583R Pipelayer Power Train Caterpillar

Disassembly Procedure (Power Shift Transmission)

Start By:

1. Separate the transmission and bevel gear.

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Illustration 1	g00506060

1. Place the transmission in position on Tooling (A). Place alignment marks on all of the housings for assembly purposes.

2. Remove three small O-ring seals (1) and large O-ring seal (2) from the transmission cover.

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Illustration 2	g00506061

3. Remove plugs (5) and the springs behind the plugs.

4. Remove bolt (4) and the retainer. Remove tube (6) and the seals from the tube.

5. Remove two tubes (3) and the seals from the tubes.

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Illustration 3	g00506062

6. The weight of the transmission control valves and the priority valve as a unit is 43 kg (95 lb). Install Tooling (B) on the transmission control valve. Fasten a hoist to Tooling (B), as shown.

7. Remove four bolts (7) that hold the transmission control valves and the priority valve as a unit.

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Illustration 4	g00506103

8. Remove bolt (9) and tube assembly (8) .

9. Remove the O-ring seal from tube assembly (8) .

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Illustration 5	g00506104

10. The weight of the planetary assembly is 341 kg (751 lb). Install Tooling (C) and attach a hoist to Tooling (C), as shown.

11. Remove 21 bolts (10) that hold the planetary assembly to the transmission cover.

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Illustration 6	g00506105

12. The weight of transmission cover (12) is 100 kg (220 lb). Install Tooling (C) to the transmission cover, and fasten a hoist. Remove the transmission cover from Tooling (A) .

13. Remove the cover for suction screen (11) and the O-ring seal from the transmission cover.

14. Remove the suction screen from transmission cover (12) .

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Illustration 7	g00506106

15. Place transmission planetary (13) in position on Tooling (A). Use four bolts and nuts (14) to fasten the planetary group to Tooling (A) .

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Illustration 8	g00506107

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Illustration 9	g00506108

16. Remove retaining ring (16) from the manifold with Tooling (D) .

17. The weight of manifold (17) is 23 kg (51 lb). Install Tooling (C) and attach a hoist to Tooling (C). Remove ten bolts (15) and manifold (17) .

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Illustration 10	g00506109

18. Use Tooling (E), and remove retaining ring (19) from manifold (17) .

19. Remove bearing (18) from manifold (17) .

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Illustration 11	g00506110

20. The weight of first clutch gear (20) and the housing assembly is 31 kg (68 lb). Remove first speed clutch gear and housing assembly (20) .

21. Remove ten springs (22) and five dowels (23) .

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NOTICE
The discs and the plates that are used in the individual clutches must be kept in order and with their original clutch housing. Different friction material is used for the different clutches, so the discs and the plates must not be mixed from one clutch to another.

22. Remove the two discs and one plate (21). The discs and the one plate make the second speed clutch.

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Illustration 12	g00506112

23. Remove retaining ring (24) and remove housing assembly (25) from first speed clutch gear (20) .

24. Remove the four discs and the three plates from first speed clutch gear (20) .

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Illustration 13	g00506113

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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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NOTICE
There is spring pressure under plate (26). A press should be used to remove retainer ring (27) and to slowly release the spring pressure.

25. Place housing assembly (25) in a press, as shown. Compress the springs under plate (26) and remove retainer ring (27). Release the spring pressure slowly, and remove plate (26) and the three spring plates under plate (26) .

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Illustration 14	g00506114

26. Remove piston (29) from housing assembly (25). Remove ring (30) and seal (28) from the piston.

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Illustration 15	g00506115

27. Turn over the housing cover, and remove two seal rings (31) from carrier (32) .

Note: Carrier (32) will be destroyed if the carrier is removed from the housing assembly.

28. If carrier (32) is removed, use a hammer and a chisel to break the carrier. Remove the carrier. After the carrier is removed, remove the dowel that holds the carrier in position.

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Illustration 16	g00506116

29. Use Tooling (F) in order to hold the two pistons in clutch housing assembly (33) .

30. The weight of clutch housing assembly (33) with the piston is 46 kg (101 lb). Use Tooling (G), and fasten a hoist to Tooling (G), as shown. Remove clutch housing assembly (33) .

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Illustration 17	g00506117

31. Remove pistons (35) and (37) from clutch housing (33) .

32. Remove teflon seal rings (34) and (36) from pistons (35) and (37) .

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Illustration 18	g00506118

33. Remove ten springs (38) .

34. Remove three discs (39) and the two plates.

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Illustration 19	g00506119

35. Use Tooling (D), and remove retaining ring (40) .

36. Remove gear (41) and planetary carrier (42) .

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Illustration 20	g00506120

37. Use a hammer and a punch in order to push pins (46) in shafts (43) .

38. Remove shafts (43), gears (44), thrust washer (45), and thrust washer (48) from planetary carrier (42). Remove bearings (47) from gears (44) .

39. Remove pins (46) from shafts (43) .

40. Install small screwdrivers in the teeth around the planetary carrier that is location (X) in order to compress the retaining ring. Remove gear (49) from planetary carrier (42) .

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Illustration 21	g00506121

41. Place wood blocks under reverse clutch housing (52) .

42. Remove two bolts (50). Use Tooling (H) in order to hold the piston in forward clutch housing (51) .

43. The weight of the piston and forward clutch housing (51) is 26 kg (57 lb). Use Tooling (J) and attach a hoist to Tooling (J), as shown. Remove the piston and forward clutch housing (51) .

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Illustration 22	g00506122

44. Remove piston (53) from forward clutch housing (51) .

45. Remove teflon seal rings (54) and (55) from piston (53) .

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Illustration 23	g00506123

46. Remove five dowels (58) and ten springs (60) .

47. Remove four discs (57), the three plates, ring gear (56), and plate assembly (59) .

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Illustration 24	g00506124

48. Remove four discs (61), and the three plates from reverse clutch housing assembly (52) .

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Illustration 25	g00506125

49. Use Tooling (D), and remove retaining ring (62). Retaining ring (62) holds the shaft and the planetary assembly to reverse clutch housing assembly (52) .

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Illustration 26	g00506126

50. The weight of output shaft (63) and the planetary assembly is 70 kg (154 lb). Use a suitable lifting strap and a hoist, and remove the shaft and the planetary assembly from reverse clutch housing assembly (52) .

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Illustration 27	g00506127

51. Remove piston (64) from reverse clutch housing assembly (52) .

52. Remove teflon seals (65) and (66) from the piston.

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Illustration 28	g00506128

53. The weight of the reverse clutch housing assembly is 42 kg (92 lb). Turn over the reverse clutch housing assembly, and use Tooling (E) to remove snap ring (67) .

54. Remove bearing (68) .

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Illustration 29	g00506129

55. Remove seal (70), three seal rings (69) and (71) from the shaft and the planetary assembly.

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Illustration 30	g00506131

56. Turn over the output shaft, planetary carriers, and the gears. Position the parts on wood blocks, as shown.

57. Remove seal (72) from output shaft (63) .

58. Remove seal ring (74) from the planetary carrier.

59. Remove retaining ring (73) that holds output shaft (63) to the planetary carrier.

60. Remove output shaft (63) from the input shaft and the planetary carrier.

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Illustration 31	g00506132

61. Use Tooling (D), and remove retaining ring (75) from output shaft assembly (63). Remove gear (76) and bearing (77) from the output shaft assembly.

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Illustration 32	g00506133

62. Remove bearing (78) from output shaft (63) .

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Illustration 33	g00506134

63. Use Tooling (D), and remove retainer ring (82) that holds gear (81) in position on input shaft (80). Remove gear (81) .

64. The weight of the planetary carrier is 26 kg (57 lb). Remove planetary carrier (79) from the input shaft.

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Illustration 34	g00506135

65. Use Tooling (K) in order to compress retaining ring (83). Remove gear (84) from the planetary carrier.

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Illustration 35	g00506137

66. Remove retaining ring (85), and remove bearing (87) and the gear as a unit from the planetary carrier.

67. Remove bearing (87) from gear (86) .

68. Use a hammer and a punch in order to push pins (88) in the planetary gear shafts.

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Illustration 36	g00506138

69. Remove planetary gear shafts (92), gears (89) and (91), and thrust washers (93) from the planetary carrier.

70. Remove bearings (90) from gears (89) and (91) .

71. Remove pins (94) from planetary gear shafts (92) .

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Illustration 37	g00506139

72. Remove planetary carrier (95) from input shaft (80) .

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Illustration 38	g00506141

73. Use Tooling (E), and remove retaining ring (96). Remove bearing (97) .

74. Use a hammer and a punch in order to push pins (98) in the planetary gear shafts.

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Illustration 39	g00506142

75. Remove planetary gear shafts (99), gears (100), and thrust washers (102) .

76. Remove bearings (101) from gears (100) .

77. Remove pins (103) from the planetary gear shafts.

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Illustration 40	g00506143

78. Remove O-ring seal (105) from input shaft (80) .

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NOTICE
If carrier (104) is removed, the carrier will be damaged.

79. If necessary, remove carrier (104) from input shaft (80) .