Caterpillar_Cat_CS-683E_Vibratory_Compactor__Prefix_DAD__Service_Repair_Manual__DAD00001_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 DAD Configuration: CS-683E Vibratory Compactor DAD00001-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 i01739979 Engine Oil Pump - Remove SMCS - 1304-011 Removal Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 1P-1855 Retaining Ring Pliers 1 Start By: a. Remove the oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install". b. Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove". Note: The engine oil pump is mounted on the No. 1 crankshaft main bearing cap. The engine oil pump can be removed without removing the front housing if the No. 1 crankshaft main bearing cap is removed. In order to remove the crankshaft main bearing cap bolt for the No. 1 crankshaft journal, use the 9U-6282 Torque Wrench Extension. The engine oil pump is then removed from the No. 1 crankshaft main bearing cap. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
3. 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. Illustration 1 g00637003 1. Remove the nut and bolt (1) from the bracket. 2. Remove bolts (3) and suction pipe (2). 3. Remove bolts (4) and (6) from oil supply tube assembly (5). 4. Remove the oil supply tube assembly (5) from the cylinder block and the engine oil pump.
4. Illustration 2 g00804182 5. Use Tooling (A) to remove retaining ring (7). 6. Remove idler gear (8) and remove washer (9). Inspect the shaft of the idler gear for wear or damage. Use a suitable press to remove the shaft for the idler gear from the main bearing cap. Illustration 3 g00804189 7. Remove bolts (10) that fasten the engine oil pump to the cylinder block. 8. Remove engine oil pump (11) from the cylinder block. Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Sun Feb 14 22:35:02 UTC+0800 2021
5. Shutdown SIS Previous Screen Product: VIBRATORY COMPACTOR Model: CS-683E VIBRATORY COMPACTOR DAD Configuration: CS-683E Vibratory Compactor DAD00001-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 i01739986 Engine Oil Pump - Install SMCS - 1304-012 Installation Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 1P-1855 Retaining Ring Pliers 1 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE If any of the parts on the engine oil pump are worn or damaged, the entire pump must be replaced. Note: If the No. 1 crankshaft main bearing cap was removed, install the No. 1 crankshaft main bearing cap with the engine oil pump. Tighten the bolts for the No. 1 crankshaft main bearing cap to a torque of 265 N·m (195 lb ft).
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7. 1. If the shaft for the idler gear on the engine oil pump was removed, remove the excess Loctite 603. Apply a new layer of Loctite 603 to the bore in the main bearing cap and install the shaft. Illustration 1 g00804189 2. Fill engine oil pump (11) with clean engine oil. Install engine oil pump (11) on the engine. 3. Install bolts (10). Tighten the bolts to a torque of 22 N·m (16 lb ft). Illustration 2 g00804182 4. Install idler gear (8) and washer (9) on the shaft. 5. Use Tooling (A) to install retaining ring (7). Note: After you install the engine oil pump and the idler gear, ensure that there is a minimum of 0.08 mm (0.003 inch) backlash between the gear on the engine oil pump and the idler gear.
8. Illustration 3 g00637003 6. Install oil supply tube assembly (5) to the engine oil pump and the cylinder block. 7. Install bolts (4) and bolts (6). 8. Install suction pipe (2) and bolts (3) to the engine oil pump. Tighten the bolts to a torque of 22 N·m (16 lb ft). 9. Install the nut and bolt (1) on the bracket. End By: a. Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install". b. Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install". Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Sun Feb 14 22:35:57 UTC+0800 2021
9. Shutdown SIS Previous Screen Product: VIBRATORY COMPACTOR Model: CS-683E VIBRATORY COMPACTOR DAD Configuration: CS-683E Vibratory Compactor DAD00001-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 i01770855 Water Pump - Remove and Install SMCS - 1361-011; 1361-012 Removal Procedure 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. 1. Drain the coolant from the cooling system into a suitable container for storage or disposal.
10. Illustration 1 g00905296 Illustration 2 g00905297 2. Remove bolts (1) and (2) that fasten the water pump to the front housing. 3. Tap water pump (3) with a soft hammer in order to loosen water pump (3). 4. Remove water pump (3) and the gasket. Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
11. Illustration 3 g00905297 Illustration 4 g00905296 1. Install water pump (3) and the gasket. 2. Install bolts (2) and (1) that fasten the water pump to the front housing. 3. Fill the cooling system with coolant. Refer to Operation and Maintenance, "Refill Capabilities". Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Sun Feb 14 22:36:53 UTC+0800 2021
12. Shutdown SIS Previous Screen Product: VIBRATORY COMPACTOR Model: CS-683E VIBRATORY COMPACTOR DAD Configuration: CS-683E Vibratory Compactor DAD00001-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 i01741307 Water Temperature Regulator - Remove and Install SMCS - 1355-010 Removal Procedure 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. 1. Drain the coolant from the cooling system into a suitable container for storage or disposal.
13. 2. Loosen the hose clamp from the upper radiator hose and remove the upper radiator hose from the water temperature regulator housing. Illustration 1 g00634312 3. Remove bolts (1) that hold cover (2) in position on the water temperature regulator housing. Illustration 2 g00634424 4. Remove cover (2) and the gasket from water temperature regulator housing (4). 5. Remove water temperature regulator (3) and the gasket from water temperature regulator housing (4). Note the position of the water temperature regulator in the water temperature regulator housing for installation. Note: Refer to Systems Operation, Testing and Adjusting, "Water Temperature Regulator - Test" for the correct procedure on testing the water temperature regulator. Installation Procedure 1. Inspect the condition of the gasket. Replace the gasket, if necessary.
14. Illustration 3 g00634424 2. Install water temperature regulator (3) and the gasket into water temperature regulator housing (4). Make sure that the water temperature regulator is installed in the original position. Illustration 4 g00634312 3. Install cover (2) on the water temperature regulator housing. 4. Install bolts (1) that fasten cover (2) to the water temperature regulator housing. 5. Install the upper radiator hose and fill the radiator to the correct level with coolant. Refer to the Operation and Maintenance Manual for the correct procedure. Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Sun Feb 14 22:37:49 UTC+0800 2021
15. Shutdown SIS Previous Screen Product: VIBRATORY COMPACTOR Model: CS-683E VIBRATORY COMPACTOR DAD Configuration: CS-683E Vibratory Compactor DAD00001-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 i01771245 Water Outlet Manifold - Remove and Install SMCS - 1362-010 Removal Procedure 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. 1. Drain the coolant from the cooling system into a suitable container for storage or disposal.
16. 2. If the engine is equipped with a vent hose and a radiator hose then disconnect the vent hose and the radiator hose. Illustration 1 g00905514 3. Loosen clamp (1) and disconnect hose (2). If your application is equipped with a heater core, then loosen the clamps and remove the hoses that are connected to the water outlet manifold for the heater core. Note: It is not necessary to remove the cover and the water temperature regulator in order to remove the water outlet manifold. 4. Remove bolts (4) that hold the water outlet manifold in position. 5. Remove water outlet manifold (3) and the gasket. Installation Procedure Illustration 2 g00905514 1. Install water outlet manifold (3) and the gasket. 2. Install bolts (4) that hold the water outlet manifold in position.
17. 3. Connect hose (2) and tighten clamp (1). If your application is equipped with a heater core, then tighten the clamps and install the hoses that are connected to the water outlet manifold for the heater core. 4. If the engine is equipped with a radiator hose and a vent hose then connect the radiator hose and the vent hose. 5. Fill the cooling system with coolant. Refer to the Operation and Maintenance Manual, "Refill Capabilities". Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Sun Feb 14 22:38:45 UTC+0800 2021
18. Shutdown SIS Previous Screen Product: VIBRATORY COMPACTOR Model: CS-683E VIBRATORY COMPACTOR DAD Configuration: CS-683E Vibratory Compactor DAD00001-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.
19. Illustration 1 g00905926 1. Remove bolts (1). Illustration 2 g00905929 2. Install Tooling (A). Illustration 3 g00905930
20. 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. Sun Feb 14 22:39:41 UTC+0800 2021
21. Shutdown SIS Previous Screen Product: VIBRATORY COMPACTOR Model: CS-683E VIBRATORY COMPACTOR DAD Configuration: CS-683E Vibratory Compactor DAD00001-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.
22. 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.
23. 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).
24. 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. Sun Feb 14 22:40:36 UTC+0800 2021
25. Shutdown SIS Previous Screen Product: VIBRATORY COMPACTOR Model: CS-683E VIBRATORY COMPACTOR DAD Configuration: CS-683E Vibratory Compactor DAD00001-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.
26. 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
27. 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. Sun Feb 14 22:41:32 UTC+0800 2021
28. Shutdown SIS Previous Screen Product: VIBRATORY COMPACTOR Model: CS-683E VIBRATORY COMPACTOR DAD Configuration: CS-683E Vibratory Compactor DAD00001-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.
29. 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).
30. 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.
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32. 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. Sun Feb 14 22:42:28 UTC+0800 2021
33. Shutdown SIS Previous Screen Product: VIBRATORY COMPACTOR Model: CS-683E VIBRATORY COMPACTOR DAD Configuration: CS-683E Vibratory Compactor DAD00001-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
34. 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.
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