Manual Repair CAT CS-683 INGLES

Service Repair Manual
Models
CS-683E Vibratory Compactor

CS-683E Vibratory Compactor ASG00001-UP (MACHINE) POWERED BY 3056E E... 1/11
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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
8B-7548 Push-Puller Tool Gp 1
1P-0520 Driver Gp 1
A
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.
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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.
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) .
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).
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) .
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.
11. Install antirotation washers (41) .
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).
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.
17. Install planetary carrier (31) in the housing.
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.
22. Install sun gears (7) and (24) in planetary carrier (23) .
23. Install planetary carrier (23) and the sun gears in housing (47) .
24. Install O-ring seals (20) and (21) in input ring gear (18) .
25. Install dowels (22) in input ring gear (18) .
26. Install input ring gear (18) and bolts (19) .
27. Install coupling (3) on sun gear (7) .
28. Install shims (8) and retaining ring (6) on sun gear (7) .
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.
31. Install flange cover (17) in input ring gear (18) . Install retaining ring (16) .
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) .
CS-683E Vibratory Compactor ASG00001-UP (MACHINE) POWERED BY 3056... 10/11
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.
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.
CS-683E Vibratory Compactor ASG00001-UP (MACHINE) POWERED BY 3056... 11/11
End By: Install the final drive planetary. Refer to Disassembly and Assembly, "Final Drive Planetary
(Drum Propel) - Install".
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i01935687
Final Drive Planetary (Drum Propel) - Install

SMCS - 5655-012
Installation Procedure
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).
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) .
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".
Shutdown SIS
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i01935182
Piston Motor (Vibratory) - Remove

SMCS - 5058-011; 5651-011
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
6V-9509 Face Seal Plug (13/16 - 16 THD) 1
ZZ
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.
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.
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) .
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i01546246
Piston Motor (Vibratory) - Disassemble

SMCS - 5058-015; 5651-015
Disassembly Procedure
Table 1
Required Tools
A 136-1452 Retaining Ring Pliers 1
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
B 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
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".
1. Remove four bolts (14) and remove flushing valve (8) from rear cover plate (4) .
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) .
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) .
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.
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.
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.
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.
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i01546250
Piston Motor (Vibratory) - Assemble

SMCS - 5058-016; 5651-016
Assembly Procedure
Table 1
Required Tools
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.
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) .
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.
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.
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).
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) .
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".
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i01935185
Piston Motor (Vibratory) - Install

SMCS - 5058-012; 5651-012
Installation Procedure
Table 1
Required Tools
A 6V-4876 Lubricant 1
B 9S-3263 Thread Lock Compound 1
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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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,
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i01935190
Vibratory Support - Remove

SMCS - 5656-011
Removal Procedure
Table 1
Required Tools
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.
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).
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,
5. Remove bolts (4). Remove vibratory motor (5) and the O-ring seal from vibratory support
(3) .

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Service Repair Manual

CS-683E Vibratory Compactor

Product: VIBRATORY COMPACTOR

Disassembly and Assembly

Final Drive Planetary (Drum Propel) - Assemble

4. Install bushings (49) in hub (48) .

8. Install retaining disc (46) .

11. Install antirotation washers (41) .

13. Install disc (34) in planetary carrier (31) .

14. Install gear pins (33) in planetary carrier (31) .

17. Install planetary carrier (31) in the housing.

18. Install disc (30) in planetary carrier (23) .

19. Install gear pins (29) in planetary carrier (23) .

21. Repeat Step 20 and install the remaining planetary gears.

25. Install dowels (22) in input ring gear (18) .

26. Install input ring gear (18) and bolts (19) .

27. Install coupling (3) on sun gear (7) .

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) .

c. Apply 1448 kPa (210 psi) of pressure to the brake piston.

Product: VIBRATORY COMPACTOR

Disassembly and Assembly

Final Drive Planetary (Drum Propel) - Install

Product: VIBRATORY COMPACTOR

Disassembly and Assembly

Piston Motor (Vibratory) - Remove

Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN

Care must be taken to ensure that fluids are contained during

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Dispose of all fluids according to local regulations and mandates.

3. Disconnect hose assembly (4) from vibratory motor (3) .

Product: VIBRATORY COMPACTOR

Disassembly and Assembly

Piston Motor (Vibratory) - Disassemble

2. Use the following procedure to disassemble the flushing valve (8) .

6. Remove lip type seal (7) from front cover (10) .

9. Remove O-ring seal (3) from housing (2) .

Product: VIBRATORY COMPACTOR

Disassembly and Assembly

Piston Motor (Vibratory) - Assemble

3. Install the cylinder barrel on the pistons and center pin.

5. Angle the cylinder barrel to one side.

7. Install new lip type seal (7) in front cover (10) .

11. Install O-ring seal (3) in housing (2) .

12. Install dowel pin (13) in rear cover plate (4) .

b. Install shim (29) and O-ring seal (30) on plug (31) .

Product: VIBRATORY COMPACTOR

Disassembly and Assembly

Piston Motor (Vibratory) - Install

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2. Install hose assemblies (5) and (6) on vibratory motor (3) .

3. Connect hose assembly (4) to vibratory motor (3) .

Product: VIBRATORY COMPACTOR

Disassembly and Assembly

Vibratory Support - Remove

A. Remove the drum. Refer to Disassembly and Assembly, "Drum - Remove".

Care must be taken to ensure that fluids are contained during