539 Knuckleboom Loader Machine Systems Caterpillar

Piston Pump (Implement) - Disassemble

Usage:

539 1PZ

Disassembly Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	138-7575	Link Bracket	2
B	136-1452	Retaining Ring Pliers As	1
C	1P-1863	Retaining Ring Pliers	1
D	1P-5546	Crossblock	1

Start By:

Remove the piston pump. Refer to Disassembly and Assembly, "Piston Pump (Implement) - Remove" for the machine that is being serviced.

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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, "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.

Note: Place identification marks across all sections of the piston pump for installation purposes.

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.

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Illustration 1	g00583138

Loosen bolts (2). Remove coupling assembly (1) from the pump housing.

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Illustration 2	g00583190

Remove bolts (4) and couplers (3) from coupling assembly (1) .

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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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Illustration 3	g00583191

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Illustration 4	g01047400

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Illustration 5	g01047395

Carefully loosen bolts (5) .

Replace one bolt (5) with a bolt (7) that is long enough to retain the spring force of spring (8) .

Remove the remaining bolts (5) and pump control housing (6) .

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Illustration 6	g00583195

Remove spring (8) .

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Illustration 7	g00583196

Remove O-ring seal (9) from the pump housing.

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Illustration 8	g00583197

Remove spring housing (10) from control housing (6) .

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Illustration 9	g00583198

Remove seat (11), spring (12), and seat (13) from spring housing (10). Remove O-ring seal (14) from spring housing (10) .

Remove spool (16) and sleeve (15) from control housing (6) .

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Illustration 10	g00583199

Remove O-ring seal (18) from control housing (6) .

Remove spring housing (17) from control housing (6) .

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Illustration 11	g00583200

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Illustration 12	g00583201

Remove seat (21), spring (22), spring (23), and seat (24) from spring housing (17). Remove O-ring seal (26) and backup ring (25) from spring housing (17) .

Remove spool (19) and sleeve (20) from the control housing.

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Illustration 13	g01031005

Attach Tooling (A) and a hoist to head (28). Remove bolts (27) from head (28). Remove head (28). The weight of the head is approximately 15 kg (33 lb).

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Illustration 14	g00583365

Remove bolts (30) from lever assembly (29) .

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Illustration 15	g00583366

Remove retaining rings (32), pins (33), and lever arm (31) from lever assembly (29) .

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Illustration 16	g00583367

Remove roller (34) from the head.

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Illustration 17	g00583368

Remove retaining ring (35) and piston (36) from roller (34) .

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Illustration 18	g00583389

Remove bolts (37). Remove cover (38) from head (28) .

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Illustration 19	g00583390

Remove plug (39) from cover (38). Remove O-ring seals (40), (41), and (42) .

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Illustration 20	g00583393

Remove swashplates (45) from cylinders (43). Remove cylinders (43) .

If necessary, remove dowel pins (44) .

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Illustration 21	g00584139

Remove spacer (47) and bevel washers (46) from the center of each cylinder (43) .

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Illustration 22	g00583783

Note: Place identification marks on pistons (51) and centering pins (50) for installation purposes.

Remove socket head screws (48) from each retaining plate (49) .

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Illustration 23	g00584132

Remove centering pin (50) and retaining plate (49) from each rotating group.

Remove pistons (51) .

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Illustration 24	g00583851

Remove rings (52) from each piston (51) .

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Illustration 25	g00583901

Remove bolts (53) and (55). Remove pilot pump (54) .

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Illustration 26	g00583902

Remove O-ring seals (56) and (57) from pilot pump (54) .

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Illustration 27	g00584099

Remove bearing (58) from the main pump housing. The bearing is a slip fit.

Remove retaining ring (59). Remove cover (60) .

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Illustration 28	g00584372

Remove lip seal (61) from cover (60) .

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Illustration 29	g00584375

Remove O-ring seal (62) from the pump housing.

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Illustration 30	g00584376

Install a suitable sized bolt (63) in the end of rotating group (64). Hit the end of bolt (63) in order to remove rotating group (64) from the pump housing.

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Illustration 31	g00584378

Remove plug (65). Install a suitable sized bolt in place of plug (65). Tighten the bolt in order to remove the lower pump rotating group from the pump housing.

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Illustration 32	g00584380

Disassemble the upper pump rotating group. Remove spanner nut (66), bearing (67), shims (68), bearing (69), spacer (70) and bearing (71) from the shaft.

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Illustration 33	g00598681

Disassemble the lower pump rotating group. Remove spanner nut (72), bearing (73), shims (74), bearing (75), spacer (76) and bearing (77) from the shaft.