Caterpillar Cat 538 EXCAVATOR (Prefix KBJ) Service Repair Manual (KBJ00001 and up).pdf

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Product: EXCAVATOR
Model: 538 EXCAVATOR KBJ
Configuration: 538 Forest Machine General Forestry KBJ00001-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
i06724515
Swivel - Disassemble
SMCS - 5060-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-2420 Transmission Repair Stand 1
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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538 Forest Machine General Forestry KBJ00001-UP (MACHINE) POWERED BY C7...
2021/2/4
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw...

Illustration 1 g01767936
2. Attach Tooling (B) and a suitable lifting device to swivel (1). The weight of swivel (1) is
approximately 496 kg (225 lb).
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).
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Thu Feb 4 20:43:01 UTC+0800 2021
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Product: EXCAVATOR
i06724539
Swivel - Assemble
SMCS - 5060-016
Assembly Procedure
Table 1
Required Tools
A 1P-2420 Transmission Repair Stand 1
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
approximately 54 kg (119 lb).
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).
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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.
Thu Feb 4 20:43:56 UTC+0800 2021
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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).
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2. Remove sheet (2) and cover assembly (3).
3. Remove cover assembly (4).
Typical Example
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4. Install Tooling (A) onto the hydraulic tank . Attach an air supply hose onto Tooling (A).
Apply 276 to 414 kPa (40 to 60 psi) of air. This procedure will pull a vacuum on the
hydraulic system.
5. Drain the swing drive oil. Refer to Operation and Maintenance Manual, "Swing Drive Oil -
Change" for the correct draining and filling procedures.
Note: Not all machines will require the removal of all the hose assemblies. Remove the
hose assemblies that will make the removal of the swing motor easier.
6. Disconnect hose assemblies (12) and (13) at the boom side of the hose assemblies.
Reposition hose assemblies (12) and (13) out of the way for more access to the swing
motor.
7. Disconnect hose assemblies (6) and (7).
8. Disconnect hose assemblies (8) and (9).
9. Disconnect harness assembly (10).
10. Disconnect clip (11).
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11. Disconnect hose assembly (14).
12. Remove bolts (16) and anti-reaction valve (17).
13. Remove bolts (15).
14. Prior to the removal of the swing motor, clean the swing motor and the area around the
swing motor. Remove any loose paint around the mating surface of the swing drive and the
swing motor to prevent contamination from entering the swing drive.
15. Attach Tooling (B) and a suitable lifting device to swing motor (18). The weight of swing
motor (18) is approximately 55 kg (120 lb).
16. Remove swing motor (18).
Installation Procedure
1. Install swing motor (18) in the reverse order of removal.
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Product: EXCAVATOR
i06726429
Swing Motor - Disassemble
SMCS - 5058-015-ZW
Disassembly Procedure
Table 1
Required Tools
A
8T-0651 Bolts 2
8T-4167 Hard Washers 2
B 1P-1859 Retaining Ring Pliers 1
C 9S-9152 Bearing Puller Gp 1
D
1P-0074 Slide Hammer Puller 1
5F-7344 Puller Block 1
5P-4750 Adjusting Screw 1
7S-7786 Puller Leg 2
Start By:
a. Remove the swing motor.
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1. If necessary, remove bolts (2) and anti-reaction valve (3) from head (1).
2. Remove mounting bolts (4).
3. Remove dipstick tube (5) and breather tube (6) from motor housing (7).
4. Remove relief valves (8).
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5. Remove O-ring seals (10), (12), and (13).
6. Remove backup rings (9) and (11).
Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
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7. Remove bolts (14) and the head.
Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
8. Remove plug (18), O-ring seal (17), spring (16), and spool valve (15) from the head. Repeat
for the other side.
9. Remove adapter (19), fitting (20), and plugs (21).
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10. Remove O-ring seal (22) from plug (21).
11. Remove O-ring seals (23) and (24) from fittings (19) and (20).
12. Remove O-ring seal (25).
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13. Remove spring pins (26) and bearing (27).
14. Remove springs (28) and port plate (29).
Typical Example
15. Install Tooling (A) and apply air pressure to unseat the piston.
Note: Use air pressure to avoid damage to the piston.
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16. Remove piston (30).
Typical Example
17. Remove plates (31).
Typical Example
18. Remove barrel (32) and the pistons as an assembly.
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19. Mark pistons (33).
20. Remove pistons (33) from barrel (32).
21. Remove pistons (33) from plates (34) and (35).
22. Separate plates (34) and (35).
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Typical Example
23. Remove O-ring seals (36) and (36a) from the motor housing.
24. Remove swashplate (37).
25. Use Tooling (B) to remove retaining ring (38) from shaft (39).
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26. Remove shaft (39).
27. Use a suitable press and Tooling (C) to remove bearing race (40).
28. Use a suitable press and Tooling (C) to remove bearing race (41).
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538 Forest Machine General Forestry KBJ00001-UP (MACHINE) POWERED BY ...
2021/2/4

Typical Example
29. Use Tooling (D) to remove bearing (42).
30. Remove lip seal (43).
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31. Remove fitting (44).
32. Remove O-ring seal (45) from fitting (44).
Thu Feb 4 20:45:48 UTC+0800 2021
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Product: EXCAVATOR
i06727706
Swing Motor - Assemble
SMCS - 5058-016
Assembly Procedure
Table 1
Required Tools
B 1P-1859 Retaining Ring Pliers 1
E 1P-0510 Driver Group 1
F 369-9451 Grease -
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry.
Note: O-ring seals, gaskets, and seals should always be replaced. A used O-ring seal may not have
the same sealing properties as a new O-ring seal. Use Tooling (F) during the assembly procedure.
Note: Apply a light film of clean hydraulic oil to all components before assembly.
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1. Install O-ring seal (45) onto fitting (44).
2. Install fitting (44).
3. Lubricate lip seal (43) with clean hydraulic oil. Install lip seal (43) with the lip toward the
inside of the motor housing.
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Typical Example
4. Use Tooling (E) to install bearing (42).
5. Raise the temperature of bearing race (41). Install bearing race (41).
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6. Raise the temperature of bearing race (40). Install bearing race (40).
7. Install shrink wrap tubing onto shaft (39). The shrink wrap tubing will protect the seal
during installation of shaft (39).
8. Install shaft (39).
4/13
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9. Use Tooling (B) to install retaining ring (38) onto shaft (39). Remove the shrink wrap
tubing.
10. Install swashplate (37).
Typical Example
11. Install O-ring seals (36) and (36a) into the motor housing.
5/13
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Caterpillar Cat 538 EXCAVATOR (Prefix KBJ) Service Repair Manual (KBJ00001 and up).pdf

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Caterpillar Cat 538 EXCAVATOR (Prefix KBJ) Service Repair Manual (KBJ00001 and up).pdf