Disassembly Procedure
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Table 1
| Required Tools |
| Tool |
Part Number |
Part Description |
Qty |
| (A) |
1P-2420 |
Transmission Stand Group |
1 |
| (B) |
138-7575 |
Link Bracket |
4 |
| (C) |
168-8395 |
Socket |
1 |
| (D) |
1P-0074 |
Slide Hammer Puller |
1 |
| 4C-5666 |
Threaded Adapter |
1 |
| 123-6702 |
Clamping Segment |
1 |
| (E) |
1P-0074 |
Slide Hammer Puller |
1 |
| (F) |
1P-1859 |
Retaining Ring Pliers |
1 |
| (G) |
138-7574 |
Link Bracket |
2 |
| (H) |
5P-4758 |
Internal Pliers |
1 |
| (I) |
1P-0510 |
Driver Group |
1 |
| (J) |
5P-1864 |
Retaining Ring Pliers |
1 |
| (K) |
5P-1863 |
Retaining Ring Pliers |
1 |
Start By:
- Remove the main hydraulic pump. Refer to Disassembly and Assembly, "Main Hydraulic Pump and Pump Drive Coupling - Remove" for the machine that is being serviced.
Note: Regular maintenance and frequent inspections are routine precautions. Practice preventive maintenance before damage occurs. Preventive maintenance can help to avoid a failure. If a failure occurs, an accurate diagnosis of the cause can prevent a recurrence. Information is available to analyze piston pump failures and motor failures. Refer to Special Publication, SEBD0641, "Analyzing Axial Piston Pump and Motor Failures".
Note: Many times, the installation of new parts is not necessary. The installation of used parts during reconditioning is acceptable. Used parts can result in a substantial cost reduction. Reuse information is available on piston pumps and motors. Refer to Guideline For Reusable Parts, SEBF8032, "Piston Pumps and Motors". During reconditioning, correct any conditions that might have caused the original failure.
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism. Dirt and contaminants can damage the precision made components of the pump or the motor. All disassembly and assembly procedures must be performed on a clean work surface. Clean all the interior components in clean solvent. Dry all the interior components with compressed air. Plug ports and plug hoses on the machine during repair.
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| NOTICE |
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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, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
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Note: The hydraulic oil must be contained in the proper manner. Refer to Special Publication, NENG7004, "Contamination Control Catalog".
Note: The rotation of the pump will depend on placement of the pump in Tooling (A). A clockwise rotation will have the input shaft upward. A counterclockwise rotation will have the input shaft downward. The rotation can be found on the nameplate that is attached to the pump housing.
- Drain the hydraulic oil from the main hydraulic pump.
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| Illustration 1 | g00602064 |
- Secure the main hydraulic pump on Tooling (A). Weight of the main hydraulic pump is 340 kg (750 lb). Remove hose assembly (1) and the O-rings.
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| Illustration 2 | g00602268 |
- Remove bolts (2). Remove valve bodies (3) and the O-rings.
- Disassemble the valve bodies, as shown.
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| Illustration 3 | g00602766 |
- Remove O-rings (5). Remove O-ring (7) .
- Remove plug (6) and the O-ring.
- Remove valve group (4).
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| Illustration 4 | g00602791 |
- Disassemble valve group (4), as follows: retainer (8), spring (9), spring (10), retainer (11), sleeve (12) and valve spool (13) .
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| Illustration 5 | g00602794 |
- Remove electrical connector (14) .
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| Illustration 6 | g00602808 |
- Remove actuator assemblies (15) .
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| Illustration 7 | g00602863 |
- Remove spring (17) from spool (16) .
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| Illustration 8 | g00602883 |
- Remove bolts (18). Remove blocks (19) and the O-rings.
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| Illustration 9 | g00602921 |
- Remove covers (20). Remove guides (21) .
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| Illustration 10 | g00602946 |
- Attach Tooling (B) and a suitable lifting device to the top of the pump. Use Tooling (C) in order to remove bolts (22).
Note: The port plate may be removed with the center housing or the port plate may stay with the lower pump body. Do not allow the port plate to fall when the center housing is removed.
- Remove the upper pump and the center housing. Weight of the upper pump and the center housing is 233 kg (515 lb).
- Remove the lower pump from Tooling (A). Weight of the lower pump is 106 kg (235 lb). Move the lower pump aside for later disassembly.
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| Illustration 11 | g00603043 |
- Turn the upper pump and center housing upside-down. Secure the pump to Tooling (A). Use Tooling (D) to remove sleeve (23) .
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| Illustration 12 | g00603051 |
- Use Tooling (E) to remove plate (24) and the bearing.
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| Illustration 13 | g00603068 |
- Remove bearing (25) from the plate.
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| Illustration 14 | g00603073 |
- Remove coupling (26) .
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| Illustration 15 | g00603090 |
- Use Tooling (F) to remove retaining ring (27) .
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| Illustration 16 | g00603108 |
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| Illustration 17 | g00603107 |
- Use Tooling (E) to remove impeller (28) .
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| Illustration 18 | g00603259 |
- Use Tooling (F) to remove retaining ring (30). Remove bushing (29) .
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| Illustration 19 | g00603268 |
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| Illustration 20 | g00603269 |
Note: The port plate may be removed with the center housing or the port plate may stay with the lower pump body. Do not allow the port plate to fall when the center housing is removed.
- Attach Tooling (G) and a suitable lifting device to center housing (32).
- Use Tooling (C) to remove bolts (31) .
- Remove the center housing from pump housing (33). The weight of the center housing is 127 kg (280 lb).
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| Illustration 21 | g00603327 |
- Remove bearing (34) from the center housing. Remove bushing (35) .
Note: The upper pump and the lower pump are similar. The disassembly process is similar for the upper pump and the lower pump.
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| Illustration 22 | g00603347 |
- Remove port plate (37). Remove piston assemblies (36) and (38). Remove O-ring (39) .
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| Illustration 23 | g00603392 |
- Disassemble piston assembly (36), as follows: rod (40), piston (41) and spring (42) .
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| Illustration 24 | g00603395 |
- Disassemble piston assembly (38), as follows: rod (43), piston (44) and spring (45) .
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| Illustration 25 | g00603426 |
- Remove bolts (46). Use caution when the bolts are removed. The bolts are installed with thread lock. Remove retainers (47) .
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| Illustration 26 | g00603437 |
- Measure the length of pins (48) for installation purposes. Loosen locknuts (49). Tighten the pins in order to contact the swashplate. Tighten the locknuts.
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| Illustration 27 | g00603450 |
- Place the pump on a level surface. Remove barrel assembly (50). Keep the barrel assembly together with the pistons.
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| Illustration 28 | g00603458 |
- Mark the pistons so the pistons can be installed in the original bores.
- Remove pistons (51) from barrel (53) and piston plate (52) .
- Remove piston plate (52) .
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| Illustration 29 | g00603460 |
- Remove spring retainer (54) .
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| Illustration 30 | g00603651 |
- Remove springs (55) .
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| Illustration 31 | g00603662 |
- Remove shims (56) .
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| Illustration 32 | g00603668 |
- Loosen the locknuts. Remove the pins. Refer to Step 31. Remove swashplate assembly (57) .
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| Illustration 33 | g00603689 |
- Remove bearings (59) from swashplate (58). Remove pins (60) .
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| Illustration 34 | g00603702 |
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| Illustration 35 | g00603703 |
- Remove bearings (61). Remove covers (62). Remove guides (63) .
Note: The following disassembly procedure is for the input shaft pump.
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| Illustration 36 | g00603712 |
- Use Tooling (H) in order to remove retaining ring (64) .
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| Illustration 37 | g00603720 |
- Remove flange (65) .
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| Illustration 38 | g00603735 |
- Use Tooling (I) in order to remove seal (66) from the flange.
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| Illustration 39 | g00603815 |
- Remove O-ring (67) .
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| Illustration 40 | g00603820 |
- Use a soft faced hammer to remove shaft assembly (68) .
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| Illustration 41 | g00603825 |
- Use Tooling (J) in order to remove retaining ring (69) .
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| Illustration 42 | g00603837 |
- Use a suitable press and remove shaft (70) from bearing (71) .
Note: The following disassembly procedure is for the stub shaft pump.
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| Illustration 43 | g00603885 |
- Use Tooling (H) in order to remove retaining ring (72) .
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| Illustration 44 | g00603891 |
- Remove cover (73) .
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| Illustration 45 | g00603895 |
- Remove O-ring (74). Use a soft faced hammer to remove shaft assembly (75) .
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| Illustration 46 | g00603907 |
- Use Tooling (K) in order to remove retaining ring (76) .
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| Illustration 47 | g00603910 |
- Use a suitable press in order to remove shaft (77) from bearing (78) .
Note: After disassembly has been completed, check the condition of all the components. Refer to Guideline For Reusable Parts, SEBF8032, "Piston Pumps and Motors". During reconditioning, correct any conditions that might have caused the original failure. Information is available to analyze piston pump failures and motor failures. Refer to Special Publication, SEBD0641, "Analyzing Axial Piston Pump and Motor Failures".
Note: In some cases, it may not be economical or it may not be practical to recondition a pump. This determination is made after disassembly and a close inspection of the pump components. Due to wear, reconditioning may not be possible. If the cost of reconditioning a pump exceeds the cost of a remanufactured pump, the pump should be replaced with a remanufactured pump instead of a reconditioned pump.
