Caterpillar_Cat_CS-663E_Vibratory_Compactor__Prefix_DAG__Service_Repair_Manual__DAG00001_and_up_.pdf

Transcript

1. Service Repair Manual Models CS-663E and CP-663E Vibratory Compactor
2. Shutdown SIS Previous Screen 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.
3. Illustration 1 g00905926 1. Remove bolts (1). Illustration 2 g00905929 2. Install Tooling (A). Illustration 3 g00905930
4. 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). Illustration 4 g00906037 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. Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Wed Feb 17 22:58:50 UTC+0800 2021
5. Shutdown SIS Previous Screen 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 i07033816 Flywheel - Install SMCS - 1156-012 Installation Procedure Table 1 Required Tools Tool Part Number Part Description Qty A - Guide Bolt (1/2 inch - 20 NF by 4 inch) 2 B 138-7575 Link Bracket 1 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 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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7. Illustration 1 g00909351 2. Install Tooling (A) on the crankshaft. Illustration 2 g00909349 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.
8. Illustration 3 g00906162 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). Illustration 4 g00909346 6. Install bolts (1) to flywheel (2). 7. Remove Tooling (A).
9. Illustration 5 g00909350 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. Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Wed Feb 17 22:59:46 UTC+0800 2021
10. Shutdown SIS Previous Screen 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 i01741403 Crankshaft Rear Seal - Remove SMCS - 1161-011 Removal Procedure Start By: a. Remove the flywheel. Refer to Disassembly and Assembly, "Flywheel - Remove". 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.
11. Engines with 14 Bolt Housing Assembly Illustration 1 g00632744 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. Engines with 10 Bolt Housing Assembly 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. Illustration 2 g00830867
12. 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. Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Wed Feb 17 23:00:41 UTC+0800 2021
13. Shutdown SIS Previous Screen 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 i01741409 Crankshaft Rear Seal - Install SMCS - 1161-012 Installation Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 9U-6205 Rear Seal Installer 1 1P-0510 Driver Group 1 B FT-2806 Alignment Tool 1 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Engines with 14 Bolt Housing Assembly 1. Inspect the condition of the gasket. Replace the gasket, if necessary. 2. Clean the areas of the parts that will contact each other.
14. Illustration 1 g00804647 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. Illustration 2 g00606404 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).
15. Illustration 3 g00632744 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). Engines with 10 Bolt Housing Assembly 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 Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
16. Illustration 4 g00831176 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. Illustration 5 g00830867 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". Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Wed Feb 17 23:01:37 UTC+0800 2021
17. Shutdown SIS Previous Screen 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 i01741450 Flywheel Housing - Remove and Install SMCS - 1157-010 Removal Procedure Table 1 Required Tools Tool Part Number Part Description Qty 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 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
18. 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. Support the engine with blocks or with a suitable lifting device on a flat level surface. Illustration 1 g00541891 Typical example 2. Remove mounting bolts (1) from the top of flywheel housing (2). Illustration 2 g00541892 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.
19. 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). Installation Procedure Table 2 Required Tools Tool Part Number Part Description Qty A 138-7574 Link Bracket 2 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 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. Illustration 3 g00541892 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).
20. Illustration 4 g00541891 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". Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Wed Feb 17 23:02:33 UTC+0800 2021
21. Shutdown SIS Previous Screen 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 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 Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Illustration 1 g00891801
22. 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. Illustration 2 g00891807 2. Remove bolts (3) . Illustration 3 g00902007 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).
23. Illustration 4 g01513048 5. Remove thrust block (5) and O-ring seal (4) . 6. Remove spacer (6) and split locks (7) from crankshaft pulley (8) . Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Wed Feb 17 23:03:28 UTC+0800 2021
24. Shutdown SIS Previous Screen 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 i02986408 Vibration Damper and Pulley - Install SMCS - 1205-012 Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 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.
25. Illustration 1 g01513048 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. Illustration 2 g00908646 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. Illustration 3 g00908642 5. Install bolts (3) . Tighten bolts (3) evenly to a final torque of 115 N·m (85 lb ft).
26. Illustration 4 g00908645 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". Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Wed Feb 17 23:04:24 UTC+0800 2021
27. Shutdown SIS Previous Screen 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 i01742537 Crankshaft Front Seal - Remove SMCS - 1160-011 Removal Procedure Table 1 Required Tools Tool Part Number Part Description Qty 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 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
28. 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. Illustration 1 g00541748 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. Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Wed Feb 17 23:05:20 UTC+0800 2021
29. Shutdown SIS Previous Screen 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 i01742545 Crankshaft Front Seal - Install SMCS - 1160-012 Installation Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 9U-6210 Front Seal Installer 1 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 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.
30. Illustration 1 g00541748 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. Illustration 2 g00622033 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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33. Shutdown SIS Previous Screen 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 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". Illustration 1 g00892726 1. Remove bolts (1) and front cover (2) . 2. Remove the crankshaft front seal. Refer to Disassembly and Assembly, "Crankshaft Front Seal - Remove".
34. Installation Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 9U-6200 Front Cover Installer 1 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 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". Illustration 2 g00892726 3. Use Tooling (A) and existing bolts to center front cover (2) . 4. Install front cover (2) and bolts (1) .
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