The document provides step-by-step instructions for disassembling and assembling the piston pump of a vibratory compactor. It lists 41 steps for disassembly, removing components like bolts, plates, seals, springs, valves and pistons. It then lists 31 steps for assembly, installing components in reverse order and noting requirements like lubrication and torque specifications. Tools required are listed in a table.
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2. 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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3. Illustration 2 g00835554
Note: Mark the orientation of port plate (4) for assembly purposes.
2. Remove port plate (4) from head assembly (2) .
Illustration 3 g00835555
Note: Mark the orientation of pin (5) for assembly purposes.
3. Remove pin (5) from port plate (4) .
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4. Illustration 4 g00835449
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) .
Illustration 5 g00835450
6. Remove O-ring seal (12) and backup ring (13) from plugs (6) and (11) .
Illustration 6 g00835451
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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5. Illustration 7 g00835452
9. Remove plug (21) from head assembly (2). Use an allen wrench and remove control orifice
(20) from head assembly (2) .
Illustration 8 g00835453
Illustration 9 g00835454
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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6. 11. Remove pistons (28) and (30) from spool (29) .
12. Remove O-ring seal (26) from plug (25) .
Illustration 10 g00835456
13. Remove O-ring seal (31) from valve (27) .
Illustration 11 g00835457
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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7. Illustration 12 g00835556
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) .
Illustration 13 g00835786
19. Remove nine pistons (41) and retainer plate (42) from cylinder block (43) .
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8. Illustration 14 g00835788
20. Remove ball joint (44) from cylinder block (43) .
Illustration 15 g00835789
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.
Illustration 16 g00835790
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9. Illustration 17 g00835792
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) .
Illustration 18 g00835816
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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10. Illustration 19 g00835818
Illustration 20 g00835819
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) .
Illustration 21 g00835831
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11. d. Remove O-ring seal (61) from both sides of valve body (52) .
Illustration 22 g00835853
25. Remove retaining ring (62) from housing (3) .
Illustration 23 g00835857
26. Remove retaining ring (63) and shaft (37) .
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12. Illustration 24 g00835860
27. Remove swashplate assembly (64) from the housing.
Illustration 25 g00835863
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.
Illustration 26 g00835866
29. Remove bearing races (72) from the housing.
30. Remove the two pins from the housing, if necessary.
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13. Illustration 27 g00835869
31. Remove plug (75) and pin (73) from housing (3) .
32. Remove O-ring seal (74) from plug (75) .
Illustration 28 g00835872
33. Remove four bolts (76) and cover (77) from housing (3) .
Illustration 29 g00835875
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14. 34. Remove nut (79) and remove piston (78) from cover (77) .
Illustration 30 g00835878
35. Remove O-ring seal (80) from cover (77) .
Illustration 31 g00835880
36. Remove four bolts (81) and cover (82) from the housing.
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15. Illustration 32 g00835931
37. Remove O-ring seal (83) from cover (82) .
Illustration 33 g00835933
38. Remove ring (84) from both sides of housing (3) .
Illustration 34 g00835934
39. Remove seal (85) from housing (3) .
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16. Illustration 35 g00835935
40. Remove retaining ring (87) and bearing (86) from housing (3) .
Illustration 36 g00835936
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.
Private Network For SIS Licensees.
Thu Feb 18 21:02:13 UTC+0800 2021
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17. 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.
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18. Illustration 1 g00835936
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).
Illustration 2 g00835935
Note: Lubricate bearing assembly with the lubricant that is being used.
3. Install bearing assembly (86) and retaining ring (87) in housing (3) .
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19. Illustration 3 g00835934
Note: Lubricate the sealing lip with the lubricant that is being used.
4. Install seal (85) in housing (3) .
Illustration 4 g00835933
5. Install ring (84) in both sides of housing (3) .
Illustration 5 g00835931
6. Install O-ring seal (83) on cover (82) .
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20. Illustration 6 g00835880
7. Install cover (82) and four bolts (81) on the housing. Tighten the bolts to a torque of 25 N·m
(18 lb ft).
Illustration 7 g00835878
8. Install O-ring seal (80) on cover (77) .
Illustration 8 g00835875
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21. 9. Install piston (78) in cover (77) and install nut (79) .
Illustration 9 g00835872
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).
Illustration 10 g00835866
11. Install the two pins in the housing. Install bearing races (72) in the housing.
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22. Illustration 11 g00835863
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) .
Illustration 12 g00835860
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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23. Illustration 13 g00835869
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).
Illustration 14 g00835857
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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24. Illustration 15 g00835853
18. Install retaining ring (62) in housing (3) .
Illustration 16 g00835831
19. Use the following procedure and assemble solenoid valve assembly (39) .
a. Install O-ring seal (61) in both sides of valve body (52) .
Illustration 17 g00835819
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25. Illustration 18 g00835818
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.
Illustration 19 g00835790
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26. Illustration 20 g00835792
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.
Illustration 21 g00836076
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.
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27. Illustration 22 g00836077
Illustration 23 g00836079
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) .
Illustration 24 g00835109
d. Install Tooling (C) on top of the cylinder block, as shown.
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28. Illustration 25 g00836080
e. Make sure that all the springs and shims have been removed from ball joint (44).
Install the ball joint over Tooling (C) .
Illustration 26 g00836081
f. Install retainer plate (42) onto ball joint (44) .
Illustration 27 g00835140
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29. Illustration 28 g00586012
g. Bolt Tooling (D) and Tooling (E) together. Place Tooling (D) and (E) on top of the
retainer plate, as shown.
Illustration 29 g00586047
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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30. Illustration 30 g00586062
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.
Illustration 31 g00835789
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.
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31. Suggest:
If the above button click is invalid.
Please download this document
first, and then click the above link
to download the complete manual.
Thank you so much for reading
32. Illustration 32 g00835788
24. Install ball joint (44) on the shim and cylinder block (43) .
Illustration 33 g00835786
25. Install nine pistons (41) and retainer plate (42) in cylinder block (43) .
Illustration 34 g00681514
26. Wrap a piece of nylon string around the pistons, as shown.
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CP-663E CS-663E Vibratory Compactor AEF00001-UP (MACHINE) POWERED ...
2021/2/18
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