Caterpillar_Cat_CS-683E_Vibratory_Compactor__Prefix_ASG__Service_Repair_Manual__ASG00001_and_up_.pdf

Transcript

1. Service Repair Manual Models CS-683E Vibratory Compactor
2. Shutdown SIS Previous Screen Product: VIBRATORY COMPACTOR Model: CS-683E VIBRATORY COMPACTOR ASG Configuration: CS-683E Vibratory Compactor ASG00001-UP (MACHINE) POWERED BY 3056E Engine Disassembly and Assembly CP-663E, CS-663E and CS-683E Vibratory Compactors Machine Systems Media Number -KENR3654-01 Publication Date -01/01/2006 Date Updated -03/01/2006 i02540039 Final Drive Planetary (Drum Propel) - Assemble SMCS - 5655-016 Assembly Procedure Table 1 Required Tools Tools Part Number Part Description Qty A 8B-7548 Push-Puller Tool Gp 1 1P-0520 Driver Gp 1 8T-0207 Bolt 2 5P-8247 Hard Washer 2 B 136-1452 Retaining Ring Pliers 1 D 138-7574 Link Bracket 2 E 220-5726 Duo-Cone Seal Installer As 1 F 5P-0960 Molybdenum Grease 1 G 9S-3263 Thread Lock Compound 1 H 8T-5096 Dial Indicator Gp 1 Note: All of the components must be cleaned and inspected before assembly. If any of the components are beyond recommended limits, replace the components. Lubricate all moving parts with clean hydraulic oil during assembly. Assemble the final drive planetary with new seals.
3. Illustration 1 g00978764 1. Install retaining rings (51) , bearing cups (53) and bearings (52) in housing (47) . 2. Use Tooling (E) to install Duo-Cone Seal (50) in housing (47) . Refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install" for the correct procedure. Illustration 2 g00978762 3. Use Tooling (E) to install Duo-Cone Seal (50) in hub (48) . Refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install" for the correct procedure. 4. Install bushings (49) in hub (48) . Illustration 3 g00978761
4. 5. Use Tooling (D) and a suitable lifting device in order to install housing (47) on hub (48) . The weight of the hub is 43 kg (95 lb). Illustration 4 g00978891 Illustration 5 g00978758 Note: Planetary gear pins (44) are not symmetrical. Install the longer end of the planetary gear pins in hub (48) . Note: Planetary gear pins (44) and the bores in hub (48) must be clean in order to allow proper installation. 6. Apply Tooling (F) on the shoulders of planetary gear pins (44) . Install antirotation washers (45) on planetary gear pins (44) . 7. Install antirotation washers (45) and planetary gear pins (44) in hub (48) . 8. Install retaining disc (46) .
5. Illustration 6 g00978851 9. Apply Tooling (F) to needle bearings (43) . Install 75 needle bearings (43) on planetary gear pin (44) . There are three rows of needle bearings (43) on planetary gear pin (44) . Each row contains 25 needle bearings. Install planetary gear (42) on the needle bearings and the planetary gear pin. 10. Repeat Step 9 and install the remaining needle bearings and the remaining planetary gears. Illustration 7 g00977635 11. Install antirotation washers (41) . Illustration 8 g00832581
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7. 12. Apply Tooling (G) on the threads of bolts (39) . Install planetary carrier (40) , bolts (39) and sun gear (38) . Tighten the bolts to a torque of 224 ± 20 N·m (165 ± 15 lb ft). Illustration 9 g00831875 13. Install disc (34) in planetary carrier (31) . 14. Install gear pins (33) in planetary carrier (31) . 15. Install the antirotation washer, 50 needle bearings (32) , planetary gear (37) , gear washer (36) and retaining ring (35) on gear pin (33) . 16. Repeat Step 15 and install the remaining two planetary gears. Illustration 10 g00977595 17. Install planetary carrier (31) in the housing.
8. Illustration 11 g00831872 18. Install disc (30) in planetary carrier (23) . 19. Install gear pins (29) in planetary carrier (23) . 20. Install the gear washer, 18 needle bearings (28) , planetary gear (25) , antirotation washer (27) and retaining ring (26) on gear pin (29) . 21. Repeat Step 20 and install the remaining planetary gears. Illustration 12 g00977467 22. Install sun gears (7) and (24) in planetary carrier (23) . Illustration 13 g00832641
9. 23. Install planetary carrier (23) and the sun gears in housing (47) . Illustration 14 g00977464 24. Install O-ring seals (20) and (21) in input ring gear (18) . 25. Install dowels (22) in input ring gear (18) . Illustration 15 g00977463 26. Install input ring gear (18) and bolts (19) .
10. Illustration 16 g00979034 27. Install coupling (3) on sun gear (7) . 28. Install shims (8) and retaining ring (6) on sun gear (7) . Illustration 17 g00979037 29. Position Tooling (H) on coupling (3) and measure the amount of end play on the coupling. Add shims (8) or remove shims (8) in order to obtain an end play of 0.3175 ± 0.0635 mm (0.0125 ± 0.0025 inch). 30. Install O-ring seals (9) and (14) and backup rings (13) and (12) in the hub.
11. Illustration 18 g00977461 31. Install flange cover (17) in input ring gear (18) . Install retaining ring (16) . Illustration 19 g00979041 32. If shim (15) was present during the disassembly of the final drive planetary, install original shim (15) . 33. Install discs (11) and friction discs (10) . 34. Install brake piston (5) . 35. Install 16 springs (4) in brake piston (5) . 36. Install retaining disc (2) .
12. Illustration 20 g00831857 37. Install Tooling (A) on the final drive planetary. Use Tooling (A) and compress the springs under the retaining disc. 38. Use Tooling (B) and install retaining ring (1) . Remove Tooling (A) from the final drive planetary. Illustration 21 g00979048 39. Use the following procedure in order to check the brake piston displacement. a. Attach a hydraulic power source and a pressure gauge to the brake release port on the final drive planetary. b. Position Tooling (H) on the final drive planetary, as shown. The indicator must be positioned on brake piston (5) . Use Tooling (H ) in order to measure the brake piston displacement. c. Apply 1448 kPa (210 psi) of pressure to the brake piston. d. Make sure that the brakes are released. If the brakes are not released, check O-ring seals (9) and (14) and backup rings (13) and (12) for damage. Replace the O-ring seals and backup rings, if necessary. e. If the brakes do not release after the O-ring seals and backup rings have been replaced the springs must be replaced. Remove 16 springs (4) and install 16 new 207-2817 Springs . f. The correct brake piston displacement is 1.30 ± 0.05 mm (0.051 ± 0.002 inch). Add shims (15) or remove shims (15) in order to obtain the correct brake piston displacement. Note: Shim (15) is available in two thicknesses. The 218-9878 Shim is 0.1 mm (0.004 inch) thick. The 218-9880 Shim is 0.2 mm (0.008 inch) thick.
13. End By: Install the final drive planetary. Refer to Disassembly and Assembly, "Final Drive Planetary (Drum Propel) - Install". Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Mon Feb 15 11:20:16 UTC+0800 2021
14. Shutdown SIS Previous Screen Product: VIBRATORY COMPACTOR Model: CS-683E VIBRATORY COMPACTOR ASG Configuration: CS-683E Vibratory Compactor ASG00001-UP (MACHINE) POWERED BY 3056E Engine Disassembly and Assembly CP-663E, CS-663E and CS-683E Vibratory Compactors Machine Systems Media Number -KENR3654-01 Publication Date -01/01/2006 Date Updated -03/01/2006 i01935687 Final Drive Planetary (Drum Propel) - Install SMCS - 5655-012 Installation Procedure Illustration 1 g00806749 1. Use a suitable lifting device to position plate (1) on final drive planetary (7). The weight of the plate is approximately 154 kg (340 lb). The weight of the final drive planetary is approximately 186 kg (410 lb). Install bolts (8). Tighten the bolts to a torque of 530 ± 70 N·m (390 ± 50 lb ft).
15. Illustration 2 g00806748 2. Use a suitable lifting device to position plate assembly (3) on final drive planetary (7). The weight of the plate assembly is approximately 95 kg (210 lb). Install bolts (6). Tighten the bolts to a torque of 530 ± 70 N·m (390 ± 50 lb ft). 3. Install the O-ring seal and drum propel motor (4) on final drive planetary (7) and install bolts (5) . Illustration 3 g00806747 Note: The CS-663E and CP-663E have ten bolts (2). The CS-683E has twelve bolts (2) . 4. Use a suitable lifting device to position plate (1), plate assembly (3), and the final drive planetary on the mounts. The weight of the plate, the plate assembly, and the final drive planetary as a unit is approximately 455 kg (1000 lb). Install bolts (2) . 5. Fill the final drive planetary with clean oil. The capacity of the final drive planetary is approximately 3.2 L (0.8 US gal). Refer to Operation and Maintenance Manual, "Final Drive Planetary (Drum) Oil - Change" for the correct procedure. End By: Install the drum. Refer to Disassembly and Assembly, "Drum - Install". Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Mon Feb 15 11:21:12 UTC+0800 2021
16. Shutdown SIS Previous Screen Product: VIBRATORY COMPACTOR Model: CS-683E VIBRATORY COMPACTOR ASG Configuration: CS-683E Vibratory Compactor ASG00001-UP (MACHINE) POWERED BY 3056E Engine Disassembly and Assembly CP-663E, CS-663E and CS-683E Vibratory Compactors Machine Systems Media Number -KENR3654-01 Publication Date -01/01/2006 Date Updated -03/01/2006 i01935182 Piston Motor (Vibratory) - Remove SMCS - 5058-011; 5651-011 Removal Procedure Table 1 Required Tools Tool Part Number Part Description Qty ZZ 6V-9509 Face Seal Plug (13/16 - 16 THD) 1 6V-9830 Cap As (13/16 - 16 THD) 1 Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLATION. THIS TOOLING IS SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN. Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.
17. 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 Tools and Shop Products Guide" 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 g00951200 1. Drain the oil from the vibratory support into a suitable container. The capacity of the vibratory support is 2.0 L (0.5 US gal). Refer to Operation and Maintenance Manual, "Vibratory Support Oil - Change" for the correct procedure. 2. Remove hose assemblies (5) and (6) from vibratory motor (3) . 3. Disconnect hose assembly (4) from vibratory motor (3) . 4. Remove bolts (1) and remove vibratory motor (3) and the O-ring seal from vibratory support (2) . Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Mon Feb 15 11:22:08 UTC+0800 2021
18. Shutdown SIS Previous Screen Product: VIBRATORY COMPACTOR Model: CS-683E VIBRATORY COMPACTOR ASG Configuration: CS-683E Vibratory Compactor ASG00001-UP (MACHINE) POWERED BY 3056E Engine Disassembly and Assembly CP-663E, CS-663E and CS-683E Vibratory Compactors Machine Systems Media Number -KENR3654-01 Publication Date -01/01/2006 Date Updated -03/01/2006 i01546246 Piston Motor (Vibratory) - Disassemble SMCS - 5058-015; 5651-015 Disassembly Procedure Table 1 Required Tools Tools Part Number Part Description Qty A 136-1452 Retaining Ring Pliers 1 B 8B-7552 Forcing Bolt 1 3H-0465 Push-Puller Plate 5 1B-4206 Nut 1 5P-4808 Cap 2 8B-7548 Push-Puller Tool Gp 1 8B-7550 Push-Puller Leg 2 1B-4207 Full Nut 2 8B-7556 Adapter 1 8B-7555 Adapter 2 0S-1575 Bolt 2 5H-1504 Hard Washer 2 Start By: A. Remove the vibratory motor. Refer to Disassembly and Assembly, "Piston Motor (Vibratory) - Remove". NOTICE
19. Dirt can damage precision made parts of the motor. Disassemble the motor on a clean work surface. Clean all the parts seperately in clean solvent and let the parts dry at room temperature. Check the condition of all parts and refer to Guidelines for Reusable Parts, SEBF8032, "Piston Pumps and Motors". Illustration 1 g00832922 1. Remove four bolts (14) and remove flushing valve (8) from rear cover plate (4) . Illustration 2 g00832924 2. Use the following procedure to disassemble the flushing valve (8) . a. Remove two O-ring seals (24) and O-ring seal (18) from valve body (25) .
20. b. Remove plug (15), spring (23) and guide (17) from valve body (25). Remove O-ring seal (16) from plug (15) . c. Remove plug (22), spring (26), guide (20) and spool (19) from valve body (25). Remove O- ring seal (21) from plug (22) . d. Remove plug (31), spring (28) and piston valve (27) from valve body (25) . e. Remove O-ring seal (30) and shim (29) from plug (31) . Illustration 3 g00832925 f. Remove retaining ring (33) and remove orifice (32) from piston valve (27) . 3. Put tape around the splined drive shaft in order to prevent damage to the drive shaft or the seals during disassembly of the vibratory motor. 4. Tap front cover (10) with a plastic hammer in order to release some of the pressure against the retaining ring (11). Use Tool (A) in order to remove retaining ring (11) from housing (2) . 5. Remove front cover (10), O-ring seal (9) and shim (6) from housing (2). 6. Remove lip type seal (7) from front cover (10) . 7. Put alignment marks on rear cover plate (4 ) and housing (2) for assembly purposes. 8. Remove six bolts (5), and remove rear cover plate (4) from housing (2) . 9. Remove O-ring seal (3) from housing (2) . 10. Remove dowel pin (13) from the rear cover plate. 11. Remove the control plate from the end of rotating group (1). The control plate is serviced as part of the rotating group.
21. Illustration 4 g00832926 12. Attach Tooling (B) to housing (2) and rotating group (1), as shown. 13. Use Tooling (B) to remove rotating group (1) from the housing. The cylinder barrel must not bind while the cylinder barrel is pulled through the housing. Illustration 5 g00832928 14. Remove cylinder barrel (36), spacer (35) and spring (34) from the rotating group. The cylinder barrel, the spacer, and the spring are serviced as part of the rotating group. Illustration 6 g00833018
22. 15. Remove screws (37), pistons (38) and the retaining plate from shaft assembly (12). The screws, pistons, and the retaining plate are serviced as part of the rotating group. The shaft assembly is serviced separately. Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Mon Feb 15 11:23:04 UTC+0800 2021
23. Shutdown SIS Previous Screen Product: VIBRATORY COMPACTOR Model: CS-683E VIBRATORY COMPACTOR ASG Configuration: CS-683E Vibratory Compactor ASG00001-UP (MACHINE) POWERED BY 3056E Engine Disassembly and Assembly CP-663E, CS-663E and CS-683E Vibratory Compactors Machine Systems Media Number -KENR3654-01 Publication Date -01/01/2006 Date Updated -03/01/2006 i01546250 Piston Motor (Vibratory) - Assemble SMCS - 5058-016; 5651-016 Assembly Procedure Table 1 Required Tools Tools Part Number Part Description Qty A 136-1452 Retaining Ring Pliers 1 C 8T-9159 Seal Guide 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 in the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement. Illustration 1 g00833018 1. Apply 9S-3263 Thread Lock Compound on screws (37). Position the retaining plate and pistons (38) on shaft assembly (12), and install screws (37) .
24. Illustration 2 g00832928 2. Install spacer (35) and spring (34) in the center pin bore of cylinder barrel (36) . 3. Install the cylinder barrel on the pistons and center pin. Illustration 3 g00833385 4. Put the rotating group in a vise, as shown. Allow clearance for the housing when the housing is installed on the rotating group. 5. Angle the cylinder barrel to one side. Note: Do not force the housing onto the rotating group. Damage to the vibratory motor may result. The assembly should be done in one smooth, easy movement. 6. Heat housing (2) evenly to a temperature of 80 °C (176 °F). Position the housing above the rotating group. Tilt the housing in order to clear the rotating group. Lower the housing onto the rotating group. Do not force the assembly together. Allow the housing to cool before continuing the procedure.
25. Illustration 4 g00832922 7. Install new lip type seal (7) in front cover (10) . 8. Position shim (6) in the housing. Use clean 5P-0960 Molybdenum Grease to lubricate O-ring seal (9). Position the O-ring seal on the shim. 9. Position Tool (C) over the shaft. Use clean oil in order to lubricate the lip type seal. Install front cover (10) in the housing. 10. Use Tool (A) and install retaining ring (11) in housing (2) . 11. Install O-ring seal (3) in housing (2) . 12. Install dowel pin (13) in rear cover plate (4) . 13. Use clean oil to lubricate the control plate. Position the control plate on the end of the rotating group. 14. Align dowel pin (13) in rear cover plate (4) with the single hole in the control plate. Place the rear cover plate in position on housing (2). Install six bolts. Tighten the bolts to a torque of 86 N·m (64 lb ft).
26. Illustration 5 g00832925 15. Use the following procedure in order to assemble flushing valve (8) . a. Install orifice (32) in piston valve (27) and install retaining ring (33) . Illustration 6 g00832924 b. Install shim (29) and O-ring seal (30) on plug (31) . c. Install piston valve (27), spring (28) and plug (31) into valve body (25) . d. Install O-ring seal (21) on plug (22). Install spool (19), guide (20), spring (26) and plug (22) in valve body (25) . e. Install O-ring seal (16) on plug (15). Install guide (17), spring (23) and plug (15) on valve body (25) . f. Install O-ring seal (18) and two O-ring seals (24) in valve body (25) . 16. Position flushing valve (8) on the rear cover plate and install five bolts (14) . End By: Install the vibratory motor. Refer to Disassembly and Assembly, "Piston Motor (Vibratory) - Install". Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Mon Feb 15 11:24:00 UTC+0800 2021
27. Shutdown SIS Previous Screen Product: VIBRATORY COMPACTOR Model: CS-683E VIBRATORY COMPACTOR ASG Configuration: CS-683E Vibratory Compactor ASG00001-UP (MACHINE) POWERED BY 3056E Engine Disassembly and Assembly CP-663E, CS-663E and CS-683E Vibratory Compactors Machine Systems Media Number -KENR3654-01 Publication Date -01/01/2006 Date Updated -03/01/2006 i01935185 Piston Motor (Vibratory) - Install SMCS - 5058-012; 5651-012 Installation Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 6V-4876 Lubricant 1 B 9S-3263 Thread Lock Compound 1 Illustration 1 g00951200 1. Apply Tooling (A) on the splines of vibratory motor (3). Install the O-ring seal and vibratory motor (3) on vibratory support (2). Apply Tooling (B) on the threads of bolts (1). Install bolts (1) .
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29. 2. Install hose assemblies (5) and (6) on vibratory motor (3) . 3. Connect hose assembly (4) to vibratory motor (3) . 4. Fill vibratory support (2) with oil to the correct level. The capacity of the vibratory support is approximately 2.0 L (0.5 US gal). Refer to Operation and Maintenance Manual, "Vibratory Support Oil - Change" for the correct procedure. Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Mon Feb 15 11:24:55 UTC+0800 2021
30. Shutdown SIS Previous Screen Product: VIBRATORY COMPACTOR Model: CS-683E VIBRATORY COMPACTOR ASG Configuration: CS-683E Vibratory Compactor ASG00001-UP (MACHINE) POWERED BY 3056E Engine Disassembly and Assembly CP-663E, CS-663E and CS-683E Vibratory Compactors Machine Systems Media Number -KENR3654-01 Publication Date -01/01/2006 Date Updated -03/01/2006 i01935190 Vibratory Support - Remove SMCS - 5656-011 Removal Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 6V-2082 Hook Assembly 1 B 138-7574 Link Bracket 1 Start By: A. Remove the drum. Refer to Disassembly and Assembly, "Drum - Remove". 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 Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.
31. Illustration 1 g00805275 1. Position supports under plate assemblies (1) and (2), as shown. Note: The CS-663E and CP-663E have five mounts on each side. The CS-683E has six mounts on each side. 2. Attach a suitable lifting device to plate assembly (1). Remove the bolts and remove plate assembly (1) from the mounts. The weight of the plate assembly is approximately 249 kg (550 lb). 3. Attach a suitable lifting device to plate assembly (2). Remove the bolts and remove plate assembly (2) from the mounts. The weight of the plate assembly is approximately 249 kg (550 lb). Illustration 2 g00805277 4. Drain the oil from vibratory support (3) into a suitable container. The capacity of the vibratory support is 1.2 L (0.3 US gal). Refer to Operation and Maintenance Manual, "Vibratory Support Oil - Change" for the correct procedure. 5. Remove bolts (4). Remove vibratory motor (5) and the O-ring seal from vibratory support (3) .
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