583R Pipelayer Power Train Caterpillar

Assembly Procedure (Power Shift Transmission)

1. Inspect all of the parts for wear or damage. Replace all of the parts that are worn or damaged. Be sure that all of the oil passages in the shafts and the housings are clean. Place clean oil on the parts during assembly.

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Illustration 1	g00506697

2. If seal carrier (4) was removed from input shaft (3), use the following steps for assembly.

   1. Heat carrier (4) to a temperature of 127° to 166°C (260° to 298°F) for a maximum of ten minutes.

   2. Align one of the holes in the carrier with the hole in input shaft (3), and install the carrier on the shaft.

   3. Install pin (1) in the carrier and the input shaft. Be sure that pin (1) is installed so that the pin is below the outer diameter of carrier (4) .

3. Install O-ring seal (2) on input shaft (3) .

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Illustration 2	g00506698

4. Install bearing (8) in gear (7) .

5. Place one thrust washer (9) on each side of gear (7). Install gear (7) in planetary carrier (5) .

6. Install planetary gear shaft (6) that holds the gear in planetary carrier (5) .

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NOTICE
The rubber in pin (10) must not be damaged. If the rubber is damaged, the pin must be replaced.

7. Align the holes in the planetary gear shaft and the planetary carrier, and install pin (10). Repeat this procedure for all of the planetary gears.

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Illustration 3	g00506699

8. Install bearing (11) in planetary carrier (5). Use Tooling (A), and install retaining ring (12) in order to hold the bearing in position.

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Illustration 4	g00506700

9. Place oil on O-ring seal (2) immediately before planetary carrier (5) is installed. Place planetary carrier (5) in position on input shaft (3) .

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Illustration 5	g00506701

10. Install bearings (13) in gears (15) .

11. Place one thrust washer (14) on each side of gears (15). Install gears (15) in planetary carrier (17) .

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Illustration 6	g00506702

12. Install planetary gear shaft (16) that holds the gear in position in planetary carrier (17) .

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NOTICE
The rubber in pin (18) must not be damaged. If the rubber is damaged, the pin must be replaced.

13. Align the hole in planetary gear shaft (16) in the hole in the planetary carrier, and install pin (18). Repeat the procedure for all of the planetary gears.

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Illustration 7	g00506703

14. Install the seal on gear (19) .

15. Place oil on the seal immediately before assembly. Install bearing (20) on gear (19) .

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Illustration 8	g00506704

16. Install gear (19) in planetary carrier (17). Install retaining ring (21) in order to hold the gear and bearing in position in the planetary carrier.

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Illustration 9	g00506705

17. Install retaining ring (22) on planetary carrier (17). Use Tooling (B), and compress the retaining ring as the planetary carrier is installed in gear (23). Remove Tooling (B). Tap the retaining ring in order to make sure that the retaining ring is seated in the groove in gear (23) .

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Illustration 10	g00506706

18. Place planetary carrier (17) and gear (23) in position on input shaft (3) .

19. Install gear (24). Use Tool (C), and install retaining ring (25) .

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Illustration 11	g00506707

20. Use Tooling (D), and install bearing (27) in the end of output shaft (26). Install the bearing to a depth of 2.0 ± 0.5 mm ( .079 ± .020 inch). The inner bearing diameter after assembly should be 50.809 ± .049 mm (2.000 ± .002 inch).

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Illustration 12	g00506708

21. Use Tooling (D), and install bearing (28) in the end of output shaft (26). Install the bearing to a depth of 13.0 ± .5 mm (.519 ± .002 inch). The inner bearing diameter after assembly should be 56.650 ± .061 mm (2.230 ± .002 inch).

22. Place gear (30) in position on output shaft (26). Use Tooling (C), and install retaining ring (29) .

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Illustration 13	g00506709

23. Place output shaft (26) over input shaft (3). Engage gear (30) with the planetary gears.

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Illustration 14	g00506710

24. Install retaining ring (31) in the planetary carrier in order to hold the bearing and output shaft (26) in position.

25. Install seal ring (33) on the planetary carrier.

26. Install O-ring seal (32) on output shaft (26) .

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Illustration 15	g00506712

27. Turn over the shaft and the planetary carrier assembly. Install O-ring seal (34) on input shaft (3) .

28. Install seal ring (36) on planetary carrier (17) .

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Illustration 16	g00506713
Correct method of making new seal rings ready for installation (nonmetal rings)

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Illustration 17	g00506715
Incorrect method of making new seal rings ready for installation (nonmetal rings)

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NOTICE
New seal rings must be preloaded before installation. Preloading the seal rings helps to prevent breakage and damage to the seal rings. Use the following method to correctly preload the seal rings: Place your hands on each end of the seal ring and pull until one end is several inches past the other end. Pull the seal ring and/or wind the seal ring until the ends of the seal ring almost make contact. See Illustration 16. Use care to keep the seal ring shaped in a circle. This will make an even bend all the way around the ring. This bend is also called the ring "set". When the seal ring is properly installed in the seal ring groove the ends of the seal will touch each other lightly. Do not use this method to preload a used seal ring or a cast iron seal ring. This method will cause a used seal ring or a cast iron seal ring to break. The wrong method of preloading the seal ring is shown in Illustration 17. Do not bend the seal ring in this manner. This method does not make an even bend all the way around the ring.

29. Install two seal rings (35) on the seal carrier.

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Illustration 18	g00506716

30. Install bearing (38) in reverse clutch housing (37) .

31. Use Tooling (A), and install retaining ring (39) .

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Illustration 19	g00506717

32. Install teflon seal rings (41) and (42) on pistons (40). The lips of the teflon seal rings should be toward the housing. Be sure that you place clean oil on the lip of the teflon seal rings.

33. Install piston (40) in reverse clutch housing (37) .

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Illustration 20	g00506718

34. Place reverse clutch housing (37) in position on Tooling (E), and use wood blocks under the reverse clutch housing.

35. Install coupling (43) in the reverse clutch housing.

36. Place oil on O-ring seal (34) immediately before assembly. Loosen the shafts and planetary carrier (17) in reverse clutch housing (37) .

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Illustration 21	g00506719

37. Use Tooling (C), and install retaining ring (44) on input shaft (3) .

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Illustration 22	g00506720

38. Install four discs (45) and three plates (46). Start with a disc and stop with a disc.

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Illustration 23	g00506721

39. Install plate assembly (47). Install ten springs (50) and five dowels (48) .

40. Install four discs (49) and three plates. Start with a disc and stop with a disc.

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Illustration 24	g00506722

41. Install teflon seal rings (52) and (54) on piston (51). The lip of the teflon seal rings should be toward the clutch housing. Place clean oil on the lip of the teflon seal rings.

42. Install piston (51) in forward clutch housing (53) .

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Illustration 25	g00506723

43. Use Tooling (F) in order to hold piston (51) in the forward clutch housing. Install Tooling (G), and attach a hoist to Tooling (G). Turn over the forward clutch housing. Place the forward clutch housing in position, and align the holes for two bolts (55) .

44. Install two bolts (55) .

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Illustration 26	g00506724

45. Install the bearing in gear (59) .

46. Place a thrust washer on each side of gear (59). Install gear (59) in planetary carrier (56) .

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NOTICE
The rubber in pin (61) must not be damaged. If the rubber is damaged, the pin must be replaced.

47. Align the hole in the planetary gear shaft with the hole in the planetary carrier, and install planetary gear shaft (57) .

48. Install pin (61). Repeat the procedure for all of the planetary gears.

49. Install retaining ring (58) on planetary carrier (56). Use small screwdrivers, and compress the retaining ring as the planetary carrier is installed in gear (60). Remove the screwdrivers. Tap the retaining ring in order to make sure that the retaining ring is seated in the groove in gear (60) .

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Illustration 27	g00506725

50. Place planetary carrier (56) in position on the output shaft. Engage gear (60) with the planetary gears.

51. Install hub (62) on the output shaft. Use Tooling (C), and install retaining ring (63) .

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Illustration 28	g00506726

52. Install three discs (65) and the two plates. Start with a disc and stop with a disc.

53. Install ten springs (64) .

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Illustration 29	g00506727

54. Install teflon seal rings (67) and (68) on pistons (66) and (69). The lip of the teflon seal rings should be toward the center of the clutch housing. Place clean oil on the lip of the seals.

55. Install piston (66) and (69) in clutch housing (70). Use Tooling (H) in order to hold piston (66) and (69) in position.

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Illustration 30	g00506728

56. Install Tooling (J), and attach a hoist to Tooling (J). Lower clutch housing (70) with pistons (66) and (69) on the shaft.

57. Remove Tooling (H) and (J) .

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Illustration 31	g00506729

58. Install two discs (72) and one plate (73) in clutch housing (70) .

59. Install five dowels (71) .

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Illustration 32	g00506730

60. Install ring gear (74) .

61. Install four discs (75) and three plates. Start with a disc and stop with a disc.

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Illustration 33	g00506731

62. If carrier (76) was removed from housing (77), use the following steps for assembly.

    1. Heat carrier (76) to a temperature of 127° to 166°C (260° to 298°F) for a maximum of ten minutes.

    2. Align one of the holes in the carrier with the hole in housing (77), and install the carrier on the housing.

    3. Install pin (78) in the carrier and the housing. Be sure that pin (78) is installed so that the pin is below the outer diameter of carrier (76) .

63. Install two seal rings (79) on carrier (76) .

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Illustration 34	g00506732

64. Install teflon seal rings (80) and (82) on piston (81). The lip of the teflon seal rings should be toward the housing. Place clean oil on the lip of the seals.

65. Install piston (81) in housing (77) .

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Illustration 35	g00506734

66. Install three springs (85) in housing (77). Use the following steps.

    1. Install the first spring so that the outside diameter of the spring contacts the housing.

    2. Install the next two springs so that the outside diameter of the springs are in contact with each other.

    3. Install ring (84) on top of the springs, and place in a press.

67. Compress springs (85) until retaining ring (83) can be installed. Install retaining ring (83). Be sure that the retaining ring is seated in the groove in housing (77). Slowly release the pressure from the press. Remove the housing from the press.

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Illustration 36	g00506737

68. Install housing (77) in gear (74). Install retaining ring (86) .

69. Install ten springs (87) .

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Illustration 37	g00506739

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NOTICE
The notch at location (X) must be installed down, as shown.

70. Use Tooling (A), and install bearing (90) in manifold (88). Install bearing (90) so that the notch that is at location (X) is down.

71. Use Tooling (A), and install retaining ring (89) .

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Illustration 38	g00506740

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NOTICE
The notch in bearing (90) at location (X) must be aligned with the locating dowel in housing (77) .

72. Install Tooling (K), and attach a hoist to Tooling (K). Align the notch at location (X) in bearing (90). Align with the locating dowel in housing (77). Install manifold (88). Remove Tooling (K) .

73. Install ten bolts (92). Tighten the bolts to a torque of 115 ± 7 N·m (85 ± 5 lb ft).

74. Use Tooling (C), and install retaining ring (91) .

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Illustration 39	g00506741

75. Install the suction screen in cover (94). Place the O-ring seal and cover (93) in position, and install the four bolts.

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Illustration 40	g00506742

76. Install Tooling (K), and attach a hoist to Tooling (K). Remove the planetary assembly from Tooling (E). Place transmission cover (94) in position on Tooling (E). Place the planetary assembly in position on cover (94), and install 21 bolts (95) .

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Illustration 41	g00506743

77. Install the O-ring seal on tube (96). Place tube (96) in position, and install bolt (97) .

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Illustration 42	g00506744

78. Install Tooling (L) on the transmission control valves, and attach a hoist to Tooling (L). Place the transmission control valves in position on the planetary assembly, and install four bolts (98). Tighten four bolts (98) to a torque of 48 ± 4 N·m (35 ± 3 lb ft).

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Illustration 43	g00506745

79. Install the O-ring seals on tubes (100). Install tubes (100) in the cover and the priority valve. Install the springs and two plugs (101) .

80. Install the O-ring seal on tube (99). Place tube (99) in position in the cover and tube (96). Install the clip and bolt (102). Install plug (103) .

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Illustration 44	g00506746

81. Install four small O-ring seals (104) and (105) .

82. Install large O-ring seal (106) .

End By: Connect the transmission and bevel gear.