988G

Wheel Loader

1
 988 Worldwide PINS

600 100

500
80 Caterpillar
Volvo
400 64 62 62 Kawasaki
66 59
62 60 Komatsu
59
CAT PINS
Units

PINS
300

40
200

20
100

0 0
1994 1995 1996 1997 1998 1999 2000

2
Worldwide Population

• 10 years
VOLVO 998

TEREX 206

TCM 33

KOMATSU 1450

KAWASAKI 375

FIAT-HITACHI 13

988 5186

0 1000 2000 3000 4000 5000 6000

3
 988 Size Class Timeline

988B 988F 988FII 988FII 988G

Enhanced

1976 1985 1987 1990 1993 1995 1996 1997 2000

L330D
L320 WA600 115Z III 115Z IV WA600-3
L330C

Approximately 24 years ago, Caterpillar introduced the 988B machine which

has continued to be the basic platform for todays loader. Throughout the
years, our competition has gone through many product updates, while we have
continued to enhance the machines performance going from the F to the FII
Enhanced.

4
 988B to 988FII “HOT”….

• 988B 988F
– STIC control and turbocharger result in improved hydraulics,
rimpull and Hp
988 FII high perf.
• 988F 988FII 988FII before 03/ 97
480
– Electronic engine, aftercooler and HEUI 470
fuel system result in Hp increase from 460

Net Power (HP)

445
400 to 430 440
430 430
– Axle shaft brakes 420 420
410
– Cab: increased viewing area and 400
390
reduced noise 380
360
• 988FII 988FII “HOT” 1400 1600 1800 2000
– Double stall Hp increase - 430 to 470 Engine RPM

Back in ‘76, we introduced the B as a 375 Hp loader pushing a 7.5 yd bucket.

Several years later, we introduced the F series and included the STIC steering
and added a turbocharger for improved hydraulics and rimpull.
Within a couple years, we updated the F to the series II machine and added an
electronic engine, aftercooler and HEUI fuel system to increase Hp from 400
to 430. Also included were updates to the braking system and operator
environment.
The latest significant update includes a change in the engine strategy that
provides and increase from 430 to 470 Hp in high lugging conditions.

5
From 988B to 988F….

• 10% increase in overall performance

• 3408 turbocharged from 375HP to 400HP
(turbocharged and aftercooled)
• Hydraulic lift and dump 11% faster
• 18% more rimpull
• STIC control

6
From 988F to 988FII….

• 3408E HEUI (turbo

charged & aftercooled
400HP to 430HP)
• Axle shaft brakes
• Cab: increased viewing
area and reduced
noise

7
From 988FII to 988FII Hot….

• 3408E HEUI increased from 430HP to 470HP

• Frame enhancement 988 FII high perf.
988FII before 03/ 97
• Same fuel efficiency 480 470
460
• +4% production

Net Power (HP)

445 440
430 430
420 420
410
400
390
380

360
1400 1600 1800 2000
Engine RPM

8
 Why the “G” Series?

• 988 design has reached its limits

• Competitive drive
• Market input
• Operator comfort
• Efficiency
• Production requirements
• Versatility as loading tool
• Emissions regulations

Why the 'G' series?....As I have presented, the 988

has gone through several enhancements and
improvements over the past 24 years that have
allowed it to approach its full design potential.
Based on competitive market pressure and your
input, the time has come to go to the next
evolutionary stage with the 988 machine. The next
evolution includes improvements to the areas of
comfort, efficiency, production, versatility as a
loading tool and environmental friendliness. If we
desired to maintain the same level of satisfaction,
effectiveness and longevity as the 24 year old
current model has given us, a new 'G' series
generation would need to be designed.

9
 • 11 Field Follow Machines
• Delivered approx. 4/99
• Over 30,000 hours total
• Well accepted
• Increased Performance/Productivity
• Fuel burn < 988F

In order to meet and exceed the growing customer requirements, virtually

every area of the "G" series machine has been impacted. Standing on the same
tires of the 988FII, the changes to the machine start with a payload rating of
12.5 Tons and include several changes ranging from the revolutionary front
linkage,to the 3456 EUI engine and ICTC torque convertor, and to the
electronic controls and power management strategies. As you can tell, the
988G is similar in technology and design to its bigger brother, the 992G, and
combines invaluable engineering and design experience with new technology
directed at making the 988G a wheel loader for the future.

Throughout the design, development and field follow stages, the LWL group
has continued to pursue and evaluate the machine in all aspects. We have
agressively pursued the participation and imput from dealers and customers
like yourselves throughout the lengthy field follow stages to insure that we do
not deliver you a test machine, rather to deliver to you a final product.

10
 Specifications
988FII 988FII HL 988G
Bucket Size (yd³) 8.25-9.0 8.25-9.0 8.2-9.2
Payload Rating (T) 12 11 12.5
Net Horsepower *430/470 *430/470 475
Dump Clearance(w/teeth) 10'7'' 12'1'' 13'1''
Reach at full lift and 45°
discharge (SAE) 5'3'' 5'6'' 5'3"
Breakout Force (lbs) 82,282 86,051 103,500
Overall Length 35'10" 37'1" 41'0"
Clearance Circle (outside
edge of bucket) 55'8" 56'11" 57'5"
Full Turn Static Tipping
Load (lbs) @ 35 Degrees 60,711 51,753 63,283
@ 43 Degrees 59,464
Operating Weight (lbs) 100,492 101,451 110,428
*In double stall conditions, power increases from 430 to 470hp

Note:
- improved dump/reach
- increased BOF
- overall length of machine has grown for:
- increased stability (29” in wheelbase)
- increased articulation angle (43 degrees)
- clearance circle
- improved FTSTL provided by better balance and increased wheelbase
- overall weight increased

11
 Specifications
988FII 988FII HL 988G
Bucket Size (m³) 6.3-6.88 6.3-6.88 6.3-7.0
Payload Rating (t) 10.9 10 11.3
Net Horsepower *430/470 *430/470 475
Dump Clearance(w/teeth) mm 3226 3683 3994
Reach at full lift and 45°
discharge (SAE) 1600 1676 1613
Breakout Force (kg) 37,316 39,025 46,938
Overall Length (mm) 10,922 11,303 12,505
Clearance Circle (outside
edge of bucket) mm 16,972 17,348 17,500
Full Turn Static Tipping Load
(kg) @ 35 Degrees 27,533 23,471 28,700
@ 43 Degrees 26,966
Operating Weight (kg) 45,575 46,010 50,090
*In double stall conditions, power increases from 430 to 470hp

Note:
- improved dump/reach
- increased BOF
- overall length of machine has grown for:
- increased stability (29” in wheelbase)
- increased articulation angle (43 degrees)
- clearance circle
- improved FTSTL provided by better balance and increased wheelbase
- overall weight increased

12
 988G Wheel Loader

*Powertrain *Operator Environment

-3456 EUI -New, 38% Larger cab
-ICTC/RCS -E/H controls
*Linkage/Hydraulics
- Increased Lift and
Breakout force

*Stability
-29” longer wheelbase
-Higher stability ratio
*Power Management
-Performance
-Efficiency

Throughout the presentation today, I will be discussing several areas of the

machine and the improvements. There are though a few main areas of
particular focus:

Powertrain
Linkage
Operator Environment
Stability
Power Management

Each of these areas are significant factors in the design criteria and resulting
performance of the machine. For the 988G, the design engineers not only
focussed on increased performance in all applications, but also focussed on
improved efficiency. After all, efficiency is a large part of your machine
performance that translates into lower owning and operating costs.

13
 Powertrain

• 3456 EUI Engine

• AMOCS Cooling • ECPC Transmission
• ICTC w/RCS • Heavy Duty Axles

In the 988G, several improvements have been made to

enhance the performance, efficiency and life of the
machine. Starting in the powertrain is the 3456 EUI
engine producing 475 net Hp. This power is cooled by the
AMOCS radiator and transferred to the ground through the
ICTC torque convertor, ECPC transmission and the new
heavy duty axles.

14
 Powertrain
3456 EUI Engine

•Performance

•Fuel Efficiency

•Reliability/Durability

•Operating Costs

•Emissions

We are going to start today with the heart of the machine, the 3456 engine.
The 3456 engine is based on Caterpillar's proven 3406E design with several
improvements incorporated into materials, design and technology. These
advances are allowing us to take advantage of improved efficiency and power
while maintaining the reliability and durability goals we have come to expect
from Caterpillar. The major advantages of this engine are reflected in life
targets, fuel efficiency, owning and operating costs, 1st major overhaul costs
and performance. All of this is accomplished while keeping an eye on the
future performance and emissions requirements.

15
 Powertrain
3456 EUI Performance

• Increased Horsepower
988FII 988G
Engine 3408E HEUI 3456 EUI
• Improved Torque rise
# of Cylinders 8 6
• Quick Engine Response
Aftercooler JWAC ATAAC
• 15% Improved BSFC Displacement 18.0l 15.8l
• Meets Tier I Gross Hp 458 520
– Tier II/III Capable Net Hp 430/470 475
• Life Expectancy Torque Rise 34% 42%
Rated BSFC 228 198

Note:
- hp and torque benefits
- torque rise improvement
- quantify hp improvement from 430/470 to 475
- ATAAC improvements
- emissions, fuel burn and life
- improved fuel efficiency
- improved life

16
 Powertrain
Life Expectancy

Engine Life in hours can be equated to:

Gallons through engine @ 100% LF (93,000 Gal)

Gal/Hr (12) = 12,917 Hrs
Average Engine Load Factor (60%)

Example @ Avg. Load Factor:

3456 EUI: Avg. Gallons to 1st MOH@100% load = 93,000
3408HEUI: Avg. Gallons to 1st MOH@100% load = 79,000
Estimated life based on reported gallons/hour and 60% load factor:

3456 EUI : 93,000 gal/(12 gal/hr) = 12,917 hrs

60%
3408HEUI : 79,000/(13 gal/hr) = 10,128 hrs
60%

The common denominator in determining engine life is gallons through the engine.
For example, the engine life of an automobile will vary greatly by its usage. If the
vehicle is driven primarily on the highway, you may expect 150-200K miles to first
major overhaul. By comparison, that same vehicle may only last 40-50K miles if
used for racing at the dragstrip. At Caterpillar, we understand that the engine load
factor can vary greatly across the board, depending on application and efficiency. For
this reason, we design engine life around gallons through the engine at 100% load
factor. The load factor combined with the fuel burn rate will dictate the number of
hours to overhaul in varying conditions.
As a design goal, the engine life targets are set to the most extreme duty cycle, or a
constant 100% load factor. To estimate a customers hours to overhaul using the
equation, the gallons through the engine figure must first be converted to the
customers average engine load factor. This is done by dividing the design goal at
100% load by the customers average load factor as a percentage. Once the customers
average gallons through the engine is determined, it can then be converted to hours to
overhaul by dividing by the average gallons per hour.
As an example, the 3456 is capable of burning approximately 18% more fuel through
the engine to the first major overhaul than the 3408. Examining fuel burn rates and
increased capabilities indicates that the 3456 EUI engine life will be greater than that
of the 3408 HEUI engine.
3456 Hours to 1st MOH@100% load = 93,000
3408E Hours to 1st MOH@100% load = 79,000
Based on reported gallons/hour and 60% efficiency, estimated life is:
3456 (12 gal/hr) = 12,917 hrs 3408E (13 gal/hr) = 10,128 hrs 17
 Powertrain
3456 EUI Engine Design

•Materials and Design Improvements

•Single Overhead Camshaft
•Stainless steel injector sleeves
•Exhaust port sleeves
•Improved water flow and cooling
•One piece, Sawcut cyl. heads
•Two-piece articulated steel pistons
•19% greater bearing area
•25% fewer wear parts

Today's advancements in materials and design have made it possible to produce higher Hp's with lower
displacement engines while still achieving the life goals we have come to expect. (The automotive
industry is an example of the efficiencies, performance and extended life.) When we look at engines
today, we need to take into consideration several factors including materials, design and fuel efficiency,
all of which we have looked at before deciding to go with the new 3456 EUI engine.
Material and design improvements allow the smaller displacement 3456 engine to sustain higher Hp
ratings in a more efficient way. The limiting factor for the horsepower to displacement ratio lies in
cylinder head pressure capability. All of the material and design improvements listed here allow the
3456 to run at a higher cylinder head pressure capabilities without sacrificing life expectancy. Combined
with materials and design improvements, the 3456 also incorporates an improved fuel management
system with the Electronic Unit Injectors and the ADEM II technology.

18
988G
Engine costs

3408E Core engine 3456

Price QTY Ext. price overhaul comparison, 3/00 Price QTY Ext. price
$ 338 8 $ 2,701 Reman cylinder pack $ 334 6 $ 2,005
$ 1,020 2 $ 2,040 Reman cylinder head $ 1,098 1 $ 1,098
$ 177 1 $ 177 Main barings (kit) $ 177 1 $ 177
$ 21 2 $ 42 Thrust bearing $ 21 2 $ 42
$ 16 8 $ 131 Connecting rod bearing $ 16 6 $ 98
$ 12 1 $ 12 Oil pan gasket $ 12 1 $ 12
$ 49 2 $ 98 Cylinder head gasket $ 55 1 $ 55
$ 26 2 $ 52 Thermostat $ 26 1 $ 26
$ 17 1 $ 17 Oil filter $ 17 1 $ 17
$ 15 1 $ 15 Fuel filter $ 15 1 $ 15
$ 5,271 Total $ 3,531
Time for overhaul 60 hours Time for overhaul 48 hours
Moderate application
Labor rate 70 $/h

19
Powertrain
Electronic Unit Injection

• High Injection Pressures Independent of Engine Speed

– Decreases smoke and emissions
– Improves response
• Injection Timing and Duration are Variable
– Improves Fuel efficiency
– Improves cold starting
• Improved Reliability w/fewer parts
• Full Electronic Control
– Provides Self Diagnostics
– Improved Performance

20
 Powertrain
AMOCS Radiator

•Separate Air Box Design

•More efficient cooling
•Reduced sound levels
•Improved Visibility
•Advanced Modular Cooling System
•Two pass cooling system
improves efficiency
•Improved serviceability

The 3456 engine features an AMOCS radiator enclosed in a separated cooling system which
isolates the radiator and fan from the engine compartment. The separate engine cooling
system design allows the AMOCS radiator to recieve outside ambient air through the side and
top vents at a much lower temperature than the hot air from the engine compartment. The
benefits of this design allows for more efficient cooling which in turn allows lower fan speeds,
reduced noise levels and a sloped hood for improved visibility.

The AMOCS radiator further improves on the cooling system efficiency by providing a two
pass system that brings water from the engine, up the fan side, over the top and back down on
the intake side. In addition to efficiency, the AMOCS radiator is also designed to improve
serviceability as there is no top tank to remove and the radiator guard does not have to be tilted
to remove the cores. Cores modules are also replaceable and interchangeable.

21
 Powertrain
ICTC/RCS

•Allows operator to vary rimpull

from 100% to 20%
•Smooth ground speed control
•Reduced Tire Wear
•Allows use of throttle lock for
faster cycle times and maximum
hydraulic efficiency
•Rimpull Control Settings to
Match Applications
•Longer engine life and better fuel
efficiency.

•The operator has better control of wheel slip. Less wheel slip, longer tire life.
•Faster cycle times. Operator dosen’t have to reduce engine rpm for
directional changes.
•Maximum hydraulic efficiency when used with Throttle Lock. Allows the
operator to maintain high engine rpms.
•The ICTC provides an excellent means for the operator to modulate vehicle
speed while operating at high engine speeds.
•Operating at high engine speeds should provide better engine life and
improved fuel economy

22
 Powertrain
How ICTC Works...

•The operator varies

rimpull from 100% to
20% with the left pedal.

• Effective ground speed

control, allows high
engine rpm (Throttle
Lock) for maximum
hydraulic efficiency.

•In the first inch or so of travel on the left brake pedal, the operator varies
rimpull from 100% to 20% of maximum. Once the operator has gone past
20%, the brake is applied.

23
 Powertrain
Rimpull Control System (RCS)

•To use RCS, depress the RCS

switch located on the implement
pod.
•Select maximum rimpull desired.
•Modulation on the left pedal will
be from the rimpull selected down
to 20%
•Only active in first gear.

•To use the RCS system, first depress the reduced rimpull switch located on
the implement pod.
•Then select from one of the 4 pre set rimpull settings. Rimpull settings are
90%, 85%, 75% and 65%. These settings can be tuned to suit the customer’s
needs using the Electronic Technician.
•After selecting the rimpull setting, the operator then has rimpull modulation
from that point down to 20% on the left pedal.
•This system is active only in first gear regardless of the rimpull switch
position.

24
 Powertrain
RCS Continued

•Using throttle lock to operate

at high engine rpm along with
ICTC/RCS provides
maximum hydraulic
efficiency

•Using throttle lock along with ICTC/RCS provides maximum hydraulic

performance. With throttle lock engaged, the operator uses the left pedal to
modulate rimpull, thus, reduce ground speed.

25
 Powertrain
Planetary Powershift Transmission

• Electronic Clutch Pressure

Control Transmission with
Control Throttle Shifting
– Improves shift quality and durability
– Uses 5 planetary drives in
combination for 4F/3R gears
– Added a planetary carrier to each of
forward planetaries

• Large 17”(431mm) Clutches

• Autoshift Feature Standard

•The 988G uses an updated version of the 988FII heavy duty

powershift transmission. Updates include the addition of the
Electronic Clutch Pressure Control with Control Throttle Shifting
for improved shift quality and durability of the large 17" clutches
by reducing the load spikes during a shift. Also included is an
additional planet carrier in each of the forward planetaries that
reduces the stress level of each planetary. Additional electronic
controls provide the Autoshift function. With the addition of
electronic controls, the operator now has a choice between manual
and automatic shifting.

26
 Powertrain
Heavy Duty Axles

•New, Heavy Duty Axles and Rims

•New Axle Housings, Differentials and Larger wheel
bearings in final drives for longer life
•Axle Shaft Brakes with separate front and rear circuits
•Driveshaft size increased
•Permanently lubed U-joints and slip shaft
•Larger rear trunnion support casting
•Bolted joint improvements

New axle housings, larger diffs and wheel bearings in final drives for
increased life expectancy
Axle shaft brakes w/ separate front and rear circuits
Oil-enclosed, multiple disc on the low torque side of final drives
Easily Serviced; no need to dismantle final drive
Trouble-free, Adjustment-free

Tires have remained the same, although the rims design has been changed to
accommodate the larger differentials. Rims on the 988G will not be
interchangeable with 988FII rims.

27
 Box Boom & Structures

•Single, Box Section

Boom
•Box Shaped Rear Frame
& Loader Tower
•90% Robotically
Welded with fewer parts
•Spread-hitch design
•Castings in High Stress
areas

Many people ask: why a single box boom ?

• better resistance to torsional stress and torsional fatigue.

•Fewer components in cylinders, linkage pins and 3:1 in z bar vs
boom
•improved visibility
•performance

28
 Box Boom & Structures
Linkage

• Single Box section • Improved Visibility

• Fewer components • Digging performance
– Reduced maintenance

Many people ask: why a single box boom ?

• better resistance to torsional stress and torsional fatigue.

•Fewer components in cylinders, linkage pins and 3:1 in z bar vs
boom
•improved visibility
•performance

29
 Box Boom & Structures
Linkage Design
Cast End

• Castings in high stress

areas
• Forked Ends
– Increase reliability
– Easier to service and
assemble
• Fabricated Boom
– Easier to repair
Fabricated Main – Same life as cast boom
Boom Body
Fabricated End

30
Box Boom & Structures
Non Engine End Frame (NEEF)

• Improved Performance without

additional weight
– Lift Height
– Payload
– Stability
– Durability
• Narrow design improves visibility
• High Strength Steel plates direct tilt
cylinder stresses down to frame
• Box sectioned tower with easier
access to hydraulic valves

31
 Box Boom & Structures
Engine End Frame (EEF) & Hitch

Old Load Path

New Load Path

• 26% increase in Spread Hitch design

• Box Section Rear Frame
• Taller, more substantial pant legs with
built in window in side frame
• Steering cylinder mounts moved
forward in frame
• Steel Castings in high stress areas

32
Box Boom & Structures
Engine End Frame (EEF)

• Box Section Rear Frame

• Taller, more substantial pant legs
with built in window in side frame
• Steering cylinder mounts moved
forward in frame
• Steel Castings in high stress areas

33
 Box Boom & Structures
Hitch

Old Load Path

New Load Path

• 26% increase in Spread Hitch design

• Vertical loads now absorbed through
top hitch
– More efficient distribution of loads
– Increased ground clearance
• Double tapered roller bearings on top
and bottom hitch

34
 Hydraulic System

• Productivity / Efficiency
– Two-position Implement pump
– Hydraulic speed and forces improved
• Load sensing steering and Demand Fan
• E/H Controls for operator comfort

The hydraulic system on the 988G is significantly updated from the

988FII to provide higher lift/tilt forces and improved speed. In
addition, the system is designed to improve on the management of
power, resulting in improved efficiency for longer life components
and improved fuel consumption.
The implement pump is a two-position implement pump that
provides hydraulic speed during travel and dump portions of the
loader cycle and reduces the speed during loading to improve fuel
efficiency and allow more usable double stall rimpull.
A manual override switch, referred to as Loose Material Mode,
allows the operator to maintain the high displacement setting for
fast hydraulic speed in loose material conditions where hydraulic
speed is required to efficiently load the bucket.
Improved efficiency is also provided for in the Load sensing
steering system, using Horsepower only when required and in the
hydraulic demand fan. The hydraulic cooling fan varies its speed
based on temperature so that the cooling system demands only the
power required to cool the engine and hydraulics.
All of this is controlled with the use of electro-hydraulic controls.

35
 Power Management

During TOUGH DIGGING….

Hydraulic Speed Decreased
….moderate to heavy dig where
speed is not required to load bucket
Fuel Efficiency & Available Rimpull

.…..When NOT DIGGING

Hydraulic Speed Increased
….faster lift/loader cycle times

With the 988G, we vary the amount of hydraulic speed provided during the
total loader cycle time. When the machine is digging, the implement pump is
set to the lower displacement setting, reducing speed and power requirements
when it is not needed resulting in increased fuel efficiency and more available
2xstall rimpull. When the machine is not digging, the implement pump position
is set to the high discplacement setting for increased hydraulic speed and faster
cycle times. A manual override switch, referred to as Loose Material Mode,
allows the operator to maintain the high displacement pump setting for fast
hydraulic speed. This will result in improved loading in easily penetrated, loose
material conditions where hydraulic speed is required to efficiently load the
bucket.

What we are talking about when we say…”Power Management” is providing

the power that you need when you need it.

“How does it Work?”……

Answer:
The speed of the hydraulics is delivered via a two-position implement pump.
This is a variable pump that delivers 155cc of pump displacement during
digging and 250cc when not digging. In order to determine when the machine
is digging, the 988G uses electronics to monitor three variables:
1. Linkage position - boom must be below horizontal
2. Gear selection - must be in 1st gear forward
3. Ground speed - must be less than 3.75 MPH 36
 Power Management

Fixed Implement System

988FII 3408 HEUI
Powertrain

Two-position Implement System

988G 3456 EUI
Powertrain

In order to fully understand the power management strategy of the 988G and
its benefits, we first must review how the classic wheel loader design manages
power. With the classic wheel loader design like the 988FII, management of
power was controlled by system components where engine horspower is
distributed in some fixed ratio to hydraulics and rimpull. The engine power is
controlled by engine rpm, or the throttle, and is distributed without any
variatoin or control. The ratio of power distribution is dictated by the sizing of
components and can not be optimized for both loading and hydraulic speed, so
one must be compromised for the other.

By combining electronic controls with the two position implement pump of

the 988G, the engine power distribution is not limited by component size.
Instead, electronics and a two-position pump are used to intelligently and
efficiently distribute power to the hydraulic and rimpull systems. During the
loading cycle, the hydraulic speed (pump displacement) is reduced requiring
less engine horsepower thus providing improved fuel efficiency and more
available rimpull. When the machine is not in the loading cycle, the hydraulic
speed (pump displacement) is increased for faster cycle times. As a result, the
988G delivers increased hydraulic and rimpull performance when it is needed
throughout the loader cycle, improving the total machine system efficiencies,
performance and fuel consumption.

37
Hydraulic System
Electro Hydraulics

• Electro Hydraulics
– Low effort fingertip controls
– Electronic kick-outs
– Automatic return to dig
– Feather catch (boom snubbing
effect)
– Productivity / Efficiency

38
 Hydraulic System
Performance Comparison

•Hydraulic pumps
988FII 988G
–2 Position Implement
Imp. Pres. 3000 psi 4500 psi
–Demand Fan Imp. Pump Fixed 2 Position
–Load Sensing Steering Steer. Pres. 3000 psi 3500 psi
Steer. Pump Fixed Load Sensing
•Faster hydraulics and
increased pressures for Brakes 1 Circuit 2 Circuits
increased lift and tilt forces Imp. Valve Pilot Hydrac
Fan System Eng. Speed Temperature
•Separate front/rear brake
circuits

•Greater control
•Easy, smooth, consistent
•Efficient, low effort operation.

39
 Hydraulic System

Optional Steering cylinder guards

40
 Operator Station

•New, 38% Larger Cab

–Improved Visibility
•Quieter cab
–77 dBA sound
•STIC Controller
•E/H Controls
•Adjustable Kickouts
•Throttle lock
•ICTC w/ RCS
•EMSII Monitoring
•Radio Ready

Operator comfort has become over the years a key to loader

productivity.

41
 Operator Station
CAT Comfort Seat

•Cast one piece back and seat pan

•Thicker seat cushions
•Automotive style lumbar support
•Fewer parts for improved
reliability

Contour

Comfort

42
 Hydraulic System
Steering - STIC Control System

Move
Speed Control controller to ... to the
Buttons the left to right to
steer left.... steer right

Direction
Control

Forward

Reverse

• Fully hydraulic system

• Less operator fatigue
• Improved cycle time

•Greater control
•Easy, smooth, consistent
•Seat or floor mounted STIC controller with adjustable armrests
•Side-to-side controller motion
•Efficient, low effort operation.

43
 Operator Station

1. Gauge Display
2. Speedometer/Tachometer Display
3. System Indicator Lights (illuminates when systems are active)
4. Monitoring System Display

1. Gauges include from top left to right:

•Engine Coolant Temperature
•Transmission Oil Temperature
•Hydraulic Oil Temperature
•Fuel Level
2. Tachometer and Gear Indicator Display

3. System Indicator Lights - Indicators illuminate when systems are active

and include:
• Ride Control
•Throttle Lock
•Reduced Rimpull
•Lock Up Torque Converter

4. Alert Indicators

44
 Operator Station

These switches are located on the lower left dash area.

•Monitoring System toggle switch. Changes the readout in the display
window from Service Hour Meter, Odometer, Tachometer and service codes
by depressing the switch.

•Ether Starting Aid. While cranking the engine, depress the switch to inject a
pre measured amount of ether into the air intake. Note: Ether wil
automatically be injected when the ambient conditions call for ether.

•Throttle Lock Switch. When this switch is in the on position, an indicator

light on the dashh will illuminate. For the set and resume functions to work,
this must be turned on.

45
 Operator Station

•Engine Start Switch

•System Indicator Lights: When systems like throttle lock, ride control or
reduced rimpull are active, these indicators will be illuminated
•Alert Indicators: From top, left to right
•Engine Oil Pressure
•Parking Brake
•Brake Oil Pressure
•Electrical System
•Coolant Flow
•Hydraulic Oil Filter
•Transmission Oil Filter
•Secondary Steering
•Monitoring System Display
•Turn Signals

46
 Operator Station

•250cc Displacement switch for loose material loading.

•Upper and Lower Kickouts: Depressing the bottom portion of the switch sets
the lower and upper kickouts. To set the lower kickout, place the bucket at the
desired height (anywhere from ground level to a position that the boom is
aboutt paralell with the ground. To use the lower kickout, after dumping and
leveling the bucket, push the hoist lever into the float detent. Make sure the
the boom is above the midpoint. To set the upper kickout, place the bucket at
the desired height andess the lower portion of the switch. To use, simply pull
the hoist lever into the lift detent.
The upper portion of the switch is used to set the bucket kickout. To use,
lower the bucket to the ground and adjust the bucket to the desired dig angle,
then depress the upper portion of the switch.

• Hazzard Lights

47
 Operator Station

•Front windshield Wiper and Washer

•Ride Control
Travel at high speeds over rough terrain causes the machine to pitch.
The ride control ssytem acts as a shock absorber by absorbing from the
bucket and by dampening forces from the bucket.l This results in less
material spilled.

The ride control is a two position switch, off and automatic. In the
automatic mode, ride control will engage when ground speed is low.
When ground speed increases, ride control will automatically engage.

•Lock Up Torque Converter:

Pressing the bottom of the switch enables the lock up clutch so that the
torque converter can lock upwhen the engine speed is in the correct
range. This happens automatically. This feature provides more
ifficient operation in a load and carry application.

•Autoshift/Quick Shift
For manual shifting, place the control in the ‘hand position’. To use
Autoshift, select the highest gear desired. Autoshift will upshift and
downshift automatically from second gear to the highest gear selected.

48
Operator Station

49
 Operator Station

Cab modesty cover

50
 Operator Station

Optional extended roof for improved water run off.

51
 Operator Station

Improved Access to Cab

Engine Shutdown Switch

& Stairway Access Light

Operator comfort has become over the years a key to loader

productivity.
For the 990II and the 992G Caterpillar has developed the most
advanced LWL cabs.

52
 Operator Station

Optional Roading Fenders which include optional right hand

stairway.

53
Serviceability

• EMSII alerts operator and logs events for easy

troubleshooting
• Diagnostic connector allows quick troubleshooting of
electrical components
• Ground level lube points are grouped and centralized into
four locations
• Ground level fuel fill
• Batteries located in the bumper accessible through hinged
doors
• Large hinged doors, bolt-on panels, and convenient
service platform help make service quick and easy

54
 Electronics & Monitoring

*Cat Data Link

*EMSII
*ADEMII *E/H Controls

*ICTC w/RCS
*ECPC Trans

Electronics are playing an increasing roll in today’s machines, and the 988G is
no exception. Electronic controls have the ability to impact the performance,
efficiency, diagnostics and serviceability of the machine. The Cat Data Link is
the vehicle that allows these systems to communicate to each other. Without
the Cat Data Link, the system communication and efficiencies would not be
possible.
Utilizing the Cat Data Link, the 988G’s EMSII monitoring system is linked to
the electronic engine, implement controls and transmission software. This
system is an analog style gauge display with electronic monitoring of several
key functions providing a three level warning system to the operator. The three
category levels are as follows:
Category 1:
- alert indicator flash and no immediate action required. Will not cause
harmful or damaging effects
Category 2:
- alert indicator flashes and action lamp flashes and requires a change to the
operation or maintenance to system. May cause severe damage to
components.
Category 3:
- alert indicator flashes, action lamp flashes and action alarm sounds requiring
an immediate safe engine shutdown. May cause operator injury or sever
damage to components.

55
 Attachments
Buckets & GET

• Multiple Bucket offerings (8.2, 8.33, 8.7, 9.0, 9.2cyd)

•Straight Edge (8.2-9.2)
•Spade Nose (8.33,8.7 & 9.0)
•H.D. Quarry (8.33)
•High Abrasion (8.33)

•Shell-Tine Construction
•Integral rock guard
•Replaceable weld-on wear plates
•Heavy Duty pins and retainers

56
Attachments
Spade Nose Buckets

•Spade Nose Rock Buckets

–Available in three capacities:
8.33, 8.7, 9.0cyd
–Bolt-on Segments
–Shouldered, Double strap
adapters
–Several tip options
–Accepts 2 sets of sidebar
protectors
–Bolt-on rear cutting edge

57
Attachments
Straight Edge Buckets

• 8.2 cyd Straight Edge Rock

–Bolt-on Segments
–Shouldered, Double strap
adapters
–Several tip options
–Accepts 2 sets of sidebar
protectors
–Bolt-on rear cutting edge

58
Attachments
Straight Edge Buckets

•9.2 cyd General Purpose

–Bolt-on GET options
–Cutting Edge
–Adapters
–Adapters w/segments
–Several tip options

59
 Attachments
H.D. Quarry Bucket

• 8.33 cyd H.D. Quarry

– Intended for moderate
abrasion and high impact
– Thicker base edge and
adapters
– Additional liners and wear
plates
– 2 sets of sidebar protectors
– Bolt-on half arrow
segments
– Several tip options

60
 Attachments
High Abrasion

• 8.33 cyd High Abrasion

– Intended for high abrasion
and low to moderate impact
– Thicker Edge Protection
– Independently attached
edge and adapter covers
– Half radius liners
– 1 set of sidebar protectors
– Several tip options

61
 Attachments
GET
Penetration Ability
Impact Resistance
Abrasion Protection
Smooth Floor Maintenance Surraded edge

Cutting Edges Flushmount Bottom-strap Two-strap H.D. Mining Heavy Duty

Adapters Adapters Adapters with System Quarry System
edge segments

Surrated edge (use in low abrasion materials):

•No risk of loosing GET in crushers & breakers
•Less weight on bucket - best cost per tonne

62
Attachments
Buckets & GET - tips

Wear Life
Penetration
Impact

Short Long Penetration Heavy Duty Heavy Duty Heavy Duty Heavy Duty
- High-impact and - General - Good penetration Long Abrasion Long Life Penetration
pry-out work applications - Self-sharpening - Longer wear life - Maximum wear - General loading - High-impact,
- Extremely strong - Greater strength - Gravel and and excavating hard-to-penetrate
- General loading shot rock - Increased wear life material
and excavation - Penetration - Longer wear life

63
Attachments
Bucket match

• Penetration is key for better cycle time/fuel efficiency

• Importance to find the best (bucket weight, resistance, longevity) /
machine cost per ton) ratio
• GET increase bucket life but reduce machine efficiency (cost, weight,
penetration)

64
 Pass Match

769D (38.1T) 771D (44.8T) 773D (54.5T) 775D (69.9T)

Height: 10'4" Height: 11'2" Height: 12'5" Height: 12'10"
Width: 11'11" Width: 11'11" Width: 14'8" Width: 14'8"
988FII Std.(12T)
Dump: 10'7'' 3 Pass 3-4 Pass
Reach: 5'3"
988FII HL (11T)
Dump: 12'1'' 3 Pass 3-4 Pass 5 Pass
Reach: 5'6''
988G (12.5T)
Dump: 13'1'' 3 Pass 3-4 Pass 4-5 Pass 5-6 Pass
Reach: 5'3''

65
Performance
Overburden

CYCLE TIME 988FII 988FII HL 988G

Travel Loaded 0.147 0.139 0.111

Dump 0.091 0.070 0.082

Travel Empty 0.096 0.097 0.098
Load 0.227 0.204 0.186
Total Cycle Time 0.561 0.510 0.477

Cycle Time in minutes

3 pass loading 769s
Overburden - Earth/Rock Mix - Est. Density 3100 lb/lcy

66
Performance
Overburden

PRODUCTION 988FII 988FII HL 988G

Cycles/60 min. hr. 107 117.6 125.8

Bucket Size 8.25 7.5 8.33
Avg. Bucket Payload 14.21 12.85 14.46
Tons/ 60 min. hr. 1521 1511 1819

988FII Baseline 100% 99% 120%

Production based on average bucket payload and cycle time, truck transfer time is not included.

FUEL 988FII 988FII HL 988G

Tons/Gallon 81.77 77.53 97.01

Gallons/Hour 18.60 19.49 18.75

988FII Baseline 100% 95% 119%
Tons/Gal

67
Performance
Rock

CYCLE TIME 988FII 988FII HL 988G

Travel Loaded .122 .130 .117

Dump .073 .060 .063

Travel Empty .095 .092 .094

Load .112 .108 .106

Total Cycle Time .402 .390 .380

3 pass loading 769’s

Cycle Time in minutes
Material: Rock - Est. Density 2700 lb/lcy

68
Performance
Rock

PRODUCTION 988FII 988FII HL 988G

Cycles/60 min. hr. 149.3 153.9 157.9

Bucket Size 8.25 7.5 9.0

Avg. Bucket Payload 11.50 10.44 12.25

Tons/ 60 min. hr. 1717 1607 1934

988FII Baseline 100% 94% 113%

Production based on average bucket payload and cycle time, it does

not reflect normal delays such as truck transfer time.

FUEL 988FII 988FII HL 988G

Tons/Gallon 101.66 90.33 113.37

Gallons/Hour 16.89 17.78 17.06

988FII Baseline 100% 89% 112%
Tons/Gal

69
Performance
600 Ton/Hr

CYCLE TIME 988FII 988G

Travel Loaded .120 .116
Dump .087 .099
Travel Empty .114 .112

Load .108 .107

Total Cycle Time 0.429 0.433

3 pass loading 769’s

Cycle Time in minutes
Material: Rock - Est. Density 2700 lb/lcy

70
 Performance
600 Ton/Hr

PRODUCTION 988FII 988G FUEL 988FII 988G

Truck Transfer Time 2.5 2.5

Gal/Hr. 9.25 8.30
!st Dump 0.087 0.099
988FII Baseline 100% 90%
Remaining Passes 0.86 0.87 Gal/Hr.

Total Truck Load Time 3.45 3.47

Trucks/60 Min Hr 17.42 17.29
Avg. Bucket Payload 11.50 11.70
Avg. Truck Payload 34.50 35.10
3 pass loading 769’s
Tons/60 Min Hr 601 606.9
Cycle Time in minutes
988FII Baseline 100% 101%
Material: Rock - Est. Density 2700 lb/lcy

71
Performance
Load & Carry

CYCLE TIME 988FII 988G

Travel Loaded .524 .493
Dump .068 .058
Travel Empty .338 .326
Load .139 .136

Total Cycle Time 1.069 1.013

Load & Carry course consisted of 120 ft. of +3%, 71 ft. of +4% and a
ramp that was 71 ft. of +15% grade.
Material: Rock - Est. Density 2900 lb/lcy

72
Performance
Load & Carry

PRODUCTION 988FII 988G

Cycles/60 min. hr. 56.1 59.2

Bucket Size 8.25 9.0

Avg. Bucket Payload 10.10 10.66

Tons/ 60 min. hr. 567 631

988FII Baseline 100% 111%

Production based on average bucket payload and cycle time, it does

not reflect normal delays such as truck transfer time.
FUEL 988FII 988G

Tons/Gallon 34.89 38.00

Gallons/Hour 16.25 16.61

988FII Baseline 100% 109%

Tons/Gal

73
Performance
Overburden - 773/775 Trucks

CYCLE TIME 988FII HL 988G

Travel Loaded .148 .134
Dump .095 .094

Travel Empty .113 .114

Load .238 .187

Total Cycle Time .594 .529

4 pass loading 773 and 5 pass loading 775

Cycle Time in minutes
Overburden - Earth/Rock Mix - Est. Density 3100 lb/lcy

74
Performance
Overburden - 773/775 Trucks

PRODUCTION 988FII HL 988G

Cycles/60 min. hr. 101 113.4
Bucket Size 7.5 8.25
Avg. Bucket Payload 13.29 14.45
Tons per 60 min. hr. 1342 1639
988FII HL Baseline 100% 122%

Production based on average bucket payload and cycle time, it does

not reflect normal delays such as truck transfer time.

FUEL 988FII HL 988G

Tons/Gallon 72.89 83.37
Gallons/Hour 18.41 19.66

988FII HL Baseline 100% 114%

Tons/Gal

75
 Special Applications

Steel Mill
Logging
Block-Handling

In the past, applications were less demanding and the same LWL
would be operated in any kind of application.
.
In today’s world, for each application, Caterpillar LWL are pushed
to the limit.
•High speed cycling with nominal payload for truck loading
•Hauling of enormous blocks on steep grades for block handling
operations.
•Loading of hot slag for steel mill applications
•Industrial….

•Caterpillar provides a customized solution for each application

and adapt the machine features to answer customer requirements.

76
 988G Wheel Loader

* Performance

* Efficiency

* Operator Comfort

As shown in this presentation, the G series wheel loader represents a

significant advancement in the 988 size class. From the revolutionary single,
box boom linkage design to the intelligent power management and increased
stability, the 988G results in improved performance, efficiency and operator
comfort.

77