Caterpillar Cat CS-663E, CP-663E Vibratory Compactor (Prefix DAG) 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 DAG
Configuration: CS-663E CP-663E Vibratory Compactor DAG00001-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
i01771917
Flywheel - Remove
SMCS - 1156-011
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A Guide Studs1/2 × 4 × 20 threads per inch 2
B 138-7575 Link Bracket 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
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CS-663E CP-663E Vibratory Compactor DAG00001-UP (MACHINE) POWERED B...
2021/2/17
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Illustration 1 g00905926
1. Remove bolts (1).
2. Install Tooling (A).
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3. Install Tooling (B).
4. Remove remaining bolts (1) that secure flywheel (2) to the crankshaft.
5. Use Tooling (B) and a suitable lifting device in order to remove flywheel (2) and ring gear
(3) from the housing. The weight of the flywheel is approximately 54 kg (120 lb).
6. Check the condition of the ring gear (3). Replace the ring gear with a new part if the gear is
worn or damaged.
Note: Identify the orientation of the ring gear on the flywheel for the correct positioning
when the new ring gear is installed.
7. Place flywheel (2) and ring gear (3) on a suitable support.
8. Use a hammer and a punch in order to remove ring gear (3) from the flywheel.
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All Rights Reserved.
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Wed Feb 17 22:58:50 UTC+0800 2021
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i07033816
Flywheel - Install
SMCS - 1156-012
Installation Procedure
Table 1
Required Tools
A -
Guide Bolt
(1/2 inch - 20 NF by 4 inch)
2
B 138-7575 Link Bracket 1
NOTICE
1. Thoroughly clean the flywheel housing. Inspect the crankshaft rear seal for leaks. If there
are any oil leaks, refer to this Disassembly and Assembly Manual, "Crankshaft Rear Seal -
Remove" for the correct procedure.
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2. Install Tooling (A) on the crankshaft.
Always wear protective gloves when handling parts that have been
heated.
3. Heat ring gear (3) to 250 °C (480 °F) in an oven to install the ring gear onto the flywheel.
Ensure that the orientation of the ring gear is correct and quickly install the ring gear onto
the flywheel.
Note: Do not use a torch to heat the ring gear.
4. Clean flywheel (2) and ring gear (3) when the ring gear has cooled.
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5. Install Tooling (B) and a suitable lifting device on flywheel (2) and position the flywheel in
the flywheel housing. The weight of the flywheel and the ring gear is approximately 54 kg
(120 lb).
6. Install bolts (1) to flywheel (2).
7. Remove Tooling (A).
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8. Install remaining bolts (1) to flywheel (2). Tighten the bolts to a torque of 140 N·m
(103 lb ft).
9. Check the alignment of flywheel (2) with the crankshaft. Refer to Testing and Adjusting,
"Flywheel - Inspect" for the correct procedure.
Wed Feb 17 22:59:46 UTC+0800 2021
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i01741403
Crankshaft Rear Seal - Remove
SMCS - 1161-011
Removal Procedure
Start By:
a. Remove the flywheel. Refer to Disassembly and Assembly, "Flywheel - Remove".
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
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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Engines with 14 Bolt Housing Assembly
The flywheel housing has been removed for photographic purposes only.
1. Remove bolts (1) from housing (3).
2. Remove socket head bolts (2) from housing (3).
3. Remove the crankshaft rear seal, the gasket, and housing (3) from the dowels in the cylinder
block.
Note: The 10 bolt housing assembly is manufactured as a one-piece assembly. The 10 bolt
housing assembly is NOT adaptable to engines that have the 14 bolt housing assembly.
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1. Remove the bolts in reverse order of the numbered sequence. Refer to Illustration 2.
2. Remove the one-piece housing assembly from the cylinder block.
Wed Feb 17 23:00:41 UTC+0800 2021
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i01741409
Crankshaft Rear Seal - Install
SMCS - 1161-012
Table 1
Required Tools
A
9U-6205 Rear Seal Installer 1
1P-0510 Driver Group 1
B FT-2806 Alignment Tool 1
NOTICE
1. Inspect the condition of the gasket. Replace the gasket, if necessary.
2. Clean the areas of the parts that will contact each other.
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3. Use Tooling (A) and a suitable press to install the crankshaft rear seal into the housing.
4. Lubricate the components with clean engine oil. Install Tooling (A) onto the crankshaft
flange.
5. Position the new gasket on the dowels in the cylinder block.
Typical example
6. Place housing (3) and crankshaft rear seal (4) over Tooling (A).
7. Position housing (3) on the dowels in the cylinder block.
8. Remove Tooling (A).
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The flywheel housing has been removed for photographic purposes only.
9. Install socket head bolts (2) onto housing (3).
10. Install bolts (1) in order to fasten housing (3) to the cylinder block. Tighten all of the bolts
to a torque of 22 N·m (16 lb ft).
Note: The 10 bolt housing assembly is manufactured as a one-piece assembly. The 10 bolt
housing assembly is NOT adaptable to engines that have the 14 bolt housing assembly.
NOTICE
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Note: The crankshaft rear seal is lubricated. There is no need to lubricate the seal or the
crankshaft flange before installation.
1. Place housing assembly (3) on crankshaft flange (1) until the housing assembly contacts the
cylinder block face. Plastic sleeve (2) will push out of the housing assembly. Discard the
plastic sleeve after the housing assembly is installed.
2. Place Tooling (B) over housing assembly (3). This will center the housing assembly onto
the crankshaft flange.
3. Install the bolts with Tooling (B) in position in order to fasten housing assembly (3) to the
cylinder block. Tighten bolts 1 and 2 to a torque of 22 N·m (16 lb ft).
4. Remove Tooling (B). Tighten the remaining bolts in sequence to a torque of 22 N·m
(16 lb ft).
End By:
a. Install the flywheel. Refer to Disassembly and Assembly, "Flywheel - Install".
Wed Feb 17 23:01:37 UTC+0800 2021
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i01741450
Flywheel Housing - Remove and Install
SMCS - 1157-010
Removal Procedure
Table 1
Required Tools
A 138-7574 Link Bracket 2
Start By:
a. Remove the electric starting motor. Refer to Disassembly and Assembly, "Electric Starting
Motor - Remove and Install".
b. Remove the flywheel. Refer to Disassembly and Assembly, "Flywheel - Remove".
NOTICE
NOTICE
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containing fluids.
1. Support the engine with blocks or with a suitable lifting device on a flat level surface.
Typical example
2. Remove mounting bolts (1) from the top of flywheel housing (2).
Typical example
3. Attach Tooling (A) and a suitable lifting device to flywheel housing (2).
4. Remove mounting bolts (3) that attach the flywheel housing to the cylinder block.
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5. Remove flywheel housing (2). If necessary, hit flywheel housing (2) with a soft faced
hammer in order to separate flywheel housing (2) from the cylinder block. The weight of
flywheel housing (2) is approximately 32 kg (70 lb).
Table 2
Required Tools
A 138-7574 Link Bracket 2
NOTICE
1. Clean the rear face of the cylinder block and the mating surface of the flywheel housing.
Inspect the felt seal on the rear flange of the engine oil pan. Replace the felt seal, if
necessary. Inspect the dowels in the cylinder block that align the flywheel housing. Replace
the dowels, if necessary.
2. Use Tooling (A) and a suitable lifting device to position flywheel housing (2) on the dowels
that are on the cylinder block. The weight of flywheel housing (2) is approximately 32 kg
(70 lb).
3. Install mounting bolts (3).
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Typical example
4. Install mounting bolts (1) that attach flywheel housing (2) to the cylinder block.
Tighten the bolts for an aluminum flywheel housing to a torque of 70 N·m (52 lb ft).
Tighten the cast iron flywheel housing bolts to the following torque:
M10 "8.8" ... 44 N·m (33 lb ft)
M10 "10.9" ... 63 N·m (46 lb ft)
M12 "8.8" ... 75 N·m (55 lb ft)
M12 "10.9" ... 115 N·m (85 lb ft)
5. Remove Tooling (A) from the flywheel housing.
End By:
a. Install the flywheel. Refer to Disassembly and Assembly, "Flywheel - Install".
b. Install the electric starting motor. Refer to Disassembly and Assembly, "Electric Starting
Motor - Remove and Install".
Wed Feb 17 23:02:33 UTC+0800 2021
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i02986402
Vibration Damper and Pulley - Remove
SMCS - 1205-011
Removal Procedure
Start By:
A. Remove the V-Belts. Refer to Disassembly and Assembly, "V-Belts - Remove and Install".
NOTICE
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1. Remove bolts (1) in order to remove vibration damper (2) .
Note: Do not use a puller tool to remove the crankshaft pulley from the crankshaft.
2. Remove bolts (3) .
3. Hold a wood block against the inner hub of the crankshaft pulley as shown. Strike the wood
block with a hammer in order to loosen the split lock and the spacer.
4. Carefully remove crankshaft pulley (8) . The weight of the crankshaft pulley is
approximately 10 kg (22 lb).
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5. Remove thrust block (5) and O-ring seal (4) .
6. Remove spacer (6) and split locks (7) from crankshaft pulley (8) .
Wed Feb 17 23:03:28 UTC+0800 2021
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i02986408
Vibration Damper and Pulley - Install
SMCS - 1205-012
NOTICE
1. Thoroughly clean the following parts: the bore of the pulley, split lock, spacer and nose of
the crankshaft.
Note: Do not use a degreaser on the parts.
Note: Do not expand the split lock.
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2. Install split locks (7) and spacer (6) on crankshaft pulley (8) .
Note: The split locks must be aligned correctly for proper installation.
3. Lubricate thrust block (5) and O-ring seal (4) with clean engine oil. Place thrust block (5)
and O-ring seal (4) into position.
Note: Ensure that the key is placed in the groove on the crankshaft at the time of the
installation.
4. Install crankshaft pulley (8) onto the crankshaft.
5. Install bolts (3) . Tighten bolts (3) evenly to a final torque of 115 N·m (85 lb ft).
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6. Position crankshaft vibration damper (2) so that the bolt holes align with the pulley.
Note: On some engines, the damper is placed on the rear of the pulley. Fit the inner flange
of the damper to the rear of the pulley.
7. Apply 9S-3263 Thread Lock Compound to bolts (1) that fasten the crankshaft to the pulley.
Install bolts (1) and tighten bolts (1) evenly. Gradually tighten the bolts to a final torque of
35 N·m (25 lb ft).
Note: Some engines are equipped with a viscous damper. Tighten the bolts for the viscous
damper to a torque of 75 N·m (55 lb ft).
End By: Install the V-Belts. Refer to Disassembly and Assembly, "V-Belts - Remove and Install".
Wed Feb 17 23:04:24 UTC+0800 2021
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i01742537
Crankshaft Front Seal - Remove
SMCS - 1160-011
Removal Procedure
Table 1
Required Tools
A 1U-8145 Drill Bit 1
B 1U-7600 Slide Hammer Puller 1
Start By:
a. Remove the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley -
Remove and Install".
NOTICE
NOTICE
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containing fluids.
Typical example
1. Use Tooling (A) to drill three evenly spaced holes in crankshaft front seal (1).
2. Place Tooling (B) in the holes in order to remove crankshaft front seal (1). Use Tooling (B)
in each of the three holes to evenly remove the crankshaft front seal.
Note: Do not damage the flange of the crankshaft during the removal process for the
crankshaft front seal.
NOTICE
Ensure that the main lip is used in order to remove the crankshaft
front seal. Do not damage the edge of the housing for the crankshaft
front seal.
Wed Feb 17 23:05:20 UTC+0800 2021
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i01742545
Crankshaft Front Seal - Install
SMCS - 1160-012
Table 1
Required Tools
A 9U-6210 Front Seal Installer 1
NOTICE
1. Clean the housing for the crankshaft front seal and inspect the housing for damage.
2. Lubricate the lip of the crankshaft front seal with clean engine oil.
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3. Place crankshaft front oil seal (1) into the housing.
NOTICE
Ensure that the lip of the crankshaft front seal that is spring loaded is
facing toward the inside of the front housing and that it is square with
the bore of the housing for the crankshaft front seal.
4. Use Tooling (A) to install crankshaft front oil seal (1).
5. Apply clean engine oil on the area of the crankshaft pulley that will be in contact with
crankshaft front seal (1).
End By:
a. Install the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley -
Remove and Install".
Wed Feb 17 23:06:16 UTC+0800 2021
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3/3
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i05593429
Front Cover - Remove and Install
SMCS - 1166-010
Removal Procedure
Start By:
A. Remove the crankshaft pulley. Refer to Disassembly and Assembly, "Vibration Damper and
Pulley - Remove and Install".
B. Remove the water pump. Refer to Disassembly and Assembly, "Water Pump - Remove and
Install".
C. Remove the alternator. Refer to Disassembly and Assembly, "Alternator - Remove".
1. Remove bolts (1) and front cover (2) .
2. Remove the crankshaft front seal. Refer to Disassembly and Assembly, "Crankshaft Front
Seal - Remove".
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Table 1
Required Tools
A 9U-6200 Front Cover Installer 1
NOTICE
1. Clean all surfaces of the front housing and clean the front cover thoroughly.
2. Install the crankshaft front seal. Refer to Disassembly and Assembly, "Crankshaft Front
Seal - Install".
3. Use Tooling (A) and existing bolts to center front cover (2) .
4. Install front cover (2) and bolts (1) .
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Caterpillar Cat CS-663E, CP-663E Vibratory Compactor (Prefix DAG) Service Repair Manual Instant Download.pdf

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