572R Pipelayer Machine Systems Caterpillar

Assembly Procedure

Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.

1. Use the following procedure in order to determine the amount of shim that is needed under plates (50) :
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   Illustration 1	g00668839

   1. Install three dowel pins (59) in the cradle.
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   Illustration 2	g00682112

   2. Install two shafts (55) and plate (50) onto cradle (57) .
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   Illustration 3	g00668708

   3. Install piston assembly (52) into cradle (57) .
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   Illustration 4	g00668703

   4. Install plate (47) and four bolts (48). Tighten bolts (48) to a torque of 64 N·m (47 lb ft).

   5. Use a feeler gauge to measure the gap between plate (47) and plate (53). Add shims in order to achieve a clearance of 0.01 to 0.03 mm (0.0004 to 0.0012 inch).

2. Assemble the cradle assembly with the shims.

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Illustration 5	g00682150

3. Heat bearing (41) to a temperature of 121 °C (250 °F). Install bearing (41) onto shaft (38). Apply 4C-9506 Retaining Compound to the inside of sleeve (54). Use a suitable press to install sleeve (54) onto shaft (38) .

4. Use the following procedure in order to determine the end play for the shaft:
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   Illustration 6	g00668690

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   Illustration 7	g00668688

   1. Use Tooling (B) to install lip seal (35) in the housing.
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   Illustration 8	g00668687

   2. Use Tooling (A) to install retaining ring (34) .
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   Illustration 9	g00682167

   3. Install shaft assembly (38) into the housing.
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   Illustration 10	g00682169

   4. Install spacer (39) onto the shaft. Heat bearing (37) to a temperature of 121 °C (250 °F). Install bearing (37) onto the shaft.
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   Illustration 11	g00668654

   5. Install head (3) and bolts (4). Tighten bolts (4) to a torque of 180 N·m (133 lb ft).
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   Illustration 12	g00682185

   6. Use a rubber mallet to seat the shaft into the bearing race.
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   Illustration 13	g00682186

   7. Install a suitable bolt into the end of the shaft. Install Tooling (E), as shown. Use a screwdriver to measure the amount of end play in the shaft. Add the appropriate amount of shims in order to achieve an end play of -0.02 to 0.07 mm (-0.0008 to 0.0028 inch).

      Note: The shims are located in the head assembly under the bearing race.

   8. Remove the motor head and the bearing.

5. Use the following procedure in order to determine the lift-off limitation for the barrel:
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   Illustration 14	g00682218

   1. Install spacer (44) into the barrel. Use Tooling (D) to install retaining ring (43) into the barrel.
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   Illustration 15	g00682225

   2. Install the barrel assembly onto the shaft. Use a depth gauge to measure the distance from the face of the housing to the port face. Repeat the measurement in several places in order to get an accurate number.
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   Illustration 16	g00682229

   3. Install the port plate onto the head assembly. Use a depth gauge to measure the distance from the port plate to the face of the head assembly. Subtract this dimension from the dimension in Step 5.b. The remaining dimension is the lift-off limitation for the barrel. Add shims to the barrel assembly in order to achieve a lift-off limitation of 0.05 to 0.12 mm (0.0020 to 0.0047 inch).

   4. Disassemble the motor assembly.

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Illustration 17	g00668702

6. Install spacer (46), spring (45), and spacer (44) in housing (40) .

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Illustration 18	g00668701

7. Use a suitable press to compress the spring.

8. Use Tooling (D) to install retaining ring (43) in housing (40) .

9. Use the following procedure in order to determine the sliding block play:
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   Illustration 19	g00682264

   1. Install the cradle assembly into the motor housing.

   2. Use a depth gauge in order to level the cradle assembly inside the motor housing. Take several measurements in order to make sure that the cradle is level.

   3. Install a 5 mm ball bearing into each spherical hole on the cradle assembly.

   4. Use the depth gauge to measure the distance from the face of the motor housing to the top of the ball bearings. This measurement will be referred to as dimension (A) .
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   Illustration 20	g00682272

   5. Measure the length of lubrication tubes (5). This measurement will be referred to as dimension (B) .
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   Illustration 21	g00682284

   6. Remove the shims from the holes in the head assembly. Use the depth gauge to measure the depth of the holes. This measurement will be referred to as dimension (C) .

   7. Use the following formula in order to determine the amount of shim that is needed:

      A + C + 5 mm = B + (0.01 to 0.15 mm)

   8. Disassemble the motor assembly.

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Illustration 22	g00668699

10. Install pistons (42) in housing (40) .

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Illustration 23	g00668697

11. Install shaft (38) in housing (40) .

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Illustration 24	g00668696

12. Install spacer (39) on the shaft.

13. Heat the bearing to a temperature of 121 °C (250 °F). Install the bearing onto the shaft.

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Illustration 25	g00668691

14. Install bearings (36) and the pins.

    Note: The pins must be installed to a depth below the bearings.

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Illustration 26	g00668690

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Illustration 27	g00668688

15. Use Tooling (B) to install lip seal (35) in the housing.

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Illustration 28	g00668687

16. Use Tooling (A) to install retaining ring (34) .

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Illustration 29	g00669004

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Illustration 30	g00669010

17. Install Tooling (C) on the shaft. Tooling (C) is used to prevent damage to the lip seal.

18. Heat Tooling (C) .

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Illustration 31	g00668686

19. Install the power unit in housing (1) .

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Illustration 32	g00668685

20. Install O-ring seals (33) on the regulator housing.

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Illustration 33	g00668684

21. Install four bolts (31) and regulator housing (32) in the housing.

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Illustration 34	g00668682

22. Install pins (30) and nuts (29) in the housing. Tighten nuts (29) to a torque of 60 N·m (44 lb ft). For the correct setting of pins (30), refer to the appropriate Testing and Adjusting for the correct procedure.

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Illustration 35	g00668681

23. Install nozzle (27), washer (28), and spring (26) .

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Illustration 36	g00668680

24. Use Tooling (F) to install housing (25) in the valve assembly.

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Illustration 37	g00668679

25. Install spring (22), nozzle (23), and washer (24) .

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Illustration 38	g00668678

26. Install O-ring seal (21) onto plug assembly (20) .

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Illustration 39	g00668677

27. Install plug assembly (20) .

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Illustration 40	g00668676

28. Install O-ring seal (18) on plunger (19) .

29. Install plunger (19), spring (17), and piston (16) in pressure relief valve (14) .

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Illustration 41	g00668675

30. Install O-ring seal (15) on pressure relief valve (14) .

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Illustration 42	g00668673

31. Install pressure relief valve (14) .

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Illustration 43	g00668672

32. Install plug assembly (12) and O-ring seal (13). Tighten plug assembly (12) to a torque of 47 N·m (35 lb ft).

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Illustration 44	g00668671

33. Put housing (3) in a vise and install plug assembly (12) .

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Illustration 45	g00668670

34. Install bearing ring (11) and two pins (10) in the housing.

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Illustration 46	g00668669

Note: Note the location of the two washers for installation.

35. Install two washers (9) in each hole.

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Illustration 47	g00668668

36. Install O-ring (7) and O-ring seal (8) on pipe (5). Repeat for the other pipe.

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Illustration 48	g00668666

37. Install plate (6) and two pipes (5) .

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Illustration 49	g00668654

38. Install bolts (4), the washers, and housing (3). Tighten bolts (4) to a torque of 180 N·m (133 lb ft).

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Illustration 50	g00668652

39. Install plug (2) in housing (1) on the hook winch motor.

End By: Install the hook winch motor. Refer to Disassembly and Assembly, "Hook Winch Motor - Install" for the machine that is being serviced.