583R Pipelayer Machine Systems Caterpillar

Disassembly Procedure

Start By:

1. Remove the winch. Refer to Disassembly and Assembly, "Winch and Winch Frame - Remove".

1. Drain the oil from the winch.

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Illustration 1	g00499080

2. Disconnect oil line (2) .

3. Remove bolts (3) and the washers and remove accumulator (1) from the winch.

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Illustration 2	g00499084

4. Disconnect oil line (6) at winch control valve (4) .

5. Remove four bolts (5) and remove control valve (4) from the winch.

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Illustration 3	g00499085

6. Remove five bolts (7) that hold winch control metering pump (8) to the winch brake housing. Use two 3/8 in -16 NC forcing screws to separate the metering pump from the winch brake housing, if necessary. Remove the winch control metering pump.

7. Disconnect oil line (6). Remove bolt (10) that secures clamp (9) and line (6) to the winch. Remove the oil line.

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Illustration 4	g00499086

8. Remove two bolts (11) and remove guard (12). Remove oil lines (13) and (14) from the winch.

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Illustration 5	g00499087

9. Remove bolt (15) and the washer from the center of coupling (16) .

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Illustration 6	g01004725

Note: Do not remove three bolts (23) at this time.

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The three bolts must be left in place. These bolts limit the spring force on the winch brake piston. The three bolts will hold the springs until the housing assembly mounting bolts can be removed. Failure to do this procedure can result in personal injury and equipment damage.

10. Remove two bolts (19) and bolts (21) and (22) from housing assembly (20) .

11. Remove eight bolts (17) from housing assembly (20) .

12. Fasten Tool (A) and a hoist to housing assembly (20). Install two 1/2 in - 13 NC guide bolts (18). Loosen three bolts (23) evenly and remove housing assembly (20). The weight of the housing assembly is 91 kg (200 lb).

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Illustration 7	g00499089

13. Put housing assembly (20) in the position that is shown. Put 2P-2506 Thread Compound on three bolts (23) that were removed in step 12. Install three bolts (23) and the washers through piston (25) in housing assembly (20) .

14. Use 1/4 inch nuts as spacers between the washers and piston (26) in order to move piston (26) away from ring (24) .

15. Turn bolts (23) downward evenly until ring (24) can be removed from housing assembly (20). Remove ring (24) .

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Illustration 8	g00499090

16. Remove bolt (27) and the O-ring seal from housing assembly (20) .

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Illustration 9	g00499091

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Do not remove any of the three bolts until the piston is clear of the housing.

17. Loosen three bolts (23) evenly until the spring force is released. Remove bolts (23), the washers and the nuts.

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Illustration 10	g00499092

18. Remove pistons (25) and (26) as a unit.

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Illustration 11	g00499094

19. Fasten Tool (B) to piston (26) and remove piston (26) from piston (25) .

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Illustration 12	g00499095

20. Remove ring (28) and seal (29) from piston (26) .

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Illustration 13	g00499096

21. Remove ring (30) from piston (25) .

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Illustration 14	g00499097

22. Remove eight sets of three springs (31) from housing (20) .

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Illustration 15	g00499098

23. Remove seal (32), screw (33) and washer (34) .

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Illustration 16	g00499099

Note: The heads of the five bolts that hold case assembly (35) in position are located on the opposite side of housing assembly (20) .

24. Remove the five bolts that secure cage assembly (35) in housing assembly (20) and remove the cage assembly.

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Illustration 17	g00499140

25. Remove disc (36) .

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Illustration 18	g00499141

26. Remove coupling (37) from housing assembly (20) .

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Illustration 19	g00499142

27. Remove retainer (38) from coupling (37), if necessary.

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Illustration 20	g00499143

28. Carefully put housing assembly (20) on wood blocks, as shown.

29. Remove nut (39), gear (40) and the key for gear (40). Remove the disc that is located beneath gear (40) .

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Illustration 21	g00499144

30. Remove gear (42), shaft (43) and disc (44) as a unit out of the bottom of housing assembly (20) .

31. Remove ring (41) from shaft (43). Remove gear (42) and the key. Remove disc (44) .

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Illustration 22	g00499145

32. Use Tool (C) and remove two bearings (45) from housing (20) .

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Illustration 23	g00499146

33. Fasten Tool (D) and a hoist to the top of housing (46) .

34. Remove two horizontal bolts that hold housing (46) to cage assembly (47) and the winch frame. Install two 3/4 in - 10 NC guide bolts (48) .

35. Remove the twelve bolts and the washers that hold housing (46) to cage (47) and the winch frame.

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The plate can fall off when the housing is removed.

36. Carefully remove housing (46) without moving plate (49). The weight of the housing is 39 kg (85 lb).

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Illustration 24	g00499147

37. Remove O-ring seal (50) from housing (46) .

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Illustration 25	g00499149

38. Remove O-ring seals (51) and (52) from housing (46) .

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Illustration 26	g00499150

39. Remove seven plates (49) and seven discs (53) from gear (54) .

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Illustration 27	g00499151

40. Move the ends of ring (55) together in order to disengage the ring with the groove in the clutch race. Push shaft (56) inward.

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Illustration 28	g00499152

41. Fasten one-way roller clutch assembly (57) to a hoist and carefully remove the clutch assembly. The weight of the clutch assembly is 45 kg (100 lb).

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Illustration 29	g00499153

42. Remove ring (59) and gear (58) .

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Illustration 30	g00499154

43. Remove bearing (61) from race (60) .

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Illustration 31	g00499155

44. Remove cam assembly (62) of the clutch assembly from gear (63) .

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Illustration 32	g00499156

45. Remove lockring (64) from gear (63) .

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Illustration 33	g00499157

46. Remove plate (65) from cam assembly (62) .

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Illustration 34	g00499158

47. Use Tool (E) to remove bearing (66) from plate (65) .

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Illustration 35	g00499159

48. Put race (60) of cam assembly (62) on a small wood block.

49. Use two flat head screwdrivers to turn cage (67) in order to release cage (67). Move cam assembly (62) and cage (67) downward from the race, as shown.

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Illustration 36	g00499160

50. Remove bearing (68) from race (60), if necessary.

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Illustration 37	g00499161

51. Remove 21 rollers (69) from cage (67) .

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Illustration 38	g00499163

52. Remove four springs (70) and cage (67) from cam (62) .

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Illustration 39	g00499164

53. Remove all of the bolts except for two of the bolts on the diameter of cover (71). Leave two bolts that are opposite of each other. Evenly loosen the two bolts in order to release the force of the wave spring and remove cover (71) .

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Illustration 40	g00499165

54. Remove wave spring (72) and O-ring seal (73) from cover (71) .

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Illustration 41	g00499166

55. Slowly remove bolt (74) and the washer. Spring force will be released during the first part of the movement.

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Illustration 42	g00499168

56. Mark the location of housing (75) for assembly purposes.

57. Install two 1/2 in - 13 NC forcing screws (76) in the tapped holes in housing (75) .

58. Remove the six bolts and the washers and remove housing (75) .

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Illustration 43	g00499169

59. Put alignment marks on race (77), support (78) and housing (75) .

60. Remove race (77) .

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Illustration 44	g00499171

61. Remove race (79) and sprag clutch (80) from race (77) .

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Illustration 45	g00499172

62. Remove sleeve (81) and support (78) .

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Illustration 46	g00499173

63. Remove O-ring seals (82) from each side of support (78) .

64. Remove bearing (83) from support (78) .

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Illustration 47	g00499174

65. Remove the piston and spring assembly (84) from housing (75) .

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Illustration 48	g00499176

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Personal injury can result from a spring that is under compression. Do not attempt to remove the snap ring without using a hydraulic press. Failure to use a press can result is the sudden release of the spring.

Note: A spacer (not shown) is located around spring (86). The spacer limits the travel (compression) of the centering spring.

66. Use Tool (F) and a press in order to compress spring (86). Remove snap ring (85) .

67. Slowly release the compression on spring (86) .

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Illustration 49	g00499177

68. Remove piston (87), bearing (88), race (89) and the spacer that is located around spring (86) (not shown).

69. Remove seal ring (90) from piston (87) .

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Illustration 50	g00499179

70. Remove spring (86), thrust race (91) and thrust bearing (92) from piston (93) .

71. Remove seal ring (94) from piston (93) .

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Illustration 51	g00499180

72. Remove seal (95) and O-ring seal (96) from housing (75) .

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Illustration 52	g00499182
Typical example

73. Fasten a nylon strap and a hoist to cable drum (97) in order to support the drum.

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Illustration 53	g00499184

74. Remove retaining ring (98) .

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Illustration 54	g00499185

75. Remove two of the bolts that hold cage (99) and install two 5/8 in - 11 NC guide bolts, as shown.

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Illustration 55	g00499186

76. Remove the remaining bolts that hold cage (99). Install two 3/8 in - 16 NC forcing screws and remove cage (99) .

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Illustration 56	g00499187

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Illustration 57	g00499188

77. Remove lip seal (100) from cage (99) .

78. Use Tool (E) and a hydraulic press to remove bearing (101) from cage (99) .

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Illustration 58	g00499189

79. Remove two of the bolts that hold flange (102) and install two 5/8 in - NC guide bolts, as shown.

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Illustration 59	g00499190

80. Remove the remaining bolts that hold flange (102). Install two 3/8 in - 16 NC forcing screws in flange (102) .

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Illustration 60	g00499191

81. Fasten Tool (D) and a hoist to flange (102) and remove the carrier assemblies as a unit. The weight of the unit is 43 kg (95 lb).

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Illustration 61	g00499192

82. Remove the six bolts that hold flange (102) to the carrier assemblies. Remove flange (102) from the carrier assemblies.

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Illustration 62	g00499194

83. Remove two retaining rings (103) that are located on each side of coupler (104). Remove coupler (104) .

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Illustration 63	g00499196

84. Remove O-ring seal (105) from flange (102) .

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Illustration 64	g00499198

85. Remove shaft (106) and coupler assembly (107) as a unit.

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Illustration 65	g00499199

86. Remove bolt (108), the washer, coupler assembly (107) and sleeve (109) from shaft (106) .

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Illustration 66	g00499200

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Illustration 67	g00499201

87. Install bolt (108), the washer and coupler assembly (107) in shaft (106) .

88. Tighten bolt (108) until retaining ring (110) can be removed. Remove retaining ring (110) .

89. Remove retaining ring (110), washer (111), springs (112), plate (113) and spacer (114) from coupler assembly (107) .

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Illustration 68	g00499202

90. Remove retaining ring (115), gear (116) and bearing (117) from the carrier assemblies.

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Illustration 69	g00499203

91. Remove retaining ring (118). Remove bearing (117) from gear (116) .

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Illustration 70	g00499204

92. Remove retaining ring (119) from carrier (121). Separate carrier (121) from carrier (120) .

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Illustration 71	g00499205

93. Remove retaining ring (122) from carrier (120) and remove bearing (123) from carrier (120) .

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Illustration 72	g00499206

94. Drive the roll pin through carrier (120) in shaft (124) in order to remove each shaft (124) .

95. Remove each shaft (124), disc (125), gear (126), and disc (127) from carrier (120) .

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Illustration 73	g00499207

96. Remove bearings (128) from gear (126) .

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Illustration 74	g00499208

97. Drive the roll pin through carrier (121) in shaft (129) in order to remove each shaft (129) .

98. Remove each shaft (129), disc (130), gear (131) and disc (132) from carrier (121) .

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Illustration 75	g00499209

99. Remove bearing (133) from gear (131) .

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Illustration 76	g00499210

100. Pull out shaft (134) .

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Illustration 77	g00499211

101. Remove retaining ring (135) and gear (136) .

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Illustration 78	g00499212

102. Remove ring (55) and shaft (56) from the other side of the winch.

103. Remove screw (138), washer (137), and the seal that is located behind washer (137) .

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Illustration 79	g00499213

104. Remove retaining ring (139) from carrier assembly (140) .

105. Install Tool (B) in carrier (140). Tool (B) will be used to hold the carrier during removal.

106. Remove carrier (140) and shaft (56) as a unit. The weight of the unit is 41 kg (90 lb).

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Illustration 80	g00499214

107. Remove shaft (56) from carrier (140) .

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Illustration 81	g00499215

108. Remove slinger (141) from carrier (140) .

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Illustration 82	g00499216

109. Remove bearing (142) from carrier (140) .

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Illustration 83	g00499217

110. Drive roll pin (147) through carrier (140) in shaft (143) in order to remove each shaft (143) .

111. Remove each shaft (143), disc (144), gear (145), and disc (146) from carrier (140) .

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Illustration 84	g00499218

112. Remove bearing (148), spacer (149), and bearing (150) from gear (145) .

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Illustration 85	g00499219

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Illustration 86	g01004708

113. Put an alignment mark from cage assembly (47) to the winch frame for assembly purposes.

114. Install two 3/4 in - 10 NC guide bolts in the horizontal bolt holes, as shown.

115. Install two 3/8 in - 16 NC forcing screws. Move cage assembly (47) far enough away from the winch frame in order to provide clearance for Tool (D) .

116. Fasten Tool (D) and a hoist to cage assembly (47) and remove the cage assembly. The weight of cage assembly (47) is 59 kg (130 lb).

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Illustration 87	g00499222

117. Remove O-ring seal (151) from cage assembly (47) .

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Illustration 88	g00499223

118. Use Tool (G) to remove bearing (152) from cage assembly (47) .

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Illustration 89	g00499224

119. Remove cable drum (97) from the winch frame. The weight of the cable drum is 263 kg (580 lb).

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Illustration 90	g00499225

120. Remove 30 bolts (153) and the washers. Remove hub (157), outer bearing race (155) and lip type seal (154) from the drum as a unit.

121. Remove lip type seal (154), race (155), and O-ring seal (156) from hub (157) .

122. Remove ring gear (158) from drum (97) .