583T Pipelayer Machine Systems Caterpillar

Assembly Procedure

Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.

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Illustration 1	g00877519

1. Install ring (70) and guide ring (69) .

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Illustration 2	g00875604

2. Install O-ring seal (68) to cover (67) .

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Illustration 3	g00875602

3. Install cover (67) and four bolts (66) .

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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.

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Illustration 4	g00875601

4. Install spring retainer (63) and rod (65) . Install springs (61) , (62) , and (64) . Install spring retainer (60) . Install O-ring seal (58) and ring assembly (59) .

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Illustration 5	g00875599

5. Use Tooling (A) and a suitable press in order to install retaining ring (57) .

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Illustration 6	g00875573

6. Install O-ring seal (56) to cover (55) .

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Illustration 7	g00875571

7. Install cover (55) and nut (54) .

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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.

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Illustration 8	g00875570

8. Install spring retainer (53) . Install springs (50) , (51) , and (52) . Install spring retainer (49) .

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Illustration 9	g00875569

9. Use Tooling (C) and a suitable press in order to Install ring assembly (48) .

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Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened.

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Illustration 10	g00875568

10. Use Tooling (A) and a suitable press in order to install retaining ring (47) .

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Illustration 11	g00875567

11. Install servo valve (46) and four bolts (45) .

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Illustration 12	g00875539

12. Install two bearings (42) .

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Illustration 13	g00875538

13. Install two bearings (41) , two rods (40) , and slide (39) .

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Illustration 14	g00875537

14. Install swashplate assembly (38) .

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Illustration 15	g00875564

15. Install joint pin (43) and plug assembly (44) .

16. Repeat Step 15 for the opposite side.

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Illustration 16	g00875224

17. Install Tooling (D) over shaft assembly (36) in order to protect the shaft during installation. Install shaft assembly (36) and O-ring seal (37) to housing (4) . Remove Tooling (D) after installation.

18. Install retaining ring (35) to housing (4) .

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Illustration 17	g00875220

19. Use Tooling (I) to install seal (34) to housing (4) .

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Illustration 18	g00875204

20. Install retaining ring (33) to housing (4) .

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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.

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Illustration 19	g00875827

21. Install washer (31) , spring (32) and washer (31) in barrel assembly (27) .

22. Install retaining ring (30) .

23. Use the following steps in order to determine the correct shim thickness on the rotating group.
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    Illustration 20	g00875829

    1. Place port plate (11) onto a surface plate. The flat side of the port plate should rest on the surface plate.
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    Illustration 21	g00875830

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    Illustration 22	g00875832

    2. Place Tooling (E) on the inside diameter of port plate (11) . The chamfered side faces upward.

    3. Install barrel assembly (27) onto Tooling (E) and port plate (11) .
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    Illustration 23	g00875866

    4. Install Tooling (F) on top of the barrel assembly (27) , as shown.
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    Illustration 24	g00875874

    5. Make sure that all the springs and shims have been removed from ball joint (26) . Install the ball joint over Tooling (F) .
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    Illustration 25	g00875876

    6. Install retainer plate (25) onto ball joint (26) .
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    Illustration 26	g00875877

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    Illustration 27	g00875879

    7. Bolt Tooling (G) and Tooling (H) together. Place Tooling (G) and (H) on top of the retainer plate (25) , as shown.
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    Illustration 28	g00875881

    8. Use a Vernier scale or a similar tool in order to measure the dimension in Step 23.i.
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    Illustration 29	g00586062

    9. Measure the distance from the top of the surface plate to the top of Tooling (G) . Record this dimension as Dimension (X) . Measure the distance from the top of Tooling (G) to the top of retainer plate (25) . Record this dimension as Dimension (W) .
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       Table 2

       CALCULATION

       Subtract Dimension (W) from Dimension (X) in order to obtain Dimension (Y) .

       Dimension (Y) is the Lift Off Height.

       Note: The dimension is 131.0 + 0.0 - 0.2 mm (5.1575 + 0.0 - 0.0079 inch). Call this Dimension (Z) .

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       Table 3

       CALCULATION

       Subtract Dimension (Y) from Dimension (Z) in order to obtain the thickness of shim (66) . This will provide the correct Lift Off Height.

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Illustration 30	g00875186

24. Install shim (29) . Refer to Step 23.i for the correct size. Install springs (28) in the correct sequence.

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Illustration 31	g00875182

25. Install ball joint (26) on the shim and barrel assembly (27) .

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Illustration 32	g00875175

26. Install pistons (24) and retainer plate (25) .

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Illustration 33	g00875902

27. Wrap a piece of nylon string around the pistons, as shown.

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Illustration 34	g00875903

28. Lower rotating assembly (23) into the pump. Use the nylon string in order to hold the assembly together during installation. Remove the nylon string.

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Illustration 35	g00875056

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Illustration 36	g00875132

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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.

29. Install O-ring seal (21) to compensator valve (22) .

30. Install piston (17) to head (7) .

31. Install retainer (18) to compensator valve (22) . Install spring (19) to compensator valve (22) . Install retainer (20) to compensator valve (22) .

32. Install compensator valve (22) to head (7) .

33. Install O-ring seal (16) to test port (15) . Install test port (15) to head (7) .

34. Install O-ring seal (14) to relief valve (13) . Install relief valve (13) to head (7) .

35. Install O-ring seal (12) to head (7) .

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Illustration 37	g00875055

36. Install port plate (11) to head (7) .

37. Install O-ring seal (9) to head (7) .

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Illustration 38	g00875035

38. Install coupler (9) .

39. Install head (7) to housing (4) .

40. Install bolts (8) to head (7) .

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Illustration 39	g01239039

41. Install flange (6) to housing (4) .

42. Install bolts (5) to flange (6) .

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Illustration 40	g01239037

43. Install cartridge (3A) and coils (3) .

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Illustration 41	g01239036

44. Install the O-ring seals, control valve (2A) , and bolts (2) .

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Illustration 42	g01239035

45. Install cover (1A) and bolts (1) .

End By: Install the steering pump. Refer to Disassembly and Assembly, "Steering Pump - Install".