572R Pipelayer Power Train Caterpillar

Assembly Procedure

1. Inspect all the parts for wear or for damage. If necessary, replace any parts that are worn or damaged. Put clean oil on the parts during the assembly procedure. Be certain that all the passages in the shafts and in the housings are clean.

Show/hide table



Illustration 1	g00648162

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

   1. Heat carrier (4) to a temperature between 127 °C (260.6 °F) and 166 °C (330.8 °F). Heat the carrier for a maximum of ten minutes.

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

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

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

Show/hide table



Illustration 2	g00648163

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

5. Install gear (7) in planetary carrier (5). One thrust washer (9) should be on each side of gear (7) for the installation.

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

Note: The rubber in pin (10) must not be damaged. If the rubber is damaged, replace the pin.

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

Show/hide table



Illustration 3	g00648165

8. Install bearing (11) in planetary carrier (5). Use Tooling (A) to install retaining ring (12). Retaining ring (12) will hold the bearing in the correct position.

Show/hide table



Illustration 4	g00648167

9. Put oil on O-ring seal (2) immediately before the installation of planetary carrier (5). Put planetary carrier (5) in the correct position on input shaft (3) .

Show/hide table



Illustration 5	g00648168

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

11. Install gears (15) in planetary carrier (17). One thrust washer (14) should be on each side of the gears for the installation.

Show/hide table



Illustration 6	g00648169

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

Note: The rubber in pin (18) must not be damaged. If the rubber is damaged, replace the pin.

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

Show/hide table



Illustration 7	g00648170

14. Install the seal on gear (19) .

15. Put oil on the O-ring seal immediately before the assembly. Install bearing (20) on gear (19) .

Show/hide table



Illustration 8	g00648171

16. Install gear (19) in planetary carrier (17). Install retaining ring (21). Retaining ring (21) holds the gear and the bearing in the correct position in the planetary carrier.

Show/hide table



Illustration 9	g00648172

17. Install retaining ring (22) on planetary carrier (17). Use Tooling (B) to compress the retaining ring during the installation of the planetary carrier in gear (23). Remove Tooling (B). Tap the retaining ring in order to ensure that the ring is seated in the groove in gear (23) .

Show/hide table



Illustration 10	g00648174

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

19. Install gear (24). Use Tooling (C) to install retaining ring (25) .

Show/hide table



Illustration 11	g00648175

20. Use Tooling (D) to install bearing (27) in the end of output shaft (26). Install the bearing to a depth of 2.0 ± 0.5 mm (0.08 ± 0.02 inch). The inner bearing diameter should be 50.81 ± 0.05 mm (2.000 ± 0.002 inch) after the assembly.

Show/hide table



Illustration 12	g00648176

21. Use Tooling (D) to install bearing (28) in the end of output shaft (26). Install the bearing to a depth of 13.0 ± 0.5 mm (0.51 ± 0.02 inch). The inner bearing diameter should be 56.65 ± 0.06 mm (2.230 ± 0.002 inch) after the assembly.

22. Put gear (30) in the correct position on output shaft (26). Use Tool (C) to install retaining ring (29) .

Show/hide table



Illustration 13	g00648177

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

Show/hide table



Illustration 14	g00648178

24. Install retaining ring (31) in the planetary carrier. The retaining ring will hold the bearing and output shaft (26) in the correct position.

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

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

Show/hide table



Illustration 15	g00648179

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

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

Show/hide table



Illustration 16	g00648180

Show/hide table



Illustration 17	g00648181

29. Install seal rings (35) on the seal carrier. Install the seals on the seal carrier with the lip of the seals in the position that is shown. Put clean oil on the lip of the seals. Preload the seal rings before the installation procedure. This will prevent the seal rings from being damaged. Use the following method to preload the new seal rings.

    1. Place your hands on each end of the seal ring. Pull the ends past each other by several inches. The ends should almost make contact. Be careful to maintain the circular shape of the ring. This will make an even bend around the ring.

    2. When the seal ring is in the groove of the hub, the ends should lightly make contact. Do not bend the seal ring. This will make an uneven bend around the ring.

       Note: Do not use this procedure to preload a used seal ring. Do not use this procedure for cast iron seal rings. This procedure will cause used seal rings or cast iron seal rings to break.

Show/hide table



Illustration 18	g00648182

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

31. Use Tooling (A) to install retaining ring (39) .

Show/hide table



Illustration 19	g00648183

32. Install seal ring (41) and seal ring (42) on pistons (40). The lips of the seal rings should be facing the housing. Put clean oil on the lips of the seal rings.

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

Show/hide table



Illustration 20	g00648185

34. Put reverse clutch housing (37) in the correct position on Tooling (E). Place wood blocks under the reverse clutch housing.

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

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

Show/hide table



Illustration 21	g00648187

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

Show/hide table



Illustration 22	g00648189

38. Install four discs (45) and three plates (46) in a alternating order. Install a disc first and last.

Show/hide table



Illustration 23	g00648190

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

40. Install four discs (49) and the three plates in an alternating order. Install a disc first and last.

Show/hide table



Illustration 24	g00648194

41. Install seal ring (52) and seal ring (54) on piston (51). The lips of the seal rings should be facing the clutch housing. Put clean oil on the lips of the seal rings.

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

Show/hide table



Illustration 25	g01033417

43. Use Tooling (F) and a suitable lifting device to hold piston (51) in the forward clutch housing. Turn over the forward clutch housing. Put the forward clutch housing in the correct position. Align the holes for two bolts (55) .

44. Install bolts (55) .

Show/hide table



Illustration 26	g00648196

45. Install the bearing in gear (59) .

46. Install gear (59) in planetary carrier (56). One thrust washer should be on each side of the gears for the installation.

47. Align the hole in the planetary gear shaft and the hole in the planetary carrier. Install planetary gear shaft (57) .

Note: The rubber in pin (61) must not be damaged. If the rubber is damaged, replace the pin.

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

49. Install retaining ring (58) on planetary carrier (56). Use small screwdrivers to compress the retaining ring during the installation of the planetary carrier in gear (60). Remove the screwdrivers. Tap the retaining ring in order to ensure that the retaining ring is seated in the groove in gear (60) .

Show/hide table



Illustration 27	g00648197

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

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

Show/hide table



Illustration 28	g00648198

52. Install three discs (65) and the two plates in an alternating order. Install a disc first and last.

53. Install springs (64) .

Show/hide table



Illustration 29	g00648199

54. Install seal ring (67) and seal ring (68) on piston (66) and piston (69). The lips of the seal rings should be facing the center of the clutch housing. Put clean oil on the lips of the seals.

55. Install piston (66) and piston (69) in housing (70) for the second speed clutch and for the third speed clutch. Use Tooling (H) to hold piston (66) and piston (69) in the correct position.

Show/hide table



Illustration 30	g01033419

56. Install Tooling (J) and a suitable lifting device to housing (70). Lower housing (70), piston (66), and piston (69) onto the shaft.

57. Remove Tooling (H), Tooling (J), and the suitable lifting device.

Show/hide table



Illustration 31	g00648204

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

59. Install dowels (71) .

Show/hide table



Illustration 32	g00648207

60. Install ring gear (74) .

61. Install four discs (75) and the three plates in an alternating order. Install a disc first and last.

Show/hide table



Illustration 33	g00648210

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

    1. Heat carrier (76) to a temperature between 127 °C (260.6 °F) and 166 °C (330.8 °F). Heat the carrier for a maximum of ten minutes.

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

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

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

Show/hide table



Illustration 34	g00648211

64. Install seal rings (80) and (82) on piston (81). The lips of the seal rings should be facing the housing. Put clean oil on the lips of the seals.

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

Show/hide table



Illustration 35	g00648212

66. Install springs (85) in housing (77) in the following manner:

    1. Install the first spring. The outside diameter of the spring should contact the housing.

    2. Install the next two springs. The outside diameters of the springs should contact each other.

    3. Install ring (84) on top of the springs. Put the ring in a press.

Show/hide table

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.

67. Compress springs (85) until retaining ring (83) can be installed. Install retaining ring (83). Be certain 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.

Show/hide table



Illustration 36	g00648214

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

69. Install springs (87) .

Show/hide table



Illustration 37	g00648216

Note: The notch at location (X) must be facing downward at installation, as shown.

70. Use Tooling (A) to install bearing (90) in manifold (88). The notch at location (X) must be facing downward.

71. Use Tooling (A) to install retaining ring (89) .

Show/hide table



Illustration 38	g00648217

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

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

73. Install bolts (92). Tighten bolts (92) to a torque of 115 ± 7 N·m (84.8 ± 5.2 lb ft).

74. Use Tooling (C) to install retaining ring (91) .

Show/hide table



Illustration 39	g00595892

75. Install rotor (94) and ring (93) .

Show/hide table



Illustration 40	g00595894

76. Install rotor (96). Use Tooling (C) to install retaining ring (95) .

Show/hide table



Illustration 41	g00595904

77. Install the guard, bracket (97), and sensors (98). Align sensors (98) and the center of the rotor. Tighten the sensor until the sensor contacts the rotor. Unscrew the sensor by a 1/4 turn. The setting of the gap will be .35.

Show/hide table



Illustration 42	g00595905

78. Install plate assembly (100), the washers, and bolts (99). Install four electrical connectors (101) in the clips behind plate assembly (100) .

Show/hide table



Illustration 43	g00648218

79. Install the cover (103) of the suction screen. Put the O-ring seal and cover (102) in the correct position. Install the four bolts.

Show/hide table



Illustration 44	g01033423

80. Install Tooling (K) and a suitable lifting device to the planetary group. Remove the planetary group from Tooling (E). Put transmission cover (103) in position on Tool (E). Put the planetary group in position on transmission cover (103). Install bolts (104) .

Show/hide table



Illustration 45	g00595906

81. Install the O-ring seal on tube (105). Put tube (105) in the correct position. Install bolt (106) .

Show/hide table



Illustration 46	g00595907

82. Put transmission control valve (107) in place. Install four 9/16 bolts (108) .

Show/hide table



Illustration 47	g00595909

83. Connect harness assembly (109) .

Show/hide table



Illustration 48	g00595910

84. Install connector (111) in the case. Install locknut (110) .

Show/hide table



Illustration 49	g00595911

85. Install tubes (113) and the seals on the tubes.

86. Install the bolts and retainers (112) .

87. Install plugs (114) and fitting (115) .

Show/hide table



Illustration 50	g00595912

88. Install small O-ring seals (116) and large O-ring seal (117) .

End By: Connect the transmission and bevel gear. Refer to Disassembly and Assembly, "Transmission and Bevel Gears - Connect".