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

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

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Product: VIBRATORY COMPACTOR
Model: CS-663E VIBRATORY COMPACTOR ASB
Configuration: CS-663E CP-663E Vibratory Compactor ASB00001-UP (MACHINE) POWERED BY 3056E Engine
Disassembly and Assembly
3056E Engine for Caterpillar Built Machines
Media Number -RENR2400-06 Publication Date -01/02/2006 Date Updated -03/05/2017
i02787464
Valve Mechanism Cover - Remove and Install
SMCS - 1107-010
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Dealer Service
Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
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CS-663E CP-663E Vibratory Compactor ASB00001-UP (MACHINE) POWERED B...
2021/2/18
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

Illustration 1 g00906439
1. Loosen hose clamp (1) from breather hose (2).
2. Disconnect breather hose (2) from the crankcase breather.
3. Remove bolts (3).
Note: Remove tube assembly, if necessary.
4. Remove valve mechanism cover (4) and the gasket from the cylinder head. Discard the
gasket.
Installation Procedure
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1. Install the new gasket and valve mechanism cover (4) on the cylinder head.
Note: Ensure that the flat face of the gasket is toward the valve cover.
2. Install bolts (3).
3. Connect breather hose (2) to the crankcase breather.
4. Tighten hose clamp (1).
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Feb 18 10:07:06 UTC+0800 2021
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i01761173
Rocker Shaft and Pushrod - Remove
SMCS - 1102-011; 1208-011
Removal Procedure
Start By:
a. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve
Mechanism Cover - Remove and Install".
NOTICE
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Typical example
Note: It is not necessary to remove the oil supply tube in order to remove the rocker shaft
assembly and the pushrods.
1. Remove nuts (1) and bolt (2) from the rocker shaft assembly. Begin with the end brackets
and move toward the center.
2. Remove rocker shaft assembly (3).
3. Remove the oil seal from the oil supply passage in the cylinder head.
Typical example
4. Remove pushrods (4). Place an identification mark on the pushrods for installation.
Thu Feb 18 10:08:02 UTC+0800 2021
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i01744175
Rocker Shaft - Disassemble
SMCS - 1102-015
Disassembly Procedure
Start By:
a. Remove the rocker shaft assembly. Refer to Disassembly and Assembly, "Rocker Shaft and
Pushrod - Remove".
Note:
1. Use a screwdriver or a similar tool in order to remove retaining ring (1) and the washer from
both ends of the rocker shaft assembly.
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2. Remove rocker arm assembly (3) and bushing (4) from rocker shaft assembly (2).
Note: Place an identification mark on each of the components for installation.
3. Check the clearance between rocker arm assembly (3) and rocker shaft assembly (2).
Replace rocker arm if the clearance is larger than 0.13 mm (0.005 inch).
4. Remove shaft bracket (5) and rocker arm assembly (6).
Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
5. Remove springs (7).
6. Repeat Steps 2 through 5.
Thu Feb 18 10:08:57 UTC+0800 2021
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i01778400
Rocker Shaft - Assemble
SMCS - 1102-016
Assembly Procedure
Note: Ensure that all of the oil holes in the rocker shaft and in the rocker arms are not plugged
before you begin the assembly procedure.
1. Lubricate all of the components with clean engine oil before assembly.
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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.
2. Install springs (7) .
3. Install rocker arm assembly (6) and shaft bracket (5) .
Note: The clearance between the rocker arm bushing and the rocker shaft is 0.03 to 0.09
mm (0.001 to 0.004 inch).
4. Install rocker arm assembly (3) and bushing (4) in rocker shaft assembly (2) .
5. Install retaining ring (1) and the washer.
End By: Install the rocker shaft assembly. Refer to Disassembly and Assembly, "Rocker Shaft
and Pushrod - Install".
Thu Feb 18 10:09:53 UTC+0800 2021
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i01749382
Rocker Shaft and Pushrod - Install
SMCS - 1102-012; 1208-012
NOTICE
Typical example
1. Install pushrods (4).
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Note: Ensure that the pushrods are installed in the original location and that the pushrods
are seated in the valve lifters correctly.
2. Install a new oil seal in the oil supply hole in the cylinder head.
Typical example
3. Put rocker shaft assembly (3) in position on the cylinder head. Make sure that the
connection for the oil supply is installed correctly into the oil seal.
Note: Ensure that the adjustment screws are properly seated in the ends of pushrods (4).
Note: It may be necessary to loosen the adjustment screws on each rocker arm. This will
help prevent a bent valve or a bent pushrod during the installation of the rocker shaft.
4. Lubricate nuts (1) and bolt (2) with clean engine oil.
5. Install nuts (1) and bolt (2).
6. Alternately tighten the nuts and the bolt. Start from the center and work toward the outside.
Tighten the nuts and the bolt on an aluminum bracket to a torque of 40 N·m (30 lb ft).
Tighten the nuts and the bolt on a cast iron or a steel bracket to a torque of 75 N·m
(55 lb ft).
7. Adjust the inlet valve lash to 0.20 mm (0.008 inch) and adjust the exhaust valve lash to
0.45 mm (0.018 inch). Refer to Testing and Adjusting, "Air Inlet and Exhaust System" for
more information on adjusting the valve lash.
End By:
a. Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism
Cover - Remove and Install".
Thu Feb 18 10:10:49 UTC+0800 2021
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i01744832
Cylinder Head - Remove
SMCS - 1100-011
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7575 Link Bracket 1
Start By:
a. Remove the fuel injection nozzles. Refer to Disassembly and Assembly, "Fuel Injection Nozzles -
Remove".
b. Remove the air inlet manifold. Refer to Disassembly and Assembly, "Inlet Manifold - Remove".
c. Remove the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove
and Install".
d. Remove the water outlet manifold. Refer to Disassembly and Assembly, "Water Outlet Manifold -
Remove".
e. Remove the rocker shaft assembly and the pushrods. Refer to Disassembly and Assembly, "Rocker
Shaft and Pushrod - Remove".
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1. Gradually loosen cylinder head bolts (1) in reverse numerical order. Refer to illustration 1. This will
help prevent distortion of the cylinder head.
2. Remove bolts (1) from cylinder head (2).
3. Install Tooling (A) and a suitable lifting device to cylinder head (2). Carefully lift cylinder head (2)
off the engine block. The weight of the cylinder head is approximately 61 kg (135 lb).
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NOTICE
Place the cylinder head on a surface that will not scratch the face of the
cylinder head.
4. Remove cylinder head gasket (3).
Note: Note the location of dowels (4) on each end of the cylinder block. Dowels (4) hold cylinder
head gasket (3) in place while cylinder head (2) is installed.
Thu Feb 18 10:11:45 UTC+0800 2021
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i01745021
Cylinder Head - Install
SMCS - 1100-012
Table 1
Required Tools
A 138-7575 Link Bracket 1
Note: Thoroughly clean the top of the cylinder block and the bottom of the cylinder head. Ensure that there
is no debris in the cylinder bores.
1. Install cylinder head gasket (3) on dowels (4) on top of the cylinder block. The cylinder head gasket
(3) is stamped "FRONT TOP". Do not use any sealant or compound on the cylinder head gasket.
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2. Install Tooling (A) and a suitable lifting device to cylinder head (2). The weight of the cylinder head
is approximately 61 kg (135 lb).
3. Install cylinder head (2) on the cylinder block.
Note: Ensure that the cylinder head is positioned on dowels (4).
4. Remove Tooling (A).
5. Lubricate cylinder head bolts (1) with clean engine oil before installation.
6. Install bolts (1) on cylinder head (2).
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7. Tighten bolt (1) through bolt (32) in numerical order to a torque of 110 N·m (80 lb ft).
8. Tighten bolt (1) through bolt (32) again in numerical order to a torque of 110 N·m (80 lb ft).
9. Place an index mark on each bolt.
a. Turn the bolts that are marked with an "S" an additional 150 degrees (2.5 flats).
b. Turn the bolts that are marked with an "M" an additional 180 degrees (3.0 flats).
c. Turn the bolts that are marked with an "L" an additional 210 degrees (3.5 flats).
End By:
a. Install the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and
Pushrod - Install".
b. Install the water outlet manifold. Refer to Disassembly and Assembly, "Water Outlet Manifold -
Install".
c. Install the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and
Install".
d. Install the air inlet manifold. Refer to Disassembly and Assembly, "Inlet Manifold - Install".
e. Install the fuel injection nozzles. Refer to Disassembly and Assembly, "Fuel Injection Nozzles -
Install".
Thu Feb 18 10:12:40 UTC+0800 2021
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i01745933
Lifter Group - Remove and Install
SMCS - 1209-010
Removal Procedure
Table 1
Required Tools
A 1U-7262 Telescoping Magnet 1
Start By:
a. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove and
Install".
NOTICE
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1. Use Tooling (A) to remove lifters (1).
Note: Ensure that the lifters are marked with the appropriate cylinder number for
installation purposes.
Table 2
Required Tools
A 1U-7262 Telescoping Magnet 1
NOTICE
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1. Use Tooling (A) to install lifters (1).
Note: Ensure that the lifters are seated correctly and that the lifters are in the correct
cylinders.
End By:
a. Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove and Install".
Thu Feb 18 10:13:36 UTC+0800 2021
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i01755583
Camshaft - Remove and Install
SMCS - 1210-010
Removal Procedure
Start By:
a. Remove the rocker shaft assembly and the pushrods. Refer to Disassembly and Assembly,
"Rocker Shaft and Pushrod - Remove".
b. Remove the fuel transfer pump. Refer to Disassembly and Assembly, "Fuel Transfer Pump -
Remove".
c. Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) -
Remove".
d. Remove the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove
and Install".
NOTICE
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
1/4
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before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Dealer Service
Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
1. Turn the engine upside-down so the valve lifters are held in a position away from the
camshaft.
2. Remove thrust washer (1). Make a note of the location of the hollow dowel (X) for
installation purposes.
NOTICE
Do not damage the lobes or the bearings when the camshaft is removed
or installed.
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3. Carefully remove camshaft (2) from the engine.
Note: Ensure that camshaft (2) is clean. Lubricate camshaft (2) with clean engine oil prior
to installation.
1. Carefully install camshaft (2) in the engine.
2. Put thrust washer (1) in position. Make sure that thrust washer (1) is aligned with hollow
Dowel (X).
End By:
a. Install the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove
and Install".
b. Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install".
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c. Install the fuel transfer pump. Refer to Disassembly and Assembly, "Fuel Transfer Pump -
Install".
d. Install the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker
Shaft and Pushrods - Install".
Thu Feb 18 10:14:32 UTC+0800 2021
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i03140046
Camshaft Gear - Remove and Install
SMCS - 1210-010-GE
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Name Qty
A
1U-6671 Puller Gp 1
8S-4712 Bolt 2
1P-0510 Driver Group 1
Start By:
a. Remove the fan. Refer to Disassembly and Assembly, "Fan - Remove and Install".
b. Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove".
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1. Rotate the crankshaft until the timing marks on the crankshaft gear, the camshaft gear, and
the fuel injection pump gear are aligned, as shown.
Note: The timing marks on the idler gear may not be aligned. This is caused by the
difference in the speed of the rotation of the idler gear.
2. Remove bolt (1) and the washer from the camshaft gear (2).
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3. Install Tooling (A) and remove camshaft gear.
Note: Do not lose the key from the camshaft gear.
4. Inspect the camshaft gear for wear and damage. Replace the gear, if necessary.
1. Install camshaft gear (2) in the front housing.
Note: When you install the camshaft gear, ensure that the teeth that have the timing marks
are facing toward the front. Also, ensure that the key is aligned properly in the keyway. If
necessary, tap the gear with a soft hammer in order to seat the key in the keyway.
2. If necessary, remove the idler gear in order to align the gear teeth correctly.
3. Install the washer and bolt (1) on the camshaft gear. Tighten bolt (1) to a torque of 95 N·m
(70 lb ft).
Note: Ensure that the timing marks on the camshaft gear, the crankshaft gear, and the fuel
injection pump gear are aligned.
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4. If a new camshaft gear is used, check the backlash of the camshaft gear. The minimum
backlash for a new gear is 0.08 mm (0.003 inch).
End By:
a. Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Install".
b. Install the fan. Refer to Disassembly and Assembly, "Fan - Remove and Install".
Thu Feb 18 10:15:28 UTC+0800 2021
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i01778792
Camshaft Bearings - Remove and Install
SMCS - 1211-010
Removal Procedure
Table 1
Required Tools
A
8S-2241 Camshaft Bearing Tool Group 1
8H-0684 Ratchet Wrench 1
Start By:
A. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove and
Install".
NOTICE
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1. Use Tooling (A). Apply 4C-5591 Anti-Seize Compound to the threads of Tooling (A) .
2. Remove camshaft bearings (1) from the cylinder block.
Table 2
Required Tools
A
8S-2241 Camshaft Bearing Tool Group 1
8H-0684 Ratchet Wrench 1
NOTICE
2/3
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Caterpillar Cat CS-663E, CP-663E Vibratory Compactor (Prefix ASB) Service Repair Manual Instant Download.pdf

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