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

1
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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 Publicat
ion Date -01/08/2017
Date Updated -02/08/2017
i06724515
Swivel - Disassemble SMCS - 5060-015 Disassembly
Procedure Table 1
Required Tools Required Tools Required Tools 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.
2

• Illustration 1 g01767936
• Attach Tooling (B) and a suitable lifting device
  to swivel (1). The weight of swivel (1) is
  approximately 496 kg (225 lb).
• Position swivel (1) onto Tooling (A).

Illustration 2
g01768234

1. Remove bolts (2) and (3).
2. Remove cover (4) from the bottom of swivel (1).

Illustration 3
g01768296
3
6. Remove O-ring seal (5), bolts (6), and
retainer (7) from the bottom of swivel (1).
Illustration 4
g01768395

• Illustration 5 g01768497
• Note Be sure that alignment marks are put on
  rotor (8) and housing (11) for assembly purposes.
• Use Tooling (B) and a suitable lifting device to
  separate rotor (8) from housing (9).
• Remove O-ring seal (10) (not shown) from housing
  (11).
• Use Tooling (B) and a suitable lifting device to
  separate rotor (8) from housing (11).

4
Illustration 6 g06092449 10. Remove seal
assemblies (12) from housing (11).
Illustration 7 g06092455 11. Remove seal
assemblies (13) from housing (9).
Copyright 1993 - 2021 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Thu Feb 4 204301 UTC0800 2021
5
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Previous Screen
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 Publicat
ion Date -01/08/2017
Date Updated -02/08/2017
i06724539
Swivel - Assemble SMCS - 5060-016 Assembly
Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
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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• Illustration 1 g01768813
• Apply clean hydraulic oil to seal assemblies
  (12).
• Install O-ring seal (10) and seal assemblies (12)
  into housing (11).

• Illustration 2 g01768833
• Position housing (9) onto housing (11). Loosely
  install bolts (2) to secure housing (9) to
• housing (11).
• Apply clean hydraulic oil to seal assemblies
  (13).
• Install seal assemblies (13) into housing (9).

8
Illustration 3 g01769453 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).

• Illustration 4 g01769537
• Attach Tooling (B) and a suitable lifting device
  to rotor (8). The weight of rotor (8) is
  approximately 54 kg (119 lb).
• Use Tooling (B) and a suitable lifting device to
  install rotor (8) into housing (11) and housing
  (9) (not shown).
• Remove four bolts (2) (not shown).

9
Illustration 5 g01768296 10. Install retainer
(7), bolts (6), and O-ring seal (5) to the bottom
of swivel (1).
Illustration 6 g01768234 11. Install cover (4),
bolts (3), and bolts (2) to the bottom of swivel
(1). End By a. Install the swivel.
Copyright 1993 - 2021 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Thu Feb 4 204356 UTC0800 2021
10
Shutdown SIS
Previous Screen
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 Publicat
ion Date -01/08/2017
Date Updated -02/08/2017
i06725205
Swing Motor - Remove and Install SMCS -
5058-010-ZW Removal Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A FT-2674 Vacuum Cap 1
B 439-3938 Link Bracket 2
Start By a. Release the hydraulic system
pressure.
Illustration 1
g01714793
1. Remove guard assembly (1).
11
Illustration 2 g06092676 2. Remove sheet (2) and
cover assembly (3).
Illustration 3
g06092691
3. Remove cover assembly (4).
Illustration 4 Typical Example
g01715574
12

1. 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.
2. Drain the swing drive oil. Refer to Operation and
   Maintenance Manual, "Swing Drive Oil - Change"
   for the correct draining and filling procedures.

• Illustration 5 g01715674
• 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.
• 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.
• Disconnect hose assemblies (6) and (7).
• Disconnect hose assemblies (8) and (9).
• Disconnect harness assembly (10).
• Disconnect clip (11).

13
Illustration 6
g01715876
11. Disconnect hose assembly (14).

• Illustration 7 g01715880
• Remove bolts (16) and anti-reaction valve (17).
• Remove bolts (15).
• 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.

Illustration 8 g01715956 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.
14
Shutdown SIS
Previous Screen
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 Publicat
ion Date -01/08/2017
Date Updated -02/08/2017
i06726429
Swing Motor - Disassemble SMCS -
5058-015-ZW Disassembly Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 8T-0651 Bolts 2
A 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
D 5F-7344 Puller Block 1
D 5P-4750 Adjusting Screw 1
D 7S-7786 Puller Leg 2
Start By a. Remove the swing motor.
15

• Illustration 1 g00704611
• If necessary, remove bolts (2) and anti-reaction
  valve (3) from head (1).
• Remove mounting bolts (4).

Illustration 2 g00704621 3. Remove dipstick tube
(5) and breather tube (6) from motor housing (7).
Illustration 3
g00704704
4. Remove relief valves (8).
16
Illustration 4
g00704710

1. Remove O-ring seals (10), (12), and (13).
2. Remove backup rings (9) and (11).

Illustration 5
g00704719
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.
17
7. Remove bolts (14) and the head.
Illustration 6
g00704734
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.
Illustration 7 g00704741 9. Remove adapter (19),
fitting (20), and plugs (21).
18
Illustration 8
g00704743
10. Remove O-ring seal (22) from plug (21).
Illustration 9 g00704749 11. Remove O-ring seals
(23) and (24) from fittings (19) and (20).
Illustration 10
g00704754
12. Remove O-ring seal (25).
19
Illustration 11 g00704771 13. Remove spring pins
(26) and bearing (27).
Illustration 12
g00704796
14. Remove springs (28) and port plate (29).
Illustration 13 Typical Example
g01021864
15. Install Tooling (A) and apply air pressure to
unseat the piston. Note Use air pressure to
avoid damage to the piston.
20
Illustration 14
g01021875
16. Remove piston (30).
Illustration 15 Typical Example
g01022038
17. Remove plates (31).
Illustration 16 Typical Example
g01021889
18. Remove barrel (32) and the pistons as an
assembly.
21
Illustration 17
g01021898

1. Mark pistons (33).
2. Remove pistons (33) from barrel (32).

Illustration 18 g01021903 21. Remove pistons
(33) from plates (34) and (35).
Illustration 19
g01021909
22. Separate plates (34) and (35).
22
Illustration 20 Typical Example
g01021919
23. Remove O-ring seals (36) and (36a) from the
motor housing.
Illustration 21
g00705209
24. Remove swashplate (37).
Illustration 22 g00705222 25. Use Tooling (B) to
remove retaining ring (38) from shaft (39).
23
Illustration 23
g00705258
26. Remove shaft (39).
Illustration 24 g00705277 27. Use a suitable
press and Tooling (C) to remove bearing race (40).
Illustration 25 g00705284 28. Use a suitable
press and Tooling (C) to remove bearing race (41).
24
Illustration 26 Typical Example
g01022013
Illustration 27
g00705295
29. Use Tooling (D) to remove bearing (42).
Illustration 28
g00705441
30. Remove lip seal (43).
25
Illustration 29
g00705442
31. Remove fitting (44).
Illustration 30 g00705445 32. Remove O-ring seal
(45) from fitting (44).
Copyright 1993 - 2021 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Thu Feb 4 204548 UTC0800 2021
26
Shutdown SIS
Previous Screen
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 Publicat
ion Date -01/08/2017
Date Updated -02/08/2017
i06727706
Swing Motor - Assemble SMCS - 5058-016 Assembly
Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
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.
27
Illustration 1
g00705445
1. Install O-ring seal (45) onto fitting (44).
Illustration 2
g00705442
2. Install fitting (44).
Illustration 3 g00705441 3. Lubricate lip seal
(43) with clean hydraulic oil. Install lip seal
(43) with the lip toward the inside of the motor
housing.
28
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Illustration 4 Typical Example
g01022013
Illustration 5
g01287176
4. Use Tooling (E) to install bearing (42).
Illustration 6 g00705595 5. Raise the
temperature of bearing race (41). Install bearing
race (41).
31
Illustration 7 g00705592 6. Raise the
temperature of bearing race (40). Install bearing
race (40).
Illustration 8
g00705597

• Illustration 9 g00705258
• Install shrink wrap tubing onto shaft (39). The
  shrink wrap tubing will protect the seal during
  installation of shaft (39).
• Install shaft (39).

32
Illustration 10 g00705602 9. Use Tooling (B) to
install retaining ring (38) onto shaft (39).
Remove the shrink wrap tubing.
Illustration 11
g00705209
10. Install swashplate (37).
Illustration 12 Typical Example
g01021919
11. Install O-ring seals (36) and (36a) into the
motor housing.
33
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Friend! Thank you very much for visiting. Full
manual if required, please enter the following
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