Caterpillar Cat 538 EXCAVATOR (Prefix GMY) Service Repair Manual Instant Download.pdf

Product: EXCAVATOR
Model: 538 EXCAVATOR GMY
Configuration: 538 Forest Machine General Forestry GMY00001-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
i06723334
Final Drive - Disassemble
SMCS - 4050-015
Disassembly 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
D 154-6181 Forcing Screw 2
E 439-3939 Link Bracket As 2
F
5F-7366 Forcing Screw 1
1P-5546 Crossblock 1
1U-9889 Crossblock 1
1P-0520 Driver Group 1
6V-7888 Puller Leg 2
1H-3112 Puller Assembly 1
1P-5551 Adjustable Screw Assembly 1
Start By:
a. Remove the final drive.
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Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of
the component should be thoroughly cleaned. This will prevent dirt from entering the
internal mechanism.
Note: Some of the images that are in this procedure do not show the sprocket assembly that
is attached to the final drive housing. If necessary, the weights that are given include the
weight of the sprocket assembly.
1. Put an alignment mark across the sections of the final drive for assembly purposes. The
parts must be reinstalled in the original locations.
Illustration 1 g01751055
2. Position final drive (3) to Tooling (A). The weight of final drive (3) is approximately 365 kg
(785 lb).
3. Remove bolts (2) that hold cover (1) in position.
4. Remove the setscrews from cover (1).
5. Attach Tooling (B) and a suitable lifting device to cover (1). The weight of cover (1) is
approximately 32 kg (70 lb).
6. Remove cover (1).
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7. Remove bolts (4) and gear (6).
8. Check plate (7). Replace plate (7) if wear is shown.
9. Remove plugs (5) from cover (1).
10. Remove O-ring seal (8) from plugs (5).
11. Remove gear (9) and spacer (10).
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12. Use Tooling (C) to remove retaining ring (11).
13. Remove washer (12) and gear (13).
14. Remove bearing assembly (14) and second washer (12).
15. Repeat Steps 12 through 14 for the remaining two gear assemblies.
16. Remove retaining ring (15).
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17. Remove carrier assembly (16).
18. Use a suitable press to remove shafts (17) from carrier assembly (16).
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20. Remove retaining ring (20) and carrier assembly (21).
21. Disassemble carrier assembly (21), as follows.
a. Use a suitable hammer and a suitable punch to drive spring pin (22) into planetary
shaft (23).
b. Remove planetary shaft (23).
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c. Use a suitable hammer and a suitable punch to remove spring pin (22) from planetary
shaft (23).
d. Remove thrust washers (24) and planetary gear (26) from the carrier assembly.
e. Remove bearing (25) from planetary gear (26).
22. Repeat Steps 21.a through 21.e for the other two planetary gears.
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24. Use two people to remove carrier assembly (29). The weight of carrier assembly (29) is
25. Disassemble carrier assembly (29), as follows.
a. Use a suitable hammer and a suitable punch to drive spring pin (31) into planetary
shaft (30).
b. Remove planetary shaft (30).
c. Use a suitable hammer and a suitable punch to remove spring pin (31) from planetary
shaft (30).
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d. Remove thrust washers (32) and planetary gear (34) from the carrier assembly.
e. Remove bearings (33) from planetary gear (34).
26. Repeat Steps 25.a through 25.e for the other two planetary gears.
27. Use two people to remove ring gear (35). The weight of ring gear (35) is approximately
41 kg (90 lb).
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28. Remove O-ring seal (36).
29. Remove bolts (37) from coupling gear (38).
30. Use Tooling (D) to remove coupling gear (38) from housing (39).
31. Remove shims (40).
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32. 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).
33. Use a suitable hammer and a suitable punch to separate housing (39) and the final drive
sprocket from the motor housing (41).
34. Remove Duo-Cone seal (43) from motor housing (41).
35. Remove dowel pins (42).
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36. Remove Duo-Cone seal (45) from housing (39).
37. Use Tooling (F) to remove bearings (44) and (46) from housing (39).
38. If necessary, remove the sprocket.
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Product: EXCAVATOR
Model: 538 EXCAVATOR GMY
Configuration: 538 Forest Machine General Forestry GMY00001-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.
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
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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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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