Caterpillar Cat CP-663E, CS-663E Vibratory Compactor (Prefix AEF) Service Repair Manual Instant Download.pdf

Service Repair Manual
Models
CP-663E and CS-663E
Vibratory Compactor

Shutdown SIS
Previous Screen
Product: VIBRATORY COMPACTOR
Model: CS-663E VIBRATORY COMPACTOR AEF
Configuration: CP-663E CS-663E Vibratory Compactor AEF00001-UP (MACHINE) POWERED BY 3056 Engine
Disassembly and Assembly
CP-663E, CS-663E and CS-683E Vibratory Compactors Machine Systems
Media Number -KENR3574-01 Publication Date -01/05/2005 Date Updated -16/05/2005
i01563926
Piston Pump (Vibratory) - Disassemble
SMCS - 5070-015; 5652-015
Disassembly Procedure
Start By:
A. Remove the vibratory pump. Refer to Disassembly and Assembly, "Piston Pump
(Vibratory) - Remove".
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This will help to prevent dirt from entering the internal
mechanism.
Illustration 1 g00835448
1. Remove four bolts (1) and remove head assembly (2) from housing (3) .
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Note: Mark the orientation of port plate (4) for assembly purposes.
2. Remove port plate (4) from head assembly (2) .
Note: Mark the orientation of pin (5) for assembly purposes.
3. Remove pin (5) from port plate (4) .
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4. Remove plug (6), spring (7) and relief valve (8) from head assembly (2) .
5. Remove plug (11), spring (10) and relief valve (9) from head assembly (2) .
6. Remove O-ring seal (12) and backup ring (13) from plugs (6) and (11) .
7. Remove plug (19), poppet valve (17), spring retainer (16), shims (15) and spring (14) from
head assembly (2) .
8. Remove O-ring seal (18) from plug (19) .
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9. Remove plug (21) from head assembly (2). Use an allen wrench and remove control orifice
(20) from head assembly (2) .
10. Remove plug (25), spring retainer (23), spring (24), spring retainer (22), spool (29) and
valve (27) from head assembly (2) .
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11. Remove pistons (28) and (30) from spool (29) .
13. Remove O-ring seal (31) from valve (27) .
14. Remove O-ring seals (32) and (34) from head assembly (2) .
15. Remove two dowels (36) from head assembly (2) .
16. Remove bushing (35) from head assembly (2). Remove bushing (33) from bushing (35) .
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17. Remove five bolts (40). Remove solenoid valve assembly (39) and the seal from housing
(3) .
18. Remove rotating assembly (38) from shaft (37) and housing (3) .
19. Remove nine pistons (41) and retainer plate (42) from cylinder block (43) .
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20. Remove ball joint (44) from cylinder block (43) .
21. Remove shim (45) and springs (46). Note the position of the springs. The springs must be
installed in the same position for proper clearance.
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Sudden release of spring force can cause injury.
To prevent the possibility of injury, follow the procedure to relieve the
spring pressure.
22. Position cylinder block (43) in a press. Install a suitable piece of square steel stock against
washer (48). Use the press and apply slight compression on spring (50). Remove retaining
ring (49) and slowly release the spring compression.
23. Remove washer (48), spring (50) and washer (47) from cylinder block (43) .
24. Use the following procedure and disassemble solenoid valve assembly (39) .
a. Remove O-ring seal (51) and seal (53) from valve body (52) .
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b. Remove four bolts (55) from both sides of the solenoid valve assembly. Remove
solenoids (54) from valve body (52) .
c. Remove spring (56), spring guide (57), piston (58), spring guide (59) and spring (60)
from valve body (52) .
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d. Remove O-ring seal (61) from both sides of valve body (52) .
25. Remove retaining ring (62) from housing (3) .
26. Remove retaining ring (63) and shaft (37) .
10/15
CP-663E CS-663E Vibratory Compactor AEF00001-UP (MACHINE) POWERED ...
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27. Remove swashplate assembly (64) from the housing.
28. Use the following procedure and disassemble swashplate assembly (64) .
a. Remove wire (69) and bearing (70) from cradle (65) .
b. Remove pin joint (66), slide (67), bearing (68) and wire (71) from cradle (65) .
c. Remove the roller from both of the bearings.
29. Remove bearing races (72) from the housing.
30. Remove the two pins from the housing, if necessary.
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31. Remove plug (75) and pin (73) from housing (3) .
33. Remove four bolts (76) and cover (77) from housing (3) .
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34. Remove nut (79) and remove piston (78) from cover (77) .
35. Remove O-ring seal (80) from cover (77) .
36. Remove four bolts (81) and cover (82) from the housing.
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37. Remove O-ring seal (83) from cover (82) .
38. Remove ring (84) from both sides of housing (3) .
39. Remove seal (85) from housing (3) .
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40. Remove retaining ring (87) and bearing (86) from housing (3) .
41. Remove two plugs (88) from housing (3). Use an allen wrench and remove two orifices (89)
from housing (3) .
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
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15/15
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Shutdown SIS
Previous Screen
Product: VIBRATORY COMPACTOR
Model: CS-663E VIBRATORY COMPACTOR AEF
Configuration: CP-663E CS-663E Vibratory Compactor AEF00001-UP (MACHINE) POWERED BY 3056 Engine
Disassembly and Assembly
CP-663E, CS-663E and CS-683E Vibratory Compactors Machine Systems
Media Number -KENR3574-01 Publication Date -01/05/2005 Date Updated -16/05/2005
i01563928
Piston Pump (Vibratory) - Assemble
SMCS - 5070-016; 5652-016
Assembly Procedure
Table 1
Required Tools
Tools Part Number Part Description Qty
A 9U-5719 Shrink Tubing 1
B 128-2741 Alignment Plug 1
C 128-2745 Test Ring 1
D 128-2744 Measuring Bell 1
E 128-2743 Measuring Hub 1
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.
1/21
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1. Install two orifices (89) in housing (3). Tighten the orifices to a torque of 3 N·m (27 lb in).
2. Install two plugs (88) in housing (3). Tighten the plugs to a torque of 15 N·m (133 lb in).
Note: Lubricate bearing assembly with the lubricant that is being used.
3. Install bearing assembly (86) and retaining ring (87) in housing (3) .
2/21
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Note: Lubricate the sealing lip with the lubricant that is being used.
4. Install seal (85) in housing (3) .
5. Install ring (84) in both sides of housing (3) .
6. Install O-ring seal (83) on cover (82) .
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7. Install cover (82) and four bolts (81) on the housing. Tighten the bolts to a torque of 25 N·m
(18 lb ft).
8. Install O-ring seal (80) on cover (77) .
4/21
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9. Install piston (78) in cover (77) and install nut (79) .
10. Install the piston and cover (77) in housing (3) and install four bolts (76). Tighten the bolts
to a torque of 25 N·m (18 lb ft).
11. Install the two pins in the housing. Install bearing races (72) in the housing.
5/21
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12. Use the following procedure and assemble swashplate assembly (64) .
Note: Apply a light coat of petroleum jelly to the bearings for installation purposes.
a. Install the roller in bearings (68) and (70) .
b. Position pin joint (66), slide (67), bearing (68) and wire (71) on cradle (65) .
c. Position bearing (70) and wire (69) on cradle (65) .
13. Install swashplate assembly (64) in the housing.
Note: Bearings (68) and (70) must be seated properly with bearing races (72) .
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14. Install pin (73) in housing (3) .
Note: Wire (69) must go into pin (73) .
Note: Use a screwdriver in order to turn pin (73). Swashplate assembly (64) must move.
This will ensure that wire (69) is in pin (73) .
15. Install O-ring seal (75) on plug (74). Install plug (74) in housing (3). Tighten the plug to a
torque of 10 N·m (89 lb in).
16. Install Tooling (A) over shaft (37) in order to protect the seal during installation. Carefully
install shaft (37). Remove Tooling (A) .
Note: Do not unseat bearings (78) and (80) from bearing races (82) .
17. Install retaining ring (63) .
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18. Install retaining ring (62) in housing (3) .
19. Use the following procedure and assemble solenoid valve assembly (39) .
a. Install O-ring seal (61) in both sides of valve body (52) .
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b. Install piston (58), spring guide (59), spring (60), spring guide (57) and spring (56) in
valve body (52) .
c. Position solenoids (54) on valve body (52) and install four bolts (55) on both sides of
the solenoid valve assembly. Tighten the eight bolts to a torque of 3.1 N·m (27 lb in).
d.
9/21
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20. Install washer (47), spring (50) and washer (48) in cylinder block (43) .
21. Position cylinder block (43) in a press. Install a suitable piece of square steel stock against
washer (48). Use the press and apply slight compression on spring (50). Install retaining
ring (49) and slowly release the spring compression.
22. The following steps are the procedure to determine the correct shim thickness for lift off
limitation adjustment of the rotating group:
a. Place port plate (4) onto a surface plate. The flat side of the port plate should rest on
the surface plate.
10/21
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b. Place Tooling (B) on the inside diameter of port plate (4). The chamfered side faces
upward.
c. Install cylinder block (43) onto Tooling (B) and port plate (4) .
d. Install Tooling (C) on top of the cylinder block, as shown.
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e. Make sure that all the springs and shims have been removed from ball joint (44).
Install the ball joint over Tooling (C) .
f. Install retainer plate (42) onto ball joint (44) .
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g. Bolt Tooling (D) and Tooling (E) together. Place Tooling (D) and (E) on top of the
retainer plate, as shown.
h. Use a Vernier scale height gauge or a similar tool in order to measure the dimension
in Step 22.i.
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i. Measure the distance from the top of the surface plate to the top of Tooling (D).
Record this dimension as dimension (X). Measure the distance from the top of
Tooling (D) to the top of retainer plate (42). Record this dimension as dimension (W).
Table 2
CALCULATION
Subtract Dimension (W) from Dimension (X) in order to obtain Dimension (Y).
Dimension (Y) is the Lift Off Limitation Height.
Note: The correct Lift Off Limitation Height is 99.96 ± 0.1 mm (3.935 ± 0.004 inch).
Call this height Dimension (Z).
Table 3
CALCULATION
Subtract Dimension (Y) from Dimension (Z) in order to obtain the thickness of
shim (45). This will provide the correct Lift Off Limitation Height.
23. Install springs (46) in the correct sequence. Install shim (45) on top of the springs. Refer to
Step 22.i for the correct size.
14/21
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24. Install ball joint (44) on the shim and cylinder block (43) .
25. Install nine pistons (41) and retainer plate (42) in cylinder block (43) .
26. Wrap a piece of nylon string around the pistons, as shown.
15/21
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Caterpillar Cat CP-663E, CS-663E Vibratory Compactor (Prefix AEF) Service Repair Manual Instant Download.pdf

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Caterpillar Cat CP-663E, CS-663E Vibratory Compactor (Prefix AEF) Service Repair Manual Instant Download.pdf