572R Pipelayer Power Train Caterpillar

Assembly Procedure

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Illustration 1	g00504759

1. Put bevel gear (5) in position on bevel gear shaft (3). Install 12 bolts (2) and the nuts.

2. Put two 1/2 inch - 13 NC bolts in the two forcing screw holes. Use a pry bar to hold the bevel gear and the shaft. Tighten bolts (2) to a torque of 540 ± 50 N·m (400 ± 37 lb ft).

3. Heat bearing race (1) to a maximum temperature of 135°C (275°F). Install the bearing race on the bevel gear shaft.

4. Use Tool (A) and install retaining ring (4) on bevel gear shaft (3) .

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Illustration 2	g00504761

5. Install three tube assemblies (6) in the bevel gear case.

6. Use a lifting strap and a hoist to put the bevel gear and shaft (3) in position in the bevel gear case.

7. Put bearing cone (7) in position on the bevel gear shaft.

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Illustration 3	g00504762

8. Align the dowel hole in bearing race (9) with the hole in cage (8) and install the bearing in the cage. Install dowel (10) in the cage that holds the bearing in place.

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Illustration 4	g00504844

9. Put cage (8) in position on the bevel gear case and install six bolts (11). Tighten the bolts to a torque of 130 ± 15 N·m (95 ± 11 lb ft).

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Illustration 5	g00504847

10. Lower the temperature of two bearing cups (12). Install the bearing cups with ring (13) in cage (14) .

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Illustration 6	g00504848

11. Install cage (14) without the shims. Loosely install bolts (15) that hold cage (14) to the bevel gear case.

12. Install bearing cone (17) on the bevel gear shaft.

13. Align the notch in the bevel gear shaft with the tooth on washer (16) and install washer (16) .

14. Align the teeth on the lock with the notch in the bevel gear shaft and put the lock in position.

15. Put 5P-3931 Anti-Seize Compound on the threads and the face of spanner nut (18). Install spanner nut (18) on the bevel gear shaft.

16. Use Tooling (B) to tighten nut (18) to a torque of 612 ± 68 N·m (450 ± 50 lb ft).

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Illustration 7	g00504849

17. Heat bearing cone (20) to a maximum temperature of 135°C (275°F) and install the bearing cone on pinion gear shaft (19). Use a 0.03 mm (.001 inch) feeler gauge to make sure that the bearing cone is seated against the shoulder of the pinion shaft.

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Illustration 8	g00504852

18. Align the splines and install transfer gear (22) on pinion gear shaft (19) .

19. Heat bearing (21) to a maximum temperature of 135°C (275°F) and install the bearing on the pinion shaft. Use a 0.03 mm (.001 inch) feeler gauge to make sure that the bearing is seated against shoulder (23) of the pinion shaft.

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Illustration 9	g00504853

20. Install Tooling (C) on the pinion and attach a hoist. Lower the pinion and transfer gear assembly (24) into position in the bevel gear case.

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Illustration 10	g00504854

21. Lower the temperature of bearing cup (25) and install the bearing cup in transfer gear case (26) .

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Illustration 11	g00504856

22. Lower the temperature of bearing cup (28) and install the bearing cup in cage (27) .

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Illustration 12	g00504855

23. Heat two bearing cones (29) to a maximum temperature of 135°C (275°F). Install the two bearing cones on lower transfer gear (30). Use a 0.03 mm (.001 inch) feeler gauge to make sure that the bearings are seated against shoulders on the transfer gear.

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Illustration 13	g00504857

24. Put lower transfer gear (30) in position in transfer gear case (26) .

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Illustration 14	g00504859

25. Use Tooling (D) and install bearing (33) in cage (32) .

26. Lower the temperature of bearing cup (31) and install the bearing cup in cage (32) .

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Illustration 15	g00504861

27. Put 7M-7260 Liquid Gasket in the seal bore of cage (32). Use Tooling (D) and install lip seal (34) in cage (32). Put clean oil on the lip of the seal.

28. Put glycerin on O-ring seal (35) and install the seal in the cage.

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Illustration 16	g00504861

29. Leave out the shims and put cage (32) in position on transfer gear case (26). Install two bolts (36). Space the bolts at 180 degrees. Do not tighten the bolts.

30. Leave out the shims and put cage (27) in position on transfer gear case (26). Install two bolts. Space the bolts at 180 degrees. Do not tighten the bolts.

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Illustration 17	g00505022

31. Install Tooling (E) on transfer gear case (26) and attach a hoist.

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NOTICE
Be sure that bolts (26) that hold cage (27) in place on the transfer gear case are loose.

32. Put transfer gear case (26) in position on the bevel gear case. Install 12 bolts (40) and washers. Tighten the bolts to a torque of 250 ± 25 N·m (185 ± 18 lb ft).

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Illustration 18	g00504862

33. Use the following Steps to adjust the end play for the lower transfer gear:

    1. In order to seat the bearings, rotate the transfer gear at least three revolutions. Then, tighten bolts (37) and (38) evenly to a torque of 2.25 N·m (20 lb in).

    2. Then, rotate the transfer gear at least three revolutions. Tighten bolts (37) and (38) evenly to a torque of 4.5 N·m (40 lb in).

    3. Use a feeler gauge to measure the gap between cage (32) and the transfer gear case. Make the measurement at the edge of the cage in line with the center of bolts (37) and (38). Average the two measurements.

    4. Add 0.23 mm (.009 inch) to the average figure that was obtained in Step 33.c. This figure will be the correct thickness for the shims that should be used.

34. Remove cage (32). Put the correct thickness of shims in position on the transfer gear case. Put cage (32) in position and install six bolts that hold the cage in place. Tighten the six bolts to a torque of 130 ± 15 N·m (95 ± 11 lb ft). The bearing end play will be 0.10 ± 0.05 mm (.004 ± .002 inch). It will not be necessary to check the bearing end play if this procedure for adjustment has been followed. If a measurement of the bearing end play is desired, See the topic "Bevel Pinion and Transfer Gears - Measurement of the Bearing End Play" in this section.

35. Put two roller assemblies (41) in position and install the two bolts that hold each one. Tighten the bolts to a torque of 250 ± 25 N·m (185 ± 18 lb ft).

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Illustration 19	g00504884

36. Use the following Steps to adjust the end play for the upper transfer and pinion gear:

    1. In order to seat the bearings, rotate the transfer gear at least three revolutions. Then, tighten bolts (36) evenly to a torque of 4.5 N·m (40 lb in).

    2. Then, rotate the transfer gear at least three revolutions. Tighten bolts (36) evenly to a torque of 9.0 N·m (80 lb in).

    3. Use a feeler gauge to measure the gap between cage (27) and the transfer gear case. Make the measurement at the edge of the cage in line with the center of bolts (36). Average the two measurements.

    4. Add 0.43 mm (.017 inch) to the average figure that was obtained in Step 36.c. This figure will be the correct thickness for the shims that should be used.

37. Remove cage (27). Put the correct thickness of shims in position on the transfer gear case. Put cage (27) in position and install six bolts that hold the cage in place. Tighten the six bolts to a torque of 130 ± 15 N·m (95 ± 11 lb ft). The bearing end play will be 0.10 ± 0.05 mm (.004 ± .002 inch). It will not be necessary to check the bearing end play if this procedure for adjustment has been followed. If a measurement of the bearing end play is desired, See the topic "Bevel Pinion and Transfer Gears - Measurement of the Bearing End Play" in this section.

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Illustration 20	g00504885

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Illustration 21	g00504886

38. Put the bevel gear case on the side so that the bevel gear shaft is in a vertical position with the bevel gear at the bottom.

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NOTICE
It is important for the bevel gear case to be in this position. The bevel gear must be held as far away from the pinion gear as possible when the gear clearance (backlash) is set.

39. Install a 5/8 inch - 11 NC forcing screw (dog point) (43) in the transfer gear case. Tighten the forcing screw until there is no measurement in the pinion gear. Be sure that the forcing screw is between the teeth of the gear.

40. Put Tooling (F) in position and check the clearance (backlash) between the bevel gear and the pinion gear. The clearance (backlash) must be 0.30 ± 0.12 mm − 0.10 mm (.012 ± .005 inch − .004 inch). Check the clearance (backlash) on three different teeth that are evenly spaced around the gear.

41. The difference between the high measurement and the low measurement must not be more than 0.15 mm (.006 inch).

42. Install the correct amount of shims (42) under bearing cage (14). Install the six bolts in the cage and tighten the bolts to a torque of 130 ± 15 N·m (95 ± 11 lb ft).

43. Check the gear clearance (backlash) in order to be certain that the clearance is still correct. If the clearance is not correct, add or remove shims (42), as needed.

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NOTICE
Forcing screw (43) must be removed.

44. Remove forcing screw (43) from the transfer gear case.

End By: Connect the transmission and the bevel gears.

Bevel Pinion and Transfer Gears - Measurement of the Bearing End Play

The bearing end play for the bevel pinion and transfer gears should be adjusted according to the procedure that is given in "Bevel and Transfer Gears - Assemble". If this procedure is used, the bearing end play (backlash) should be correctly set at 0.10 ± 0.05 mm (.004 ± .002 inch).

If a check of bearing end play is desired, the measurement must be made only while the bearings are being rotated and loaded with the Tooling that is shown. See Illustration 22.

Illustration 22	g00504888

The 2P-8257 Plate (6) requires an additional hole that is 16 mm (.630 inch) (5/8 inch) in diameter. The plate is also a part of the 2P-8260 Liner Installer. Drill the hole for bolt (10) 25 mm (1.0 inch) from the tapped center hole, as shown. See Illustration 23.

Illustration 22 shows the order of assembly for the tooling. This is the tooling that will be used to check the bearing clearance for the input transfer gear. The transfer gear is clamped between two adapters (4). Lever (7) is used to force the gear to move. The gear can be moved upward or the gear can be moved downward with the lever. Two washers (1) fit in adapters (4) to center threaded rod (5) in the gear.

Illustration 23	g00504889

Illustration 24	g00504891

Note: Use the following Steps to measure the bearing clearance for the input transfer gear.

1. Install the Tooling in the transfer gear so that threaded rod (5) and adapters (4) are centered in the gear. Install threaded rod (5) with the 5/8 inch - 11 NC thread on top.

2. Tighten one of nuts (8) on top of the adapter in order to prevent movement of the gear. Two nuts (3) can then be used to turn the gear.

3. Fasten modified plate (6) and lever assembly (7) to the housing with bolt (10), as shown. See Illustration 24. Use washers (11) to support the plate.

4. Put the slotted end of the lever in a horizontal position on the threaded rod. Be sure that there is 1 mm (.04 inch) clearance between washers (2) and the lever.

5. Lubricate the washers so that the assembly will turn smoothly.

6. Put dial indicator (9) in position. Be sure that the indicator tip is vertical and that the indicator tip is in contact with the top adapter. Lubricate the surface of the adapter or lubricate the indicator tip.

7. Push the adapter downward and hold the adapter down while the lever is up. Use a ratchet wrench to turn the gear with two nuts (3). Rotate the gear for at least three revolutions. Watch the needle on the dial indicator. Watch the backward movement and the forward movement. Stop rotating the gear at the point of the maximum needle movement.

   Note: The needle may move back and forth during rotation due to runout in the adapter. The reading should always be taken at the same location so that the measurement will be accurate and consistent.

8. Mark the location of area (X). Mark the location at the point of maximum needle movement on the surface of the adapter. See Illustration 23. Set the dial indicator to zero as you force the gear downward.

9. Pull the gear upward by pulling the lever downward. Do this procedure as you turn the gear at least three revolutions. Record the maximum reading that is obtained when the indicator tip is returned to location (X). This reading will be the actual bearing clearance. The reading should be 0.10 ± 0.05 mm (.004 ± .002 inch).

10. Repeat the procedure. The result should be identical if the first procedure was correctly done.

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Illustration 25	g00504893

Note: Use the following Steps to measure the bearing clearance for the pinion gear.

11. Screw the 5/8 inch - 11 NC end of threaded rod (5) in the pinion shaft.

12. Put the lever assembly and modified plate (6) in position. Install bolt (10) in the bearing retainer. Use washers (11) to support the plate.

13. Adjust nuts (8) so that the slotted end of the lever is horizontal.

14. Allow 1 mm (.04 inch) clearance between the lever and each washer (2). Lubricate both washers.

15. Put dial indicator (9) in position, as shown. See Illustration 25. Be sure that the indicator tip is vertical and that the indicator tip is in contact with the flat end surface of the pinion gear. Lubricate the flat end surface of the pinion gear or lubricate the indicator tip.

16. Rotate the pinion for at least three revolutions as you force the pinion gear downward by lifting up on lever (7). Watch the backward movement and the forward movement of the needle on the dial indicator as the pinion gear is being rotated. Stop rotating the pinion gear at the point of the maximum needle movement. Mark the location at the point of maximum needle movement on the surface of the pinion gear. Set the dial indicator to zero as you force the pinion gear downward.

    Note: The needle may move back and forth during rotation due to runout in the surface of the pinion gear. The reading should always be taken at the same location so that the measurement will be accurate and consistent.

17. Pull the pinion gear upward by pulling the lever downward. Do this procedure as you turn the pinion gear at least three revolutions. Record the maximum reading that is obtained when the indicator tip is returned to the marked location. This reading will be the actual bearing clearance. The reading should be 0.10 ± 0.05 mm (.004 ± .002 inch).

18. Repeat the procedure. The result should be identical if the first procedure was correctly done.