SERV7105-01

January 2005
Vol. 1, No. 3

SERVICE TRAINING
TECHNICAL PRESENTATION

988H WHEEL LOADER

New Product Introduction

(NPI)
988H WHEEL LOADER
AUDIENCE

Level II - Service personnel who understands the principles of machine system operation,
diagnostic equipment, and procedures for testing and adjusting.

CONTENT

This presentation provides new and different New Product Introduction (NPI) information on
the 988H Wheel Loader. This presentation may be used for self-paced and self-directed
training.

OBJECTIVES
After learning the information in this presentation, the technician will be able to:
1. locate and identify the new components on the 988H Wheel Loader; and
2. explain the operation of the new components in the systems.

REFERENCES

TIM "988G Wheel Loader - 3456 Engine Controls" SERV2675

TIM "988G Wheel Loader - Power Train" SERV2680
TIM "988G Wheel Loader - Steering and Brake Systems" SERV2681
TIM "988G Wheel Loader - Implement Hydraulic System" SERV2682
TIM "988G Wheel Loader - Caterpillar Monitoring System" SERV2683

Estimated Time: 1 Hour

Illustrations: 17
Handouts: 6
Form: SERV7105-01
Date: 1/05

© 2005 Caterpillar Inc.

SERV7105-01 -3- NPI
Vol. 1, No. 3, 2005

TABLE OF CONTENTS

INTRODUCTION ........................................................................................................................5

SIMILARITIES AND DIFFERENCES .......................................................................................6

ENGINE........................................................................................................................................7

FAN HYDRAULIC SYSTEM ...................................................................................................11

IMPLEMENT HYDRAULIC SYSTEM....................................................................................14

ATTACHMENTS .......................................................................................................................16

POWER TRAIN .........................................................................................................................17

COOLING PACKAGE...............................................................................................................23

CONCLUSION...........................................................................................................................24

HYDRAULIC SCHEMATIC COLOR CODE...........................................................................25

HANDOUTS...............................................................................................................................27

POSTTEST .................................................................................................................................29

POSTTEST ANSWERS .............................................................................................................31

SERV7105-01 -4- NPI
Vol. 1, No. 3, 2005

NOTES
SERV7105-01 -5- NPI
Vol. 1, No. 3, 2005

988H WHEEL LOADER

© 2005 Caterpillar Inc.

INTRODUCTION

The 988H Wheel Loader has been updated to enhance performance and to meet the Tier III
EPA regulations. The serial number prefix of the 988H Wheel Loader is BXY. The 988H
Wheel Loader retains most of the features of the 988G Wheel Loader. The 988H Wheel Loader
is a direct replacement for the 988G Wheel Loader.
SERV7105-01 -6- NPI
Vol. 1, No. 3, 2005

SIMILARITIES AND DIFFERENCES

FEATURES DIFFERENT SIMILAR SAME
Engine X
Fan Hydraulic System X
Implement Hydraulic System X
Attachments X
Power Train X
Cooling Package X
Monitoring System X
Machine Appearance X
Operator‘s Station X

SIMILARITIES AND DIFFERENCES

The most significant changes to the 988H Wheel Loader are the engine, the hydraulic fan
system, the power train system, and the attachments. The engine is changing from the
Caterpillar 3456 to the Caterpillar C18 ACERT.

The most significant change to the hydraulic system is the fan control. The fan control is
changing from a thermostatic, wax capsule control to an electronic control.

The Lincoln Automatic Lubrication System (Autolube) is an attachment. The Autolube control
will be integrated in the Power Train Electronic Control Module (ECM). The priority valve has
been removed from the power train hydraulic system.

The diagnostic lines group is standard on the 988H Wheel Loader. The diagnostic lines group
provides remote pressure taps for the power train hydraulic system.

The cooling package is changed on the 988H Wheel Loader. The 988G Wheel Loader is
equipped with the Advanced Modular radiator Cores (AMOCS). The 988H Wheel Loader is
equipped with the Next Generation Modular Radiator (NGMR) cores.
SERV7105-01 -7- NPI
Vol. 1, No. 3, 2005

4
2

1 5

ENGINE

The 988H Wheel Loader is equipped with the Caterpillar C18 ACERT engine, serial number
prefix RHX. The displacement of the C18 ACERT engine is 18.1 liters with a rated power of
555 hp at 1800 rpm. The performance test specification for the C18 ACERT engine in the
988H Wheel Loader is 0K4826.

The C18 ACERT engine is equipped with an A4E4 Engine Electronic Control Module
(ECM) (1). The A4E4 Engine ECM is equipped with one 120 pin connector, one 70 pin
connector, and 26 output drivers. Also visible in this illustration are the fuel filter bypass
switch (2), the differential fuel pressure switch (3), the fuel temperature sender (4), and the
secondary fuel filter (5).
SERV7105-01 -8- NPI
Vol. 1, No. 3, 2005

1
2

6
3
4

The engine on the 988H Wheel Loader is equipped with an electric fuel priming pump (1) and a
turbocharger (2) that is cooled with engine coolant. Also shown are the primary fuel filter and
water separator (3), the engine oil filter (4), the engine oil cooler (5), and the transmission oil
cooler (6).
SERV7105-01 -9- NPI
Vol. 1, No. 3, 2005

C18 ACERT ENGINE SYSTEM BLOCK DIAGRAM (988H)

ENGINE MOUNTED COMPONENTS
6 Drivers
Injector
Connector
3 Returns

Electronic Unit A4E4

Injectors ECM

Crankshaft Speed / Timing Sensor

To Machine Wiring
Harness
Camshaft Speed / Timing Sensor

Ground Bolt
Coolant Temperature Sender

Fuel Temperature Sender Fuel Pressure Sensor

Timing
Inlet Air Temperature Sender Calibration Sensor

Atmospheric Pressure Sensor Differential Fuel

Pressure Switch

Turbo Outlet Pressure Sensor Oil Pressure Sensor

The above illustration shows the engine mounted electrical components on the 988H Wheel
Loader.

The differential fuel pressure switch monitors the condition of the secondary fuel filter.
SERV7105-01 - 10 - NPI
Vol. 1, No. 3, 2005

A4E4 C18 ACERT EUI SYSTEM (988H)

Electronic
Control Module MACHINE MOUNTED COMPONENTS
(ECM)

Ground Disconnect
Bolt Switch
24 V
Main Power Key Start
15 Amp Relay Switch
Breaker
Tachometer Output

Right Brake Switch

Throttle Accelerator
Throttle Lock Sensor Pedal
Resume / Accelerate Switch

Throttle Lock Manual Ether

Set / Decelerate Switch Aid Switch

Throttle Lock Ground Level Shutdown Switch

Enable Switch

Fan Proportional
Throttle Lock Lamp Solenoid Valve

+ Battery Relay Ether Start Valve

Transmission Lubrication
Temperature Sender Cylinder

Caterpillar Monitoring System

Engine
15
10 20
5

X100
25
Service Tool Connector
44
CAT Data Link
MPH
0 km/h

The above illustration shows the machine mounted input electrical components and output
electrical components of the Engine ECM on the 988H Wheel Loader.

The fan proportional solenoid valve controls the fan speed.

SERV7105-01 - 11 - NPI
Vol. 1, No. 3, 2005

3
1

HYDRAULIC FAN SYSTEM

The hydraulic fan system on the 988H Wheel Loader now includes an electronically controlled
hydraulic demand fan.

The Engine ECM (1) sends a current to the fan proportional solenoid valve (2) to control the
demand fan speed. The inlet air temperature, the engine coolant temperature, and the hydraulic
oil temperature are inputs to the Engine ECM. The Engine ECM then determines the desired
fan speed based on the temperatures.

Also shown is the hydraulic fan pump (3).

NOTE: For more detailed information on the electronically controlled hydraulic

demand fan system refer to Service Training Meeting Guide "938G Series II Wheel
Loader/IT38G Series II Integrated Tool Carrier with Tier II Emissions Engines " (Form
SERV1787).
SERV7105-01 - 12 - NPI
Vol. 1, No. 3, 2005

HYDRAULIC FAN SYSTEM

MINIMUM FAN SPEED

Fan
Motor Solenoid
Valve

Fan Pump
Control Valve

Flow
Control
Oil Spool
Cooler
Pressure
Cutoff
Spool

Fan
Pump Actuator
Min Angle

Filter

Hydraulic Tank

The above illustration is a hydraulic schematic of the 988H Wheel Loader hydraulic fan system
at MINIMUM FAN SPEED. As the current from the Engine ECM to the fan proportional
solenoid valve increases, the speed of the fan decreases.

If there is a failure in the electronic control of the fan drive system, the fan will go to maximum
speed.
SERV7105-01 - 13 - NPI
Vol. 1, No. 3, 2005

The hydraulic fan system must be calibrated on the 988H Wheel Loader using Caterpillar
Electronic Technician (Cat ET). The above illustration shows the Engine ECM Service drop
down menu and the Engine Cooling Fan Calibration line item.
SERV7105-01 - 14 - NPI
Vol. 1, No. 3, 2005

PUMP AND PUMP CONTROL VALVE

MINIMUM DISPLACEMENT - DIG TRIGGER MODE
Pressure
Sensor
To Implement Control Valve

Pressure
Tap

Actuator
Pump
From Swashplate Solenoid
Tank Lever Arm Valve
Super From
Charger Pump
Brake / Pilot
Pump

Pump Case
Fill

Pump Case Pump Case

Air Bleed Drain Filter

To
Tank

10

IMPLEMENT HYDRAULIC SYSTEM

The 988H Wheel Loader implement hydraulic system is equipped with the current implement
pump. The implement pump was effective with the 988G Wheel Loader BNH01062. The
pump is controlled directly by the pump solenoid valve. The pump solenoid valve directs
brake/pilot pump oil flow to and from the actuator. The actuator upstrokes and destrokes the
pump.

When the 988H Wheel Loader is in DIG TRIGGER, the Implement ECM sends the minimum
current to the pump solenoid valve and the implement pump is at MINIMUM
DISPLACEMENT.
SERV7105-01 - 15 - NPI
Vol. 1, No. 3, 2005

IMPLEMENT HYDRAULIC Lift Tilt Lift

Cylinder Cylinder Cylinder
SYSTEM
HOLD Ride
Control
Auxiliary Valve
Pressure
Reducing
Valve
Shut t le
Valve

Lower Tilt Back

Manual Lower
Valve

Pilot
Supply Float Balance
Valve Sequence Valve
Valve

Main
Relief
Lift Tilt Auxiliary Valve
St em St em St em

Raise Dump

Float Check Valve

From
Brake/Pilot
Implement
Pump
Pump

11

The ride control system for the 988H Wheel Loader has been updated. The ride control system
for the 988H has a balance valve and two accumulators compared to a single accumulator and
no balance valve on the 988G.

The balance valve in the ride control system equalizes the pressure between the lift cylinders
and the ride control accumulators. If the pressure in the lift cylinders circuit is higher than the
pressure in the accumulators, the balance valve will shift to the left allowing supply oil to
charge the accumulators. The implement pump can charge the accumulators up to the main
relief valve setting of the implement system.
SERV7105-01 - 16 - NPI
Vol. 1, No. 3, 2005

12

ATTACHMENTS

The most significant change to the mandatory attachment list for the 988H Wheel Loader is the
addition of the 3.88 meter lift linkage. The 3.88 meter lift linkage is designed for loading
trucks in the 27 000 kg to 36 000 kg (30 ton to 40 ton) payload range. The 4.25 meter lift
linkage is designed for loading trucks in the 45 000 kg to 64 000 kg (50 ton to 70 ton) payload
range.
SERV7105-01 - 17 - NPI
Vol. 1, No. 3, 2005

1 7
6 2
8
5 3
4 9 10

13

POWER TRAIN

The power train hydraulic system on the 988H Wheel Loader is equipped with remote pressure
taps. The remote pressure taps are located in the pump bay, behind the cab. The remote
pressure taps are:

1. Transmission reverse clutch pressure

2. Transmission forward clutch pressure

3. Transmission fourth speed clutch pressure

4. Transmission third speed clutch pressure

5. Transmission second speed clutch pressure

6. Transmission first speed clutch pressure

7. Torque converter inlet pressure

8. Torque converter outlet pressure

9. Impeller clutch pressure

10. Lockup clutch pressure

SERV7105-01 - 18 - NPI
Vol. 1, No. 3, 2005

POWER TRAIN HYDRAULIC SYSTEM

NEUTRAL

Transmission
Relief Valve
Lockup Clutch
Solenoid Valve

Torque Convert er
Inlet Relief Valve
Impeller Clutch
Solenoid Valve

Torque Converter
Outlet Relief
Valve
Scavenge
Pump

R 3

1 4

F 2

Power Train
Oil Cooler 2 5

To Transmission
Lube
4 1

Transmission
Housing 3 Solenoid 6
Valves

14

The priority valve has been removed from the power train hydraulic system on the 988H Wheel
Loader. The priority valve was removed due to the power train pump providing an adequate
flow rate for the power train hydraulic system.

The torque converter no longer features a free wheel stator when the machine is equipped with
the lockup clutch attachment. With the removal of the free wheel stator, the durability of the
torque converter on the 988H has increased.
SERV7105-01 - 19 - NPI
Vol. 1, No. 3, 2005

15

The power train system calibrations can be selected by using Caterpillar Electronic Technician
(Cat ET) on the 988H Wheel Loader.

The Power Train Electronic Control Module (ECM) configuration screen has line items to
program both the Autolube interval and the minimum Autolube pressure. Autolube is now
controlled by the Power Train ECM.

The default settings for reduced rimpull on the 988H Wheel Loader are 60%, 70%, 80%, and
90%. The default settings for reduced rimpull on the 988G Wheel Loader are 35%, 50%, 65%,
and 80%.
SERV7105-01 - 20 - NPI
Vol. 1, No. 3, 2005

POWER TRAIN CAT Data Link

Control and Monitor
Power
ELECTRICAL SYSTEM Train
Systems
ECM
INPUT COMPONENTS

STIC
Upshift, Downshift, Key Start Switch
Forward, Neutral,
Reverse

Auto/Manual Transmission Oil

Shift Switch Temperature Sensor

Reduced Rimpull Impeller Clutch

Enable Switch Pressure Sensor

Reduced Rimpull
Selection Switch Autolube
Pressure Sensor

Ride Control
Auto / Off Switch Autolube
Level Switch

Lockup Clutch Parking Brake

Enable Switch Pressure Switch

Steering / Transmission Torque Converter

Lock Switch Output Speed Sensor

Torque Converter
Pedal Position Sensor
Transmission Output
Speed Sensors

Engine Speed
From Engine ECM

16

The above illustration shows the inputs to the Power Train ECM on the 988H Wheel Loader.
On a machine equipped with the Autolube attachment, the 988H Wheel Loader is equipped
with an Autolube pressure sensor and an Autolube level switch.
SERV7105-01 - 21 - NPI
Vol. 1, No. 3, 2005

POWER TRAIN Power CAT Data Link Control and Monitor

ELECTRICAL SYSTEM Train Systems
OUTPUT COMPONENTS ECM

Autolube Reduced Rimpull

Indicator Lamp Indicator Lamp

Primary Steering Autoshift

Pressure Indicator Lamp Indicator Lamp

Ride Control Clutch 1

Solenoid Reverse Solenoid

Start Relay Clutch 2

Forward Solenoid
Back-up Alarm Clutch 3
4th Gear Solenoid

Impeller Clutch Clutch 4

Solenoid 3rd Gear Solenoid

Lockup Clutch Clutch 5

Solenoid 2nd Gear Solenoid

Autolube Clutch 6
Solenoid 1st Gear Solenoid

17

The above illustration shows the outputs of the Power Train ECM on the 988H Wheel Loader.
On a machine equipped with the Autolube attachment, the 988H Wheel Loader is equipped
with an Autolube solenoid and an Autolube indicator lamp.
SERV7105-01 - 22 - NPI
Vol. 1, No. 3, 2005

Return
Supply
AXLE OIL COOLER
Solenoid HYDRAULIC CIRCUIT
Valve
Fan
Motor

Axle
Oil Cooler

Rear Axle Screen

Temperature
Sensor
Temperature
Sensor
Front Axle Screen

Axle
Oil
Pump

Rear
Axle
Front
Axle

Power
CAT Data Link
MPH
km/h

Train
Caterpillar Monitoring System ECM

18

The axle oil cooler circuit now has a separate pump to supply oil to fan motor. A second
section was added to the brake/pilot pump (not shown) to supply oil to the fan motor.

The Power Train ECM controls the solenoid valve for the axle oil cooler system. When the
Power Train ECM sends current to the solenoid valve, supply oil from the pump is allowed to
flow through the solenoid valve. The oil from the solenoid valve bypasses the fan motor and is
sent to tank. When the Power Train ECM de-energizes the solenoid valve, the supply oil is
blocked by the solenoid valve. The oil flows to the fan motor cooling causing the fan motor to
rotate at maximum speed.

The two-section axle oil pump circulates oil from the axle housings through the axle screens
and axle oil cooler and back to the axle housings. The axle oil pump is driven off of the pump
drive at the torque converter.
SERV7105-01 - 23 - NPI
Vol. 1, No. 3, 2005

19

COOLING PACKAGE

The cooling package on the 988H Wheel Loader is equipped with NGMR cores to cool the
engine coolant. The NGMR cores have six fins per inch and utilize two pass cooling.
SERV7105-01 - 24 - NPI
Vol. 1, No. 3, 2005

20

CONCLUSION

This presentation has provided New Product Introduction (NPI) information for the Caterpillar
988H Wheel Loader. All new components and their locations were identified and discussed.
Use this presentation with:

- TIM "988G Wheel Loader - 3456 Engine Controls" (SERV2675)

- TIM "988G Wheel Loader - Steering and Brake Systems" (SERV2681)
- TIM "988G Wheel Loader - Power Train" (SERV2680)
- TIM "988G Wheel Loader - Electro-hydraulic Implement System" (SERV2682)
- TIM "988G Wheel Loader - Caterpillar Monitoring System" (SERV2683)
- 988H Service Manual

The information in this package should permit the serviceman to analyze problems in any of the
major systems on this tractor.
SERV7105-01 - 25 - NPI
Vol. 1, No. 3, 2005 Handout No. 1

HYDRAULIC SCHEMATIC COLOR CODE

Black - Mechanical Connection. Seal Red - High Pressure Oil

Dark Gray - Cutaway Section Red / White Stripes - 1st Pressure Reduction

Light Gray - Surface Color Red Crosshatch - 2nd Reduction in Pressure

White - Atmosphere Or Air (No Pressure) Pink - 3rd Reduction in Pressure

Purple - Pneumatic Pressure Red / Pink Stripes - Secondary Source Oil Pressure

Yellow - Moving or Activated Components Orange - Pilot, Signal or Torque Converter Oil

Cat Yellow - (Restricted Usage) Orange / White Stripes -

Identification of Components Reduced Pilot, Signal or TC Oil Pressure
Within a Moving Group
Orange / Crosshatch - 2nd Reduction In
Brown - Lubricating Oil Pilot, Signal or TC Oil Pressure

Green - Tank, Sump, o r Return Oil Blue - Trapped Oil

Green / White Stripes -

Scavenge / Suction Oil or Hydraulic Void

HYDRAULIC SCHEMATIC COLOR CODE

This illustration identifies the meanings of the colors used in the hydraulic schematics and
cross-sectional views shown throughout this presentation.
 HYDRAULIC SCHEMATIC COLOR CODE
SERV7105-01

Black - Mechanical Connection. Seal Red - High Pressure Oil

Vol. 1, No. 3, 2005

Dark Gray - Cutaway Section Red / White Stripes - 1st Pressure Reduction

Light Gray - Surface Color Red Crosshatch - 2nd Reduction in Pressure

White - Atmosphere Or Air (No Pressure) Pink - 3rd Reduction in Pressure

Purple - Pneumatic Pressure Red / Pink Stripes - Secondary Source Oil Pressure
- 26 -

Yellow - Moving or Activated Components Orange - Pilot, Signal or Torque Converter Oil

Cat Yellow - (Restricted Usage) Orange / White Stripes -

Identification of Components Reduced Pilot, Signal or TC Oil Pressure
Within a Moving Group
Orange / Crosshatch - 2nd Reduction In
Brown - Lubricating Oil Pilot, Signal or TC Oil Pressure

Green - Tank, Sump, o r Return Oil Blue - Trapped Oil

Green / White Stripes -

Scavenge / Suction Oil or Hydraulic Void
Handout No. 2
NPI
SERV7105-01 - 27 - NPI
Vol. 1, No. 3, 2005 Handout No. 3

Machine Orientation Checklist

Directions: Use this sheet when performing the machine orientation lab exercise.
Place a check in the blank if the fluid level is acceptable.
____ Engine oil level
____ Hydraulic system oil level
____ Hood actuator system oil level
____ Autolube lubrication system grease level (if equipped)
____ Final drive and differential oil level
____ Cooling system fluid level
____ Fuel level

Place a check in the blank if acceptable or after task was performed.

____ Check the Caterpillar Monitoring System for abnormal machine conditions
____ Check seat belt
____ Check the air filter precleaners

Place a check in the blank if the indicator, switch, or control is working correctly.
____ Key start switch
____ Engine coolant temperature gauge
____ Fuel level gauge
____ Power train oil temperature gauge
____ Hydraulic oil temperature gauge
____ Ride control indicator light (if equipped)
____ Autoshift indicator light
____ Autolube indicator light (if equipped)
____ Reduced rimpull indicator lights
____ Throttle lock indicator light
____ Horn
____ Front and rear work lights
____ Windshield wipers (if equipped)
____ Heating and air conditioner controls (if equipped)
____ Back-up alarm
SERV7105-01 - 28 - NPI
Vol. 1, No. 3, 2005 Handout No. 4

Machine Orientation Checklist - continued

Place a check in the blank after locating and reading the following warnings label on the
machine.

____ ROPS
____ Parking brake
____ No clearance (articulation joint)
____ Radiator
____ Batteries
____ Unit injectors
____ Do not operate

Place a check in the blank after locating each of the following controls.

____ Throttle pedal

____ Left brake pedal
____ Right brake pedal
____ Tilt lever
____ Lift lever
____ Parking brake knob
____ STIC
____ Ground level shutdown switch
____ Engine brake (if equipped)
____ Battery disconnect switch

Place a check in the blank after locating each of the following identification plates.

____ Product Identification Number (PIN)

____ Engine serial number
____ Transmission serial number
____ Bucket serial number
SERV7105-01 - 29 - NPI
Vol. 1, No. 3, 2005 Handout No. 5

Machine Posttest
Directions: Answer each question with the best possible answer.

1. The 988H Wheel Loader is equipped with which engine?

a. 3406E
b. C18 ACERT
c. C15 ACERT
d. 3456

2. The 988H Wheel Loader is equipped with which fan hydraulic system control?
a. Electronic
b. Wax capsule
c. Thermostatic
d. Wiggins

3. The diagnostic lines group is an attachment on 988H Wheel Loader.

a. True
b. False

4. The 988H Wheel Loader is equipped with which style radiator core?
a. AMOCS
b. Folded
c. Single Panel
d. NGMR

5. The 988H Wheel Loader requires service personnel to use Cat ET to calibrate the fan
hydraulic system.
a. True
b. False
SERV7105-01 - 30 - NPI
Vol. 1, No. 3, 2005 Handout No. 6

Machine Posttest - Continued

6. The 988H Wheel Loader ride control system utilizes
a. Two solenoid valves
b. A balance valve
c. Four accumulators
d. One accumulator

7. The 988H Wheel Loader is equipped with what type Engine ECM?
a. ADEM III
b. A4E4
c. ADEM IV
d. A4M1

8. Which linkage lengths are offered as mandatory attachments for the 988H Wheel
Loader?
a. 3.25 meter
b. 3.88 meter
c. 4.25 meter
d. Both b and c

9. Where are the remote pressure taps located on the 988H Wheel Loader?
a. On the rear bumper, left side of the machine
b. On the rear bumper, right side of the machine
c. Behind the cab, in the pump bay
d. Next to the battery disconnect switch

10. The 988H Wheel Loader is equipped with a priority valve in the power train hydraulic
system.
a. True
b. False
SERV7105-01 - 31 - NPI
Vol. 1, No. 3, 2005 Posttest Answers

Machine Posttest Answers

Quiz Answers:

1. b
2. a
3. b
4. d
5. b
6. b
7. b
8. d
9. c
10. b