Caterpillar Cat CS-683E Vibratory Compactor (Prefix AGR) Service Repair Manual Instant Download.pdf

Service Repair Manual
Models
CS-683E Vibratory Compactor

Shutdown SIS
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Product: VIBRATORY COMPACTOR
Model: CS-683E VIBRATORY COMPACTOR AGR
Configuration: CS-683E Vibratory Compactor AGR00001-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
i05331819
Piston Pump (Propel) - Assemble
SMCS - 3203-016; 5070-016; 5070-016-PQ
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.
Note: Perform Steps 1 through 45 and 51 through 58 in order to assemble the drum propel pump.
Note: Perform Steps 1 through 50 in order to assemble the axle propel pump.
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Illustration 1 g00834388
Note: Lubricate bearing assembly with the lubricant that is being used.
1. Install bearing assembly (96) and retaining ring (97) in housing (58) .
Note: Lubricate the sealing lip with the lubricant that is being used.
2. Install seal (95) in housing (58) .
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3. Install ring (94) in both sides of housing (58) .
4. Install O-ring seal (93) on cover (92) .
5. Install cover (92) and four bolts (91) on the housing.
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6. Install O-ring seal (90) on cover (87) .
7. Install piston (88) in cover (87) and install nut (89) .
8. Install the piston and cover (87) in housing (58) and install four bolts (86) .
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9. Install the two pins in the housing. Install bearing races (82) in the housing.
10. Use the following procedure and assemble swashplate assembly (74) .
Note: Apply a light coat of petroleum jelly to the bearings for installation purposes.
a. Install the roller in bearings (78) and (80) .
b. Position pin joint (76) , slide (77) , bearing (78) and wire (81) on cradle (75) .
c. Position bearing (80) and wire (79) on cradle (75) .
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11. Install swashplate assembly (74) in the housing.
Note: Bearings (78) and (80) must be seated properly with bearing races (82) .
12. Install pin (83) in housing (58) .
Note: Wire (79) must go into pin (83) .
Note: Use a screwdriver in order to turn pin (83) . Swashplate assembly (74) must move.
This will ensure that wire (79) is in pin (83) .
13. Install O-ring seal (85) on plug (84) . Install plug (84) in housing (58) .
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14. Install Tooling (A) over shaft (57) in order to protect the seal during installation. Carefully
install shaft (57) . Remove Tooling (A) .
Note: Do not unseat bearings (78) and (80) from bearing races (82) .
15. Install retaining ring (73) .
16. Install retaining ring (72) in housing (58) .
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17. Install washer (68) , spring (71) and washer (69) in cylinder block (64) .
18. Position cylinder block (64) in a press. Install a suitable piece of square steel stock against
washer (69) . Use the press and apply slight compression on spring (71) . Install retaining
ring (70) and slowly release the spring compression.
19. The following steps are the procedure to determine the correct shim thickness for lift off
limitation adjustment of the rotating group:
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a. Place port plate (22) onto a surface plate. The flat side of the port plate should rest on
the surface plate.
b. Place Tooling (B) on the inside diameter of port plate (22) . The chamfered side faces
upward.
c. Install cylinder block (64) onto Tooling (B) and port plate (22) .
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d. Install Tooling (C) on top of the cylinder block, as shown.
e. Make sure that all the springs and shims have been removed from ball joint (65) .
Install the ball joint over Tooling (C) .
f. Install retainer plate (63) onto ball joint (65) .
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CS-683E Vibratory Compactor AGR00001-UP (MACHINE) POWERED BY 3056 ...
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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.
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h. Use a Vernier scale height gauge or a similar tool in order to measure the dimension
in Step 19.i.
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 (63) . 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 (66) . This will provide the correct Lift Off Limitation Height.
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20. Install three spring cups (67) in the correct sequence. Install shim (66) on top of the springs.
Refer to Step 19.i for the correct size.
21. Install ball joint (65) on the shim and cylinder block (64) .
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22. Install nine pistons (62) and retainer plate (63) in cylinder block (64) .
23. Wrap a piece of nylon string around the pistons, as shown.
24. Lower rotating assembly (59) into the pump. Use the nylon string in order to hold the
assembly together during installation. Remove the nylon string.
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25. Position the seal and control (60) on housing (58) . Install five bolts (61) .
Note: The joint of bushing (56) must be at position (Y) . The lubrication grooves of bushing
(56) must be in the position of line (X) .
26. Install bushing (56) in the head assembly.
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Note: Bushing (55) must be flush with face (Z) .
27. Install bushing (55) in the head assembly.
28. Install O-ring seal (54) on valve (50) .
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29. Install O-ring seal (48) on plug (49) .
30. Install pistons (51) and (53) in spool (52) .
31. Install valve (50) , spool (52) , spring retainer (45) , spring (46) , spring retainer (47) and
plug (49) in head assembly (3) .
32. Install O-ring seal (43) on plug (44) .
33. Install spring (39) , shims (40) , spring retainer (41) , poppet valve (42) and plug (44) in
head assembly (3) .
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34. Install backup ring (38) and O-ring seal (37) on plugs (31) and (36) .
35. Install relief valve (34) , spring (35) and plug (36) in head assembly (3) .
36. Install relief valve (33) , spring (32) and plug (31) in head assembly (3) .
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37. Install O-ring seal (30) on sequence valve (29) .
38. Install sequence valve (29) in head assembly (3) .
39. Remove solenoid assembly (27) and nut (28) on the sequence valve.
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Note: Pin (26) must be installed in the original orientation. Refer to Disassembly and
Assembly, "Piston Pump (Propel) - Disassemble".
40. Install pin (26) in port plate (22) .
Note: Port plate (22) must be installed in the original orientation. Refer to Disassembly and
Assembly, "Piston Pump (Propel) - Disassemble".
Note: Apply a light coat of petroleum jelly to the port plate for installation purposes.
41. Install port plate (22) on head assembly (3) .
42. Install two dowels (25) in head assembly (3) .
43. Install O-ring seals (23) and (24) in head assembly (3) .
44. Position head assembly (3) on the housing and install four bolts (21) .
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45. Install seal (20) in head assembly (3) .
46. Install retaining ring (19) in coupling (18) .
47. Install plate (17) and coupling (18) in the head assembly.
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48. Install O-ring seal (16) in mounting flange (13) .
50. Install mounting flange (13) on the head assembly and install four bolts (14) .
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51. Install retaining ring (12) in coupling (10) .
52. Install woodruff key (11) in coupling (10) .
53. Install plate (9) and coupling (10) in head assembly (3) .
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54. Install gerotor pump (8) .
55. Install bushing (6) in mounting flange (1) .
56. Install seal (5) and O-ring seal (7) in mounting flange (1) .
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58. Install mounting flange (1) on head assembly (3) and install four bolts (2) .
End By: Install the propel pumps. Refer to Disassembly and Assembly, "Piston Pumps (Axle
Propel and Drum Propel) - Install".
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Tue Feb 16 22:27:26 UTC+0800 2021
25/25
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Shutdown SIS
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i01935666
Piston Pumps (Axle Propel and Drum Propel) - Install
SMCS - 3203-012; 5070-012
Installation Procedure
1. Make sure that the O-ring seal is in place and position drum propel pump (7) on axle propel
pump (14). Install two bolts (21) .
2. Install hub (26) on the shaft of axle propel pump (14). Install the hub and maintain a
dimension of 30.8 ± 1.0 mm (1.21 ± 0.04 inch) between the splines of the hub and the face
of the axle propel pump. Tighten bolt (25) to a torque of 145 ± 20 N·m (107 ± 15 lb ft).
3. Install rod (23) and two nuts (24) .
4. Install hose assemblies (20) and (22) on propel pumps (7) and (14) .
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5. Use a lifting strap and a hoist to install propel pumps (7) and (14) on the engine. Install two
bolts (19) .
6. Position clamp (17) and heater hoses (18). Install the bolt that fastens clamp (17) to the
flywheel housing.
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7. Install hose assemblies (16) on drum propel pump (7) .
8. Install hose assemblies (15) on axle propel pump (14) .
9. Connect electrical connector (12). Install the cable straps that fasten electrical harnesses (11)
to propel pumps (7) and (14) .
10. Install fittings (10) and (13) on propel pumps (7) and (14) .
11. Install electrical connectors (8) and (9) on the control valves. Install the screws that fasten
electrical connectors (8) and (9) to the control valves on propel pumps (7) and (14) .
12. Install hose assembly (6) on drum propel pump (7) .
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13. Position cable assembly (4) on the propel pump and install pin (5) and the cotter pin.
Tighten nut (3) .
14. Install hose assemblies (1) and (2) on the propel pumps.
End By: Install the vibratory pump. Refer to Disassembly and Assembly, "Piston Pump
(Vibratory) - Install".
Tue Feb 16 22:28:22 UTC+0800 2021
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i01553987
Pump Drive - Remove and Install
SMCS - 3108-010
Removal Procedure
Start By:
A. Remove the propel pumps. Refer to Disassembly and Assembly, "Piston Pumps (Axle and
Drum Propel) - Remove".
1. Remove eight bolts (1) .
2. Remove flange (2) from the flywheel.
Installation Procedure
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1. Position flange (2) on the flywheel.
2. Apply 9S-3263 Compound on the threads of eight bolts (1). Install eight bolts (1) .
End By: Install the propel pumps. Refer to Disassembly and Assembly, "Piston Pumps (Axle and
Drum Propel) - Install".
Tue Feb 16 22:29:18 UTC+0800 2021
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Caterpillar Cat CS-683E Vibratory Compactor (Prefix AGR) Service Repair Manual Instant Download.pdf

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Caterpillar Cat CS-683E Vibratory Compactor (Prefix AGR) Service Repair Manual Instant Download.pdf