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

538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED BY C... 1/12 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 5F-7366 Forcing Screw 1 1P-5546 Crossblock 1 1U-9889 Crossblock 1 F 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED BY C... 2/12 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. Illustration 2 g01751153 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED BY C... 3/12 Illustration 3 g01760156 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). Illustration 4 g01760155 10. Remove O-ring seal (8) from plugs (5). Illustration 5 g01760169 11. Remove gear (9) and spacer (10). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

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538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED BY C... 4/12 Illustration 6 g01760152 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. Illustration 7 g01760149 16. Remove retaining ring (15). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED BY C... 5/12 Illustration 8 g01760143 17. Remove carrier assembly (16). Illustration 9 g01760162 18. Use a suitable press to remove shafts (17) from carrier assembly (16). Illustration 10 g01760150 19. Remove gear (18) and spacer (19). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED BY C... 6/12 Illustration 11 g01760170 20. Remove retaining ring (20) and carrier assembly (21). Illustration 12 g01760159 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). Illustration 13 g01760168 b. Remove planetary shaft (23). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED BY C... 7/12 c. Use a suitable hammer and a suitable punch to remove spring pin (22) from planetary shaft (23). Illustration 14 g01760153 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. Illustration 15 g01760166 23. Remove gear (27) and spacer (28). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED BY C... 8/12 Illustration 16 g01760164 24. Use two people to remove carrier assembly (29). The weight of carrier assembly (29) is approximately 38 kg (85 lb). Illustration 17 g01760160 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). Illustration 18 g01760161 b. Remove planetary shaft (30). c. Use a suitable hammer and a suitable punch to remove spring pin (31) from planetary shaft (30). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED BY C... 9/12 Illustration 19 g01760167 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. Illustration 20 g01760259 27. Use two people to remove ring gear (35). The weight of ring gear (35) is approximately 41 kg (90 lb). Illustration 21 g01760357 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED B... 10/12 28. Remove O-ring seal (36). Illustration 22 g01760374 29. Remove bolts (37) from coupling gear (38). Illustration 23 g01760397 30. Use Tooling (D) to remove coupling gear (38) from housing (39). Illustration 24 g01760477 31. Remove shims (40). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED B... 11/12 Illustration 25 g01760493 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). Illustration 26 g01760513 34. Remove Duo-Cone seal (43) from motor housing (41). 35. Remove dowel pins (42). Illustration 27 g01760573 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED B... 12/12 Illustration 28 g01760574 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED BY C... 1/16 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED BY C... 2/16 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. Illustration 2 g01760875 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED BY C... 3/16 Illustration 3 g01760892 (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). Illustration 4 g01761534 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED BY C... 4/16 Illustration 5 g01760875 h. Use Tooling (E) and the suitable lifting device to remove housing (39) from motor housing (41). Illustration 6 g01761876 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". Illustration 7 g01761954 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED BY C... 5/16 6. Use Tooling (G) to install Duo-Cone seal (43) in motor housing (41). Illustration 8 g01760513 7. Apply Tooling (H) to the surfaces that contact dowel pins (42). 8. Install dowel pins (42). Illustration 9 g01760875 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED BY C... 6/16 Illustration 10 g01760477 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. Illustration 11 g01760374 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED BY C... 7/16 Illustration 12 g01760357 15. Install O-ring seal (36). Illustration 13 g01760259 16. Use two people to install ring gear (35). The weight of ring gear (35) is approximately 41 kg (90 lb). Illustration 14 g01760160 Illustration 15 g01760167 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED BY C... 8/16 Illustration 16 g01762255 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. Illustration 17 g01760164 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED BY C... 9/16 18. Use two people to install carrier assembly (29). The weight of carrier assembly (29) is approximately 39 kg (85 lb). Illustration 18 g01760166 19. Install spacer (28) and gear (27). Illustration 19 g01760159 Illustration 20 g01760153 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED B... 10/16 Illustration 21 g01758493 20. Assemble carrier assembly (21), as follows. 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. Illustration 22 g01760663 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED B... 11/16 21. Install carrier assembly (21) into ring gear (35). 22. Install retaining ring (20). Illustration 23 g01760645 23. Install spacer (19) and gear (18). Illustration 24 g01760655 Note: Make sure that the oil passages in shafts (17) are oriented toward the center of carrier assembly (16). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED B... 12/16 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). Illustration 25 g01760651 26. Assemble carrier assembly (16), as follows. a. Install carrier assembly in position on gear (18). Illustration 26 g01760641 b. Install retaining ring (15) onto gear (18). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED B... 13/16 Illustration 27 g01760647 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. Illustration 28 g01760669 27. Install spacer (10) and gear (9). Illustration 29 g01760650 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED B... 14/16 28. Install O-ring seal (8) on plugs (5). Illustration 30 g01760653 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). Illustration 31 g01751153 Illustration 32 g01751055 31. Place a piece of solder in the center of gear (9) (not shown). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

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538 Forest Machine General Forestry GMY00001-UP (MACHINE) POWERED B... 15/16 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 approximately 32 kg (70 lb). 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 approximately 32 kg (70 lb). 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 approximately 32 kg (70 lb). 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. Illustration 33 g06092181 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 approximately 365 kg (785 lb). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2021/2/9

https://www.ebooklibonline.com Hello dear friend! Thank you very much for reading. Enter the link into your browser. The full manual is available for immediate download. https://www.ebooklibonline.com