use new parts for replacement.

2. Replace all the O-ring seals that are used in the hose assemblies and the tube assemblies. Use new parts for replacement during the installation of the engine and the torque converter.

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Illustration 1	g00635680

3. Install Tooling (A) to the top of the torque converter housing.

4. Attach Tooling (B) to Tooling (A) and the engine, as shown.

5. Attach a suitable hoist and lifting chains to Tooling (B), as shown.

Note: It may be necessary to adjust Tooling (B) several times. This is done in order to achieve proper balance of the engine and the torque converter.

6. Use the hoist in order to carefully install the engine and the torque converter. The combined weight of the engine and the torque converter is 2495 kg (5500 lb).

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Illustration 2	g00635676

7. Install trunnion cap (49) and two bolts (48). Repeat this procedure for the opposite side. The torque for bolts (48) is 460 ± 60 N·m (340 ± 45 lb ft).

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Illustration 3	g00635677

8. Install mount (51) and bolt (50). Repeat this procedure for the opposite side. The torque for bolts (50) is 460 ± 60 N·m (340 ± 45 lb ft).

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Illustration 4	g00635679

9. Install bolt (52) and the clamp.

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Illustration 5	g00635675

10. Place wiring harness (47) in position on the machine.

11. Install bolt (46) and the clamp.

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Illustration 6	g00635674

12. Install two bolts (45) and the clamps.

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Illustration 7	g00635671

13. Connect two electrical connectors (44) .

14. Install bolt (42) and the clamp for wire harness (43) .

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Illustration 8	g00635670

15. Install four bolts (40) and the clamps for wire harness (41) .

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Illustration 9	g00635669

16. Install tube section (39) .

17. Tighten eight clamps (38) .

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Illustration 10	g00635668

18. Install bolt (37) and the clamp for the inlet line for the fuel filter (34) .

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Illustration 11	g00635667

19. Connect two hose assemblies (35) to refrigerant compressor (36) .

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Illustration 12	g00635665

20. Connect inlet line (34) for the fuel filter.

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Illustration 13	g00635664

21. Connect cables (31) and (32) to starting motor (33). The torque for the terminal nuts is 30.5 ± 3.5 N·m (23 ± 3 lb ft).

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Illustration 14	g00635662

22. Connect four hose assemblies (29) to the fan drive pump (30) .

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Illustration 15	g00635661

23. Install tube section (28) .

24. Tighten eight clamps (27) .

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Illustration 16	g00635660

25. Install the sleeve for the tube assembly (26) .

26. Tighten clamps (24) and (25) .

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Illustration 17	g00635659

27. Install tube assembly (23) and tighten clamp (22) .

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Illustration 18	g00635658

28. Install clamp (21) .

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Illustration 19	g00635657

29. Connect tube assembly (20) and tighten clamp (19) .

30. Connect two hose assemblies (17) and (18) .

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Illustration 20	g00635656

31. Connect hose assemblies (14) and (15) to the power train oil cooler (16) .

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Illustration 21	g00635655

32. Connect the coolant drain line (12) for the engine oil cooler (13) .

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Illustration 22	g00635653

33. Connect hose assembly (11) for the fuel/water separator.

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Illustration 23	g00635652

34. Connect four coolant hose assemblies (10) .

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Illustration 24	g00635650

35. Place hoses (9) in position.

36. Install bolt (8) and two clamps.

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Illustration 25	g00635649

37. Install lower front panel (2) and two bolts (6) and (7) .

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Illustration 26	g00635648

38. Install bolt (5) and the clamp.

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Illustration 27	g00635647

39. Install bolt (3) to bracket (4) .

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Illustration 28	g00635646

40. Install two bolts (1) to lower front panel assembly (2) .

41. Evacuate the air conditioner system. Charge the air conditioner system. The correct charge is 2.3 kg (5.0 lb). Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the correct procedure. Refer to Special Publication, NEDG5065, "Air Conditioning Tools" for the correct tools.

42. Fill the implement hydraulic system. Refer to the appropriate Operation and Maintenance Manual for the correct procedure.

43. Fill the cooling system. Refer to the appropriate Operation and Maintenance Manual for the correct procedure.

44. Fill the transmission with oil. Refer to the appropriate Operation and Maintenance Manual for the correct procedure.

End By:

1. Install the power train guard. Refer to Disassembly and Assembly, "Power Train Guard (Transmission) - Remove and Install" for the machine that is being serviced.
2. Install the input drive shaft. Refer to Disassembly and Assembly, "Input Drive Shaft - Remove and Install" for the machine that is being serviced.
3. Install the axle oil cooler pump. Refer to Disassembly and Assembly, "Gear Pump (Axle Oil Cooler) - Remove and Install" for the machine that is being serviced.
4. Install the implement pump. Refer to Disassembly and Assembly, "Piston Pump (Implement) - Install" for the machine that is being serviced.
5. Install the steering pump. Refer to Disassembly and Assembly, "Piston Pump (Steering) - Install" for the machine that is being serviced.
6. Install the pump for pilot and braking. Refer to Disassembly and Assembly, "Gear Pump (Pilot and Braking) - Install" for the machine that is being serviced.
7. Install the hood and engine enclosure. Refer to Disassembly and Assembly, "Hood and Engine Enclosure - Install" for the machine that is being serviced.
8. Install the front and rear hood panels. Refer to Disassembly and Assembly, "Hood Panels (Front and Rear) - Install" for the machine that is being serviced.
9. Install the muffler. Refer to Disassembly and Assembly, "Muffler - Remove and Install" for the machine that is being serviced.