Caterpillar Cat 568 FM EXCAVATOR (Prefix YJX) Service Repair Manual (YJX00001 and up)

1
Service Repair Manual
Models 568 FM EXCAVATOR
2
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Product EXCAVATOR Model 568 FM EXCAVATOR
YJX Configuration 568 Forest Machines
YJX00001-UP (MACHINE) POWERED BY C9.3 Engine
Disassembly and Assembly 568 Forest Machines
Machine Systems Media Number -UENR0109-03 Publicat
ion Date -01/01/2011
Date Updated -31/07/2017
i03863290
Travel Motor - Disassemble SMCS -
4351-015 Disassembly Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 1U-7506 Adapter 1
A 8T-4244 Nut 6
A 8T-4223 Hard Washer 6
A - M12 x 1.75 by 250 mm (10 inch) Threaded Rod 1
B 8T-0651 Bolt 1
B 8T-4167 Hard Washer 1
C 3E-3882 Eyebolt 1
D 1P-1859 Retaining Ring Pliers 1
E 1P-0510 Driver Gp 1
E 9S-9152 Bearing Puller Gp 1
F 1P-1861 Retaining Ring Pliers 1
Start By a. Remove the travel motor. 1. Fasten
the travel motor in Tooling (A) in a vertical
position. The weight of the travel motor is
approximately 60 kg (132 lb).
3
2. Put an alignment mark across the head and the
body of the travel motor for assembly purposes.
The head must be reinstalled in the head's
original position on the body of the travel
motor.
Illustration 1
g00887295
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.

• Note During the removal of head (2) from the
  travel motor, be careful not to damage the
  mating surfaces of the components.
• Remove bolts (1).
• Remove head (2) from the body of the travel motor.

4
Illustration 2 g00887302 5. Remove O-ring seal
(3), port plate (4), and bearing (5).
Illustration 3 g00887311 6. Remove O-ring seals
(6). Remove springs (7).
Illustration 4
g00887331
Illustration 5 This is an example of the use of
Tooling (B).
g00890074
5
7. Place a shop towel over brake piston (8).
Retain brake piston (8) with Tooling (B). Apply
approximately 525 kPa (75 psi) of shop air
pressure to brake release Port (Y). Make sure
that the shop air pressure is free of water.
Brake piston (8) will move up the piston guide,
and out of the piston guide. Remove brake piston
(8) from the body of the travel motor.

• Illustration 6 g00887336
• Remove seal (9) and backup ring (10) from the
  brake piston.
• Remove seal (11) and backup ring (12) from the
  brake piston.

Illustration 7 g00887355 10. Remove plates (13)
and friction discs (14).
6
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Illustration 8
g02107957
Illustration 9
g00887405

• Illustration 10 g00887424
• Install Tooling (C) into shaft (15). Use a prybar
  to remove the rotating assembly (16) from the
  housing.
• Remove Tooling (C) from shaft (15).
• Remove shaft (15) from rotating assembly (16).

Illustration 11
g00887426
8
14. Use Tooling (D) in order to remove retaining
ring (17) from shaft (15).
Illustration 12 g00887445 15. Use a suitable
press in order to remove bearing race (18) from
shaft (15).
Illustration 13 g00887463 16. Rotate shaft (15).
Use a suitable press and tooling (E) in order to
remove bearing race (19) from shaft (15).
Illustration 14 g00887501 17. Remove cam plate
(20) from barrel assembly (21).
9
Illustration 15 g00887520 18. Remove piston
assemblies and retainer plate (22) from barrel
assembly (21). Note Place marks on the pistons
and the barrel assembly. The pistons must be
returned to the original position.
Illustration 16
g00887558
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.
19. Remove ball (23) and springs (24).
10
Illustration 17
g02107975

1. Remove bearing (25).
2. Remove keys (26) and locating pins (not shown)
   from the body of the travel motor.

• Illustration 18 g00887589
• Rotate the housing. Use Tooling (F) in order to
  remove retaining ring (27).
• Remove lip seal (28).

Illustration 19
g00887619
24. Remove bolts (29) and cover (30).
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Illustration 20
g00887729
25. Remove seal (31) and backup ring (32).
Illustration 21 g00887754 26. Remove piston
actuator (33) and seal (34).
Illustration 22 g00887762 27. Remove O-ring seal
(35) from the housing of the travel motor.
12
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Previous Screen
Product EXCAVATOR Model 568 FM EXCAVATOR
YJX Configuration 568 Forest Machines
YJX00001-UP (MACHINE) POWERED BY C9.3 Engine
Disassembly and Assembly 568 Forest Machines
Machine Systems Media Number -UENR0109-03 Publicat
ion Date -01/01/2011
Date Updated -31/07/2017
i07175112
Travel Motor - Assemble SMCS - 4351-016 Assembly
Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 1U-7506 Adapter 1
A 8T-4244 Nut 6
A 8T-4223 Hard Washer 6
A - M12 x 1.75 X 250 mm (10 inch) Threaded Rod 1
C 3E-3882 Eyebolt 1
D 1P-1859 Retaining Ring Pliers 1
E 1P-0510 Driver Gp 1
E 9S-9152 Bearing Puller Gp 1
F 1P-1861 Retaining Ring Pliers 1
G - Loctite 242 -
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Illustration 1 g00887762 1. Install O-ring seal
(35) onto the housing of the travel motor.
Illustration 2 g00887754 2. Install seal (34)
and piston actuator (33). Lubricate the surfaces
of piston actuator (33) with lubricant that is
being sealed.
Illustration 3
g00887729
3. Install backup ring (32) and seal (31).
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Illustration 4 g00887619 4. Install cover (30)
and bolts (29). Tighten bolts (29) to a torque of
28 7 Nm (21 5 lb ft).

• Illustration 5 g00887589
• Apply Tooling (G) to the mating surface of lip
  seal (28). Use Tooling (E) to install lip seal
  (28). Lubricate the sealing lip of lip seal (28)
  with lubricant that is being sealed.
• Use Tooling (F) to install retaining ring (27).

Illustration 6
g02107975
7. Rotate the housing.
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1. Install keys (26) and locating pins (not shown)
   into the body of the travel motor.
2. Install bearing (25).

Illustration 7
g00887558
Improper assembly of parts that are spring loaded
can cause bodily injury. To prevent possible
injury, follow the established assembly procedure
and wear protective equipment.
10. Install springs (24) into the barrel
assembly. Install ball (23) onto springs (24).
Lubricate ball (23) with lubricant that is being
sealed.
Illustration 8 g00887520 11. Lubricate the
piston assemblies with lubricant that is being
sealed. Install piston assemblies and retainer
plate (22) into barrel assembly (21).
16
Note Take note of the mark on the piston
assembly and the barrel assembly. The pistons
must be returned to the same position.
Illustration 9 g00887501 12. Lubricate cam plate
(20) with lubricant that is being sealed. Install
cam plate (20) onto barrel assembly (21).
Illustration 10 g00888697 13. Install shaft (15)
into a suitable press. Install bearing race (19)
onto shaft (15).
Illustration 11
g00887426
17
14. Rotate shaft (15) in the suitable press. Use
Tooling (D) to install retaining ring (17) onto
shaft (15).
Illustration 12
g00888710
15. Install bearing race (18) onto shaft
(15). Note Bearing race (18) must contact
retaining ring (17).

• Illustration 13 g00887405
• Install Tooling (C) into shaft (15). Install
  shaft (15) into rotating assembly (16).
• Place the pump housing into Tooling (A).

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Illustration 14 g02107957 18. Use Tooling (C) to
install rotating assembly (16) into the housing.
Illustration 15
g00887501
Illustration 16 g02107975 19. The notches in cam
plate (20) must align with keys (26). The keys
are located in the bottom of the housing of the
travel motor.
Illustration 17
g00887355
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20. Install plates (13) and friction discs (14)
into the housing. Note Install the plates and
the discs alternately.

• Illustration 18 g00887336
• Install backup ring (12) and seal (11) onto the
  brake piston.
• Install backup ring (10) and seal (9) onto the
  brake piston.

Illustration 19
g00888967

• Rotate brake piston (8).
• Install brake piston (8) into the housing so that
  the cast mark on brake piston (8) is aligned
  with the brake supply passage in the housing.
• Note Brake piston (8) must be level upon
  installation. The brake piston must be level to
  prevent damage to the O-ring seals.

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Illustration 20
g00887311
25. Install springs (7) and O-ring seals (6).
Illustration 21 g00887302 26. Lubricate port
plate (4) with lubricant that is being sealed.
Install O-ring seal (3), port plate (4), and
bearing (5).
Illustration 22
g00887295
21
Improper assembly of parts that are spring loaded
can cause bodily injury. To prevent possible
injury, follow the established assembly procedure
and wear protective equipment.

• Install head (2) onto the body of the travel
  motor.
• Note During the installation of head (2) onto
  the travel motor, be careful not to damage the
  mating surfaces of the components.
• Install bolts (1). Tighten bolts (1) to a torque
  of 240 40 Nm (177 30 lb ft).
• End By
• a. Install the travel motor.

Copyright 1993 - 2021 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Mon Feb 1 022357 UTC0800 2021
22
Shutdown SIS
Previous Screen
Product EXCAVATOR Model 568 FM EXCAVATOR
YJX Configuration 568 Forest Machines
YJX00001-UP (MACHINE) POWERED BY C9.3 Engine
Disassembly and Assembly 568 Forest Machines
Machine Systems Media Number -UENR0109-03 Publicat
ion Date -01/01/2011
Date Updated -31/07/2017
i02785246
Final Drive - Disassemble SMCS -
4050-015 Disassembly Procedure Table 1 Required
Tools
Tool Part Number Part Description Qty
A 138-7576 Link Bracket 2
B 1P-1855 Retaining Ring Pliers 1
C 1P-1862 Retaining Ring Pliers 1
D 5P-5197 Retaining Ring Pliers 1
E 1P-2321 Puller Assembly(1) 1
F 1P-0520 Drive Group 1
G 2P-8312 Retaining Ring Pliers 1
H 138-7574 Link Bracket 3
1P-5546 Crossbar 1
5F-7366 Screw 1
1P-0523 1P-0523 Drive Plate 1
9S-8546 9S-8546 Seal Installer 1
6V-3532 6V-3532 Bolt 2
8T-3282 8T-3282 Washer 2
J
K 1U-8758 Retaining Ring Pliers 1
23
L 1P-0074 Slide Hammer Puller Gp 1
L 1P-0069 2P-2312 Head Puller leg 1 3
M 1P-7407 Eyebolt 2
N 199-6557 Spanner socket 1
P 4C-8359 Eyebolt 2
Q 127-8458 Final Drive Bench Ar 1
QQ 127-8467 Reaction Plate(2)
R 127-8468 Reaction Bar As 1
3S-6224 Electric Hydraulic Pump 1
8T-0820 Pressure Gauge 1
S 3B-7722 1P-2376 Bushing Coupler Assembly 2 2
1P-2377 Plug 2
8F-0024 Hose Assembly 2
T 154-6182 Forcing Bolt 2
(1) Use 6C-7887 Leg on the two gears that are
removed in Step 22. (2) Part of Tooling
(Q) Start By a. Remove the final drive. Refer
to Disassembly and Assembly, "Final Drive -
Remove". 1. Thoroughly clean the outside of the
final drive and travel motor prior to disassembly.
Illustration 1 g00659659 2. Remove bolts (2)
that hold travel motor (1) to the final drive.
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Illustration 2 g00659674 3. Fasten two suitable
lifting straps and a suitable lifting device to
travel motor (1). The weight of travel motor (1)
is approximately 54 kg (120 lb). Carefully remove
travel motor (1) from the final drive.
Illustration 3 g00676009 4. Remove O-ring seal
(3) from the travel motor.
Illustration 4
g00659679
25

• Illustration 5 g00659682
• Fasten Tooling (A) and a suitable lifting device
  to the final drive, and turn the final drive on
  the side. The weight of the final drive is 500 kg
  (1100 lb).
• Remove plug (4).
• NOTICE
• Care must be taken to ensure that fluids are
  contained during performance of inspection,
  maintenance, testing, adjusting, and repair of
  the product. Be prepared to collect the fluid
  with suitable containers before opening any
  compartment or disassembling any component
  containing fluids.
• Refer to Special Publication, NENG2500, "Dealer
  Service Tool Catalog" for tools and supplies
  suitable to collect and contain fluids on Cat
  products.
• Dispose of all fluids according to local
  regulations and mandates.

1. Drain the oil from the final drive into a
   suitable container for storage or disposal. Refer
   to Operation and Maintenance Manual, "Capacities
   (Refill)" for the capacity. Refer to Operation
   and Maintenance Manual, "Final Drive Oil -
   Change" for the proper procedure.
2. Reinstall plug (4).

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• Illustration 6 g00659729
• Position the final drive onto suitable blocking,
  as shown.
• Remove the sprocket bolts (5) from final drive
  sprocket (6).

• Illustration 7 g00659738
• Use a suitable lifting device to remove final
  drive sprocket (6). If necessary, use a soft
  faced hammer in order to unseat the sprocket.
• The weight of the final drive sprocket is 91 kg
  (200 lb).

Illustration 8
g00659746
27
13. Remove bolts (7) that hold cover (8) in place.

• Illustration 9 g01391477
• Use Tooling (T) to elevate cover (8). This will
  allow enough clearance for your fingers in order
  to lift cover (8) off the final drive.
• Remove cover (8).
• If necessary, remove the spacer (Not Shown) from
  cover (8).

Illustration 10
g01391490

1. Remove carrier assembly (9).
2. Disassemble carrier assembly (9), as follows

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Illustration 11 g01391499 a. Use Tooling (B) to
remove retaining ring (10).
Illustration 12 g01391503 b. Use a soft faced
hammer in order to remove planetary gear assembly
(11). Note Rotate the planetary gear assembly
so that the gear assembly comes off
perpendicular to the carrier shaft. c.
Disassemble planetary gear assembly (11), as
follows.
Illustration 13
g01391501
29

• Illustration 14 g01391500
• Use Tooling (C) to remove the second retaining
  ring (12).
• Note When you remove the bearing assembly, the
  rollers will fall out of the bearing race. Put a
  rubber band around the bearing rollers as you
  remove the bearing assembly.
• Remove two rings (13), and bearing (13) from
  planetary gear assembly (11).
• Repeat Steps 18.a through 18.e for the other two
  planetary gears.

Illustration 15 g01391513 g. Remove center shaft
(15) from carrier assembly (9).
30
Illustration 16 g01391515 h. Use a hammer and a
punch to remove washer (16) from center shaft
(15).
Illustration 17
g00659844
Illustration 18 g00659863 i. Use Tooling (D) in
order to remove retaining ring (17). j. Remove
sun gear (18) from carrier assembly (10).
Illustration 19
g00659867
31

1. Remove carrier assembly (19).
2. Disassemble carrier assembly (19), as follows

Illustration 20
g00659873

• Illustration 21 g00659879
• Use Tooling (D) to remove retaining ring (20).
• Use Tooling (E) in order to remove planetary gear
  assembly (21).

Illustration 22
g00659889
32
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c. Use Tooling (F) and a suitable press in order
to drive the bearing assembly out of planetary
gear (21). Note This is only one method for
removing the bearing. You may also cut the
bearing. Make sure that you catch the rollers,
while you drive the bearing assembly out of
planetary gear (21). d. Repeat Steps 20.a through
20.c for the other two planetary gear assemblies.
Illustration 23
g00660095
Illustration 24 g00660100 e. Use Tooling (D) in
order to remove retaining ring (22). f. Remove
sun gear (23) from carrier assembly (19).
34
Illustration 25 g00660105 21. Use Tooling (D) in
order to remove two retaining rings (26) from two
of the planetary gear assemblies (24) from
carrier assembly (25). Note There are two sets
of bearing rollers for each planetary gear
assembly. The bearing rollers for the lower
bearing assembly will fall after the planetary
gear assembly is removed.
Illustration 26 g00660136 22. Use Tooling (E) in
order to remove two planetary gear assemblies
(24). Note Two planetary gear assemblies (24)
are removed in order to access the retaining ring
that holds the carrier assembly (25) to the
motor housing.
35
Illustration 27 g00660143 23. Use Tooling (G) in
order to remove retaining ring (27).

• Illustration 28 g00660173
• Use Tooling (H) and a suitable lifting device to
  remove carrier assembly (25).
• Disassemble carrier assembly (25), as follows

Illustration 29 g00765592 a. Use Tooling (E) to
remove bearing race (28) from the two shafts of
carrier assembly (25).
36
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