Caterpillar Cat 538 EXCAVATOR (Prefix JEY) Service Repair Manual (JEY00001 and up).pdf

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Product: EXCAVATOR
Model: 538 EXCAVATOR JEY
Configuration: 538 Forest Machine Log Loader JEY00001-UP (MACHINE) POWERED BY C7.1 Engine
Disassembly and Assembly
538 LL GF Forest Machine Machine Systems
Media Number -M0071454-01 Publication Date -01/08/2017 Date Updated -02/08/2017
i06723435
Final Drive - Assemble
SMCS - 4050-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-2420 Transmission Repair Stand 1
B 439-3938 Link Bracket 2
C 1P-1863 Retaining Ring Pliers 1
E 439-3939 Link Bracket As 2
G 1U-5933 Duo-Cone Seal Installer As 1
H - Loctite C5A Copper Anti-Seize -
J - Loctite 5188 -
K 369-9451 Grease -
L - Loctite 243 -
M FT-2770 Leak Down Test Tool 1
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are
worn or damaged, use new parts for replacement. All disassembly and all assembly procedures
must be performed on a clean work surface and in a clean hydraulic area. Always keep cleaned
parts covered and protected.
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Note: O-rings, gaskets, and seals should always be replaced. A used O-ring may not have the
same sealing properties as a new O-ring. Use Tooling (K) during the assembly procedure.
Note: Apply a light film of hydraulic oil to all components before assembly.
1. If necessary, install the sprocket.
Illustration 1 g01760833
2. Lower the temperature of bearings (44) and (46).
3. Use a suitable press to install bearings (44) and (46). Make sure that bearings (44) and (46)
contact the counterbore in housing (39).
4. Use the following procedure to preload the bearings and determine the correct thickness of
shims.
a. Attach Tooling (E) and a suitable lifting device to housing (39). Install housing (39)
onto motor housing (41).
b. Position housing (39) and motor housing (41) onto a suitable press. The combined
weight of housing (39) and motor housing (41) is approximately 82 kg (180 lb).
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(a) Bearing surface
(b) Housing surface
c. Use a suitable press and a spacer to apply a load of 4000 kg (8820 lb) on the bearings.
Rotate the housing to seat the bearings.
d. Reduce the load on the bearings to 1000 ± 100 kg (2200 ± 220 lb).
e. Use a depth micrometer to measure the step length between the bearing surface and
the housing surface. Take measurements at several different locations around the
housing. Compute the average of the measured dimensions and record the number.
Call this Dimension (Y).
f. Use a depth micrometer to measure the step length of coupling gear (38). Take
measurements at several different locations around coupling gear (38). Compute the
average of the measured dimensions and record the number. Call this Dimension (X).
g. The thickness of the shims is equal to (X − Y) ± 0.05 mm (0.002 inch).
Note: Use no more than two shims. If two shims are required, install the thinner shim
next to coupling gear (38).
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h. Use Tooling (E) and the suitable lifting device to remove housing (39) from motor
housing (41).
Note: The rubber seals and sealing surfaces must be clean and dry. Apply a thin film of
clean SAE 30 oil on the contact surfaces of the metal seals prior to assembly.
5. Use Tooling (G) to install Duo-Cone seal (45) in housing (39). Refer to Disassembly and
Assembly, "Duo-Cone Conventional Seals - Install".
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6. Use Tooling (G) to install Duo-Cone seal (43) in motor housing (41).
7. Apply Tooling (H) to the surfaces that contact dowel pins (42).
8. Install dowel pins (42).
Note: Do not damage the Duo-Cone seals in the housing or in motor housing (41) during
the assembly of the two components. After installation of the housing on motor housing
(41), there will be a small gap between the components. The gap is caused by the Duo-Cone
seals. This gap will be eliminated during installation of coupling gear (26) (not shown).
9. Attach Tooling (E) and a suitable lifting device to housing (39). The combined weight of
housing (39) and the final drive sprocket is approximately 82 kg (180 lb).
10. Install housing (39) on motor housing (41).
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11. Install shims (40) that were determined in Step 4.g in the housing.
Note: If two shims are required, install the thinner shim next to the coupling gear.
12. Install coupling gear (38).
13. Apply Tooling (L) to the clean threads and dry threads of bolts (37).
14. Install bolts (37) in an even pattern until coupling gear (38) is seated against the bearing.
Tighten bolts (37) in a crisscross pattern to a torque of 570 ± 80 N·m (420 ± 60 lb ft).
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15. Install O-ring seal (36).
16. Use two people to install ring gear (35). The weight of ring gear (35) is approximately 41 kg
(90 lb).
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17. Assemble carrier assembly (29), as follows.
a. Install bearings (33) in planetary gear (34).
b. Install thrust washers (32) and planetary gear (34) in carrier assembly (29).
c. Use a deburring tool to remove the metal burr from the openings in the carrier. Install
planetary shaft (30) in carrier assembly (29).
d. Align the split in spring pin (31) to the top or the bottom of the carrier. Make a stake
mark on each side of the spring pin hole. Dimension (AA) indicates the location of
the stake marks. Dimension (AA) is 2.25 ± 0.75 mm (0.089 ± 0.030 inch) from the
outside diameter of the spring pin hole to the stake.
e. Use a suitable hammer and a suitable punch to drive spring pin (31) into planetary
shaft (30).
f. Repeat Steps 17.a through 17.d to install the other two planetary gears in the carrier.
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18. Use two people to install carrier assembly (29). The weight of carrier assembly (29) is
approximately 39 kg (85 lb).
19. Install spacer (28) and gear (27).
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a. Install bearing (25) in planetary gear (26).
b. Install thrust washers (24) and planetary gear (26) in carrier assembly (21).
c. Use a deburring tool to remove the metal burr from the openings in the carrier. Install
planetary shaft (23) in carrier assembly (21).
d. Align the split in spring pin (22) to the top or the bottom of the carrier. Make a stake
mark on each side of the spring pin hole. Dimension (BB) indicates the location of the
stake marks. Dimension (BB) is 2.25 ± 0.75 mm (0.089 ± 0.030 inch) from the
outside diameter of the spring pin hole to the stake.
e. Use a suitable hammer and a suitable punch to drive spring pin (22) into planetary
shaft (23).
f. Repeat Steps 20.a through 20.d for the other two planetary gears in the carrier.
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538 Forest Machine Log Loader JEY00001-UP (MACHINE) POWERED BY C7.1 ...
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21. Install carrier assembly (21) into ring gear (35).
22. Install retaining ring (20).
Note: Make sure that the oil passages in shafts (17) are oriented toward the center of carrier
assembly (16).
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24. Raise the temperature of carrier assembly (16). Lower the temperature of (17) shafts. Install
shafts (17) into carrier assembly (16) until the groove of shafts (17) is at Dimension (A).
Dimension (A) equals 21.70 ± 0.10 mm (0.854 ± 0.004 inch).
25. Make eight stake marks at distance of Dimension (C) from each shaft (17). Dimension (C)
equals 2.0 ± 1.0 mm (0.08 ± 0.04 inch). The width of each stake mark should be equal to
Dimension (B). Dimension (B) equals 4.0 ± 1.0 mm (0.16 ± 0.04 inch).
a. Install carrier assembly in position on gear (18).
b. Install retaining ring (15) onto gear (18).
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c. Install washer (12) and bearing assembly (14).
d. Install gear (13) and second washer (12).
e. Use Tooling (C) to install retaining ring (11).
f. Repeat Steps 26.a through 26.e for the other two planetary gears.
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28. Install O-ring seal (8) on plugs (5).
29. Install plugs (5) in cover (1). Install one 8.00 mm (0.315 inch) plate (7).
30. Position gear (6) and install bolts (4).
31. Place a piece of solder in the center of gear (9) (not shown).
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Note: You may need to apply some grease to the solder to keep the solder in position on
gear (9).
32. Use Tooling (B) and a suitable lifting device to install cover (1). The weight of cover (1) is
33. Install four bolts (2) at 90 degrees from each other. Tighten bolts (2) in a crisscross pattern
to a torque of 420 ± 60 N·m (310 ± 44 lb ft). Turn bolts (2) and additional 60 ± 5 degrees.
34. Remove bolts (2).
35. Use Tooling (B) and a suitable lifting device to remove cover (1). The weight of cover (1) is
36. Use a micrometer to measure the thickness of the solder. Record this measurement to
determine the required thickness of plates (7). Adjust plates (7) to obtain a clearance of
1.000 + 1.000 mm (0.0394 + 0.0394 inch) between plate (7) and gear (9).
37. Apply Tooling (J) to the mating surfaces of cover (1) and the housing.
38. Use Tooling (B) and a suitable lifting device to install cover (1). The weight of cover (1) is
39. Install bolts (2). Tighten bolts (2) in a crisscross pattern to a torque of 420 ± 60 N·m
(310 ± 44 lb ft). Turn bolts (2) and additional 60 ± 5 degrees.
40. Remove plug (5) (not shown). Attach Tooling (M) to the cover. Reduce the air pressure at
the source to 103 kPa (15 psi). Apply air pressure to Tooling (M). This air will test the Duo-
Cone seals.
41. Use the ball valve on Tooling (M) to eliminate the air pressure to the final drive. A pressure
of 98 kPa (14.2 psi) must be maintained for 30 seconds.
42. Remove Tooling (M). Install plug (5) (not shown). Tighten plug (5) to a torque of
80 ± 10 N·m (59 ± 7 lb ft).
43. Remove the final drive from Tooling (A). The weight of the final drive assembly is
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44. If necessary, install the sprocket.
End By:
a. Install the final drive.
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Feb 5 09:43:32 UTC+0800 2021
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Shutdown SIS
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Product: EXCAVATOR
i06724220
Swivel - Remove and Install
SMCS - 5060-010
Removal Procedure
Table 1
Required Tools
A FT-2674 Vacuum Cap 1
B 1U-9200 Lever Puller Hoist 1
C 439-3938 Link Bracket 2
Start By:
a. Release the hydraulic system pressure.
Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the
engine has been stopped. Serious injury can be caused if this pressure is
not released before any service is done on the hydraulic system.
Make sure all of the work tools have been lowered to the ground, and
the oil is cool before removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the filler cap is cool
enough to touch with your bare hand.
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Typical Example
1. Install Tooling (A) onto the hydraulic tank . Attach an air supply hose onto Tooling (A).
Apply 276 ± 414 kPa (40 ± 60 psi). This procedure will pull a vacuum on the hydraulic
system.
2. Remove bolts (2) and covers (1).
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3. Disconnect hose assemblies (6). Disconnect fitting (7). Disconnect hose assemblies (3).
Remove fittings (5). Remove bolts (4).
4. Remove bolts (9) and platform assembly (8).
5. Disconnect hose assemblies (10). Remove the bolts from bracket (11). Reposition bracket
(11) out of the way.
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6. If necessary, use Tooling (B) to secure the hose assemblies out of the way. Disconnect the
hose assembly and remove fitting (12). Remove support (17). Loosen clamp (13). Remove
bolts (14), retainer (15), and boot (16).
7. Attach Tooling (C) and a suitable lifting device to swivel (18). The weight of swivel (18) is
approximately 102 kg (225 lb). Remove swivel (18).
Installation Procedure
1. Install swivel (18) in the reverse order of removal.
Fri Feb 5 09:44:27 UTC+0800 2021
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Shutdown SIS
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Product: EXCAVATOR
i06724515
Swivel - Disassemble
SMCS - 5060-015
Disassembly Procedure
Table 1
Required Tools
B 439-3940 Bracket As 2
Start By:
a. Remove the swivel.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: Put orientation and location marks on housings for installation purposes.
1. Thoroughly clean the outside of the swivel prior to disassembly.
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2. Attach Tooling (B) and a suitable lifting device to swivel (1). The weight of swivel (1) is
3. Position swivel (1) onto Tooling (A).
4. Remove bolts (2) and (3).
5. Remove cover (4) from the bottom of swivel (1).
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6. Remove O-ring seal (5), bolts (6), and retainer (7) from the bottom of swivel (1).
Note: Be sure that alignment marks are put on rotor (8) and housing (11) for assembly
purposes.
7. Use Tooling (B) and a suitable lifting device to separate rotor (8) from housing (9).
8. Remove O-ring seal (10) (not shown) from housing (11).
9. Use Tooling (B) and a suitable lifting device to separate rotor (8) from housing (11).
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10. Remove seal assemblies (12) from housing (11).
11. Remove seal assemblies (13) from housing (9).
Fri Feb 5 09:45:23 UTC+0800 2021
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Shutdown SIS
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Product: EXCAVATOR
i06724539
Swivel - Assemble
SMCS - 5060-016
Assembly Procedure
Table 1
Required Tools
B 439-3940 Bracket As 2
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: Check the O-ring seals and the seals for wear or for damage. Replace the components, if
necessary.
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1. Apply clean hydraulic oil to seal assemblies (12).
2. Install O-ring seal (10) and seal assemblies (12) into housing (11).
3. Position housing (9) onto housing (11). Loosely install bolts (2) to secure housing (9) to
housing (11).
4. Apply clean hydraulic oil to seal assemblies (13).
5. Install seal assemblies (13) into housing (9).
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6. Use two people to position housing (9) and housing (11) onto Tooling (A). The combined
weight of housing (9) and housing (11) is approximately 41 kg (91 lb).
7. Attach Tooling (B) and a suitable lifting device to rotor (8). The weight of rotor (8) is
8. Use Tooling (B) and a suitable lifting device to install rotor (8) into housing (11) and
housing (9) (not shown).
9. Remove four bolts (2) (not shown).
3/4
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10. Install retainer (7), bolts (6), and O-ring seal (5) to the bottom of swivel (1).
11. Install cover (4), bolts (3), and bolts (2) to the bottom of swivel (1).
End By:
a. Install the swivel.
Fri Feb 5 09:46:19 UTC+0800 2021
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Shutdown SIS
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Product: EXCAVATOR
i06725205
Swing Motor - Remove and Install
SMCS - 5058-010-ZW
Removal Procedure
Table 1
Required Tools
A FT-2674 Vacuum Cap 1
B 439-3938 Link Bracket 2
Start By:
a. Release the hydraulic system pressure.
1. Remove guard assembly (1).
1/5
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2. Remove sheet (2) and cover assembly (3).
3. Remove cover assembly (4).
Typical Example
2/5
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Caterpillar Cat 538 EXCAVATOR (Prefix JEY) Service Repair Manual (JEY00001 and up).pdf

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