Caterpillar Cat 259D COMPACT TRACK LOADER (Prefix FTL) Service Repair Manual (FTL00001 and Up)

Service Repair Manual
Models
259D COMPACT TRACK LOADER

259D Compact Track Loader FTL00001-UP (MACHINE) POWERED BY C3.3B Eng... 1/2
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Product: COMPACT TRACK LOADER

Model: 259D COMPACT TRACK LOADER FTL
Configuration: 259D Compact Track Loader FTL00001-UP (MACHINE) POWERED BY C3.3B Engine
Disassembly and Assembly

259D, 279D, 289D, 299D and 299D XHP Compact Track Loaders, 257D, 277D, 287D,
297D and 297D XHP Multi Terrain Loaders and 236D, 242D, 246D, 262D, 272D and
272D XHP Skid Steer Loaders Power Train
Media Number -UENR3730-09 Publication Date -01/05/2015 Date Updated -13/08/2018
i06027012
System Pressure - Release

SMCS - 4350-553-PX; 5050-553-PX
Release Procedure
Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the
engine has been stopped. Serious injury can be caused if this pressure is
not released before any service is done on the hydraulic system.
Make sure all of the attachments have been lowered, oil is cool before
removing any components or lines. Remove the oil filler cap only when
the engine is stopped, and the filler cap is cool enough to touch with
your bare hand.
1. Start the engine and allow the engine to run for at least 15 seconds in order to recharge the
accumulator.
2. Stop the engine. Keep the armrests in the LOWERED position. Turn the engine start switch
to the ON position. Push the parking brake switch.
3. Move the hydraulic operated controls through all of the positions.
4. Turn the engine start switch to the OFF position.
5. Disconnect the battery cable or turn the battery disconnect switch to the OFF position.
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i07202363
Piston Pump (Hydrostatic) - Remove and Install

SMCS - 5070-010-H7
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 386-6031 Lever Puller Hoist 2
304-8950 Tube As
B 304-8951 Trolley 1
305-0041 Base As 1
8S-7631 Tube 1
C 8S-7615 Pin 1
8S-7640 Stand 1
D 439-3940 Link Bracket 2
E 387-9124 Wrench Adapter 1
Start By:
a. Remove the piston pump.
Illustration 1 g02824547
1. Disconnect hose assemblies (1), hose assemblies (2), and hose assembly (3).
2. Disconnect hose assemblies (4) and hose assemblies (5).
3. Disconnect harness assemblies (6). Repeat this step for the opposite side.
Typical Example
4. Position Tooling (B) onto Tooling (C).
5. Use Tooling (A), Tooling (D), and a suitable lifting device to support the opposite end of
Tooling (B).
6. Attach an additional Tooling (A) and a suitable lifting device onto Tooling (B) and piston
pump (7). The weight of piston pump (7) is approximately 73 kg (160 lb). Apply a slight
lifting tension.
7. Use suitable blocking to support piston pump (7).
8. Use Tooling (E) to remove bolts (8). Remove piston pump (7).
Installation Procedure
1. Install piston pump (7) in the reverse order of removal.
Copyright 1993 - 2019 Caterpillar Inc. Tue Nov 5 21:44:21 UTC+0800 2019
All Rights Reserved.
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i06659865
Piston Pump (Hydrostatic) - Disassemble

SMCS - 5070-015-H7
Disassembly Procedure
Table 1
Required Tools
A 1P-0510 Driver Gp 1
B 9S-9152 Puller Attachment As. 1
0S-1527 Bolt 1
C 2J-3506 Full Nut 1
8T-4122 Hard Washer 2
D 1P-1859 Retaining Ring Pliers 1
Start By:
a. Remove the pump. Refer to Disassembly and Assembly, "Piston Pump (Hydrostatic) -
Remove".
1. Remove bolts (1) and valve (2).
2. Remove nut (3), the O-ring seal, coil (4), bolts (5), and cartridge (6).
3. Remove screen (6A).
4. Remove gasket (7) and control arm (8).
5. Remove bolts (9) and valve (10).
6. Repeat Steps 2 through Steps 4 for valve (10).
7. Remove nut (13), coil (12), and cartridge (14).
8. Remove valve (11).
9. Remove plugs (14A), O-ring seal (14E), O-ring seal (14C), backup ring (14D) and
crossover relief valves (14B), from the head.
10. Remove O-ring seal (15), backup rings (16), and O-ring seals (17).
11. Remove O-ring seal (18), backup ring (19), and O-ring seal (20).
12. Remove bolts (21) and housing (22).
13. Remove bolts (25), retainer (24), and set screw (23).
14. Repeat Step 13 for the opposite side.
15. Remove O-ring seal (26).
16. Remove piston assembly (27) and swashplate (28).
17. Remove seals (29) and block (30).
18. Remove bearings (31) from swashplate (28).
19. Remove shaft (32).
20. Use Tooling (A), Tooling (B), and a suitable press to remove bearing (33) from the shaft.
21. Remove barrel assembly (34).
22. Remove port plate (36) and gasket (35).
23. Remove coupling (37).
24. Remove head (38).
25. Repeat Step 22 for head (38).
26. Remove bearings (39).
27. Remove barrel assembly (40).
28. Repeat Step 13 through Step 19.
29. Remove retaining ring (47).
30. Remove plate (46).
259D Compact Track Loader FTL00001-UP (MACHINE) POWERED BY C3.3B E... 10/10
31. Remove O-ring seal (45).
32. Remove seal (44) and shaft assembly (41).
33. Use Tooling (D) to remove retaining ring (43).
34. Use Tooling (B) and a suitable press to remove bearing (42).
Copyright 1993 - 2019 Caterpillar Inc. Tue Nov 5 21:45:17 UTC+0800 2019
All Rights Reserved.
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i06660138
Piston Pump (Hydrostatic) - Assemble

SMCS - 5070-016-H7
Assembly Procedure
Table 1
Required Tools
D 1P-1859 Retaining Ring Pliers 1
E 9S-3263 Thread Lock Compound 1
1. Raise the temperature of bearing (42).
2. Install bearing (42).
3. Use Tooling (D) to install retaining ring (43).
4. Install shaft assembly (40) and seal (44).
5. Install O-ring seal (45).
6. Install plate (46).
7. Install retaining ring (47).
8. Raise the temperature of bearing (33).
9. Install bearing (33) onto shaft (32).
10. Install shaft (32).
11. Install bearings (31) onto swashplate (28).
12. Install seals (29) and block (30).
13. Install piston assembly (27) and swashplate (28).
14. Install O-ring seal (26).

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Service Repair Manual

259D COMPACT TRACK LOADER

Product: COMPACT TRACK LOADER

Disassembly and Assembly

System Pressure - Release

3. Move the hydraulic operated controls through all of the positions.

4. Turn the engine start switch to the OFF position.

Product: COMPACT TRACK LOADER

Disassembly and Assembly

Piston Pump (Hydrostatic) - Remove and Install

a. Remove the piston pump.

2. Disconnect hose assemblies (4) and hose assemblies (5).

4. Position Tooling (B) onto Tooling (C).

7. Use suitable blocking to support piston pump (7).

Product: COMPACT TRACK LOADER

Disassembly and Assembly

Piston Pump (Hydrostatic) - Disassemble

1. Remove bolts (1) and valve (2).

3. Remove screen (6A).

4. Remove gasket (7) and control arm (8).

5. Remove bolts (9) and valve (10).

6. Repeat Steps 2 through Steps 4 for valve (10).

7. Remove nut (13), coil (12), and cartridge (14).

8. Remove valve (11).

12. Remove bolts (21) and housing (22).

14. Repeat Step 13 for the opposite side.

15. Remove O-ring seal (26).

16. Remove piston assembly (27) and swashplate (28).

17. Remove seals (29) and block (30).

18. Remove bearings (31) from swashplate (28).

19. Remove shaft (32).

21. Remove barrel assembly (34).

22. Remove port plate (36) and gasket (35).

23. Remove coupling (37).

24. Remove head (38).

25. Repeat Step 22 for head (38).

26. Remove bearings (39).

27. Remove barrel assembly (40).

28. Repeat Step 13 through Step 19.

29. Remove retaining ring (47).

30. Remove plate (46).

31. Remove O-ring seal (45).

32. Remove seal (44) and shaft assembly (41).

33. Use Tooling (D) to remove retaining ring (43).

Product: COMPACT TRACK LOADER

Disassembly and Assembly

Piston Pump (Hydrostatic) - Assemble

1. Raise the temperature of bearing (42).

2. Install bearing (42).

3. Use Tooling (D) to install retaining ring (43).

4. Install shaft assembly (40) and seal (44).

5. Install O-ring seal (45).

6. Install plate (46).

7. Install retaining ring (47).

8. Raise the temperature of bearing (33).

9. Install bearing (33) onto shaft (32).

10. Install shaft (32).

11. Install bearings (31) onto swashplate (28).

12. Install seals (29) and block (30).