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CP-563D VIBRATORY COMPACTOR

Product: VIBRATORY COMPACTOR

Model: CP-563D VIBRATORY COMPACTOR 9ZW

Configuration: CS-563D CP-563D Vibratory Compactors 9ZW00001-UP (MACHINE) POWERED BY 3116 Engine

Disassembly and Assembly

3116 ENGINE SUPPLEMENT FOR CP-563D, CS-563D, & CS-583D VIBR

Media Number -KENR7023-02

Air Cleaner

SMCS - 1051-010

Publication Date -01/02/2001

Date Updated -28/06/2002

Remove & Install Air Cleaner

1. Open the engine enclosure.

2. Disconnect tube (1) from the air cleaner housing.

3. Loosen hose clamp (3), and remove hose (2) from the air cleaner housing.

4. Loosen four clamps (5), and remove cover (4) from the air cleaner housing. Remove the seal from the cover. Check the seal for damage or wear and replace if necessary.

5. Remove primary element (6) from the air cleaner housing.

6. Remove secondary element (7) from the air cleaner housing.

7. Remove four bolts (8), and remove air cleaner housing (9) from the bracket.

NOTE: For installation of the air cleaner, reverse the removal steps.

Rights Reserved.

Network For SIS Licensees. Fri Feb 23 22:44:56 UTC+0530 2024

This is the sample of the manual click on the download link for complete manual

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Product: VIBRATORY COMPACTOR

Model: CP-563D VIBRATORY COMPACTOR 9ZW

Configuration: CS-563D CP-563D Vibratory Compactors 9ZW00001-UP (MACHINE) POWERED BY 3116 Engine

Disassembly and Assembly

3116 ENGINE SUPPLEMENT FOR CP-563D, CS-563D, & CS-583D VIBR

Media Number -KENR7023-02

Alternator Belt

SMCS - 1357-010

Publication Date -01/02/2001

Date Updated -28/06/2002

Remove & Install Alternator Belt

1. Open the engine enclosure

2. Move the disconnect switch to the OFF position.

3. Loosen bolts (2) and (3), and push alternator (1) towards the engine to loosen the belt. Remove alternator belt (4).

NOTE: To install the alternator belts, reverse the removal steps.

NOTE: On installation, see the Operation And Maintenance Manual, Form No. KEBU7503, for the proper belt tension.

Product: VIBRATORY COMPACTOR

Model: CP-563D VIBRATORY COMPACTOR 9ZW

Configuration: CS-563D CP-563D Vibratory Compactors 9ZW00001-UP (MACHINE) POWERED BY 3116 Engine

Disassembly and Assembly

3116 ENGINE SUPPLEMENT FOR CP-563D, CS-563D, & CS-583D VIBR

Media Number -KENR7023-02

Alternator

SMCS - 1405-010

Publication Date -01/02/2001

Date Updated -28/06/2002

Remove & Install Alternator

1. Open the engine enclosure.

2. Move the disconnect switch to the OFF position.

3. Remove three wires (3) from alternator (1).

4. Loosen bolts (2) and (4). Move alternator toward the engine, and remove the alternator belt.

5. Remove bolts (2) and (4), and remove alternator (1) and guard (5) from the engine.

NOTE: To install the alternator, reverse the removal steps.

NOTE: On installation, see the Operation And Maintenance Manual, Form No. KEBU7503, for the proper belt tension.

Product: VIBRATORY COMPACTOR

Model: CP-563D VIBRATORY COMPACTOR 9ZW

Configuration: CS-563D CP-563D Vibratory Compactors 9ZW00001-UP (MACHINE) POWERED BY 3116 Engine

Disassembly and Assembly

3116 ENGINE SUPPLEMENT FOR CP-563D, CS-563D, & CS-583D VIBR

Media Number -KENR7023-02

Engine

SMCS - 1000-010

Publication Date -01/02/2001

Date Updated -28/06/2002

Remove & Install Engine

Start By:

a. * tilt operators platform or tilt cab

*This procedure is in the Machine Systems Disassembly & Assembly module, Form No. KENR7037.

1. Open the engine enclosure.

2. Move the disconnect switch to the OFF position.

At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap from the radiator slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.

3. Drain the coolant from radiator into a suitable container. The capacity of the cooling system is 30.0 liters (8 U.S. gallons).

At operating temperatures, the oil tank is hot and under pressure. Hot oil can cause burns. Remove the fill plug only when the engine is stopped and when the fill plug is cool enough to touch with your bare hands.

NOTE: Identify all hydraulic lines as they are removed for reinstallation purposes. Cap and plug all lines and fittings to prevent any contaminants from entering the system.

4. Release the pressure in the hydraulic system by slowly loosening the fill cap located on the top of the hydraulic oil tank.

5. Drain the hydraulic oil from the hydraulic oil tank. The capacity of the hydraulic oil tank is 80 liters (21.1 U. S. gallons).

NOTE: Use steps 6 through 14 only if the machine is equipped with air conditioning.

6. Disconnect two electrical connectors (2).

7. Remove the bolt from air conditioner compressor strap (1).

8. Remove bolt (3) and remove air conditioning unit. Move the air conditioning unit out of the way.

9. Remove three clamps (4) from two hose assemblies (5).

10. Turn shut off valves (8) off.

11. Disconnect two hose assemblies (7) from shut off valves (8). Plug hose assemblies immediately.

12. Remove clamp (6) from two hose assemblies (7).

13. Remove clamps (9) from two hose assemblies (5) and (7).

14. Remove clamps (10) from two hose assemblies (5) and (7).

15. Disconnect air indicator tube (11) from the hydraulic oil tank frame.

16. Loosen the clamp, and remove coolant hose (12) from the top of the hydraulic oil tank frame.

17. Remove the three bolts that fasten air cleaner bracket (14) to the hydraulic oil tank frame.

18. Remove oil level indicator (13).

19. Disconnect two fuel lines (15) from the engine. Cap and plug immediately.

20. Disconnect three electrical connectors (16).

21. Disconnect three wires (17) from the fuel shutoff solenoid.

22. Remove the cable ties that fasten wiring harness (18) to the engine. Move the wiring harness out of the way.

23. Disconnect four hose assemblies (19) from the steering pump. Cap and plug immediately.

24. Disconnect wire (20) from the engine heater.

25. Disconnect electrical connector (21).

26. Disconnect two wires (22) from the alternator.

27. Remove the cable ties that fasten wiring harness (23) to the engine. Move the wiring harness out of the way.

28. Loosen the clamp, and remove coolant hose (24) from the engine.

29. Remove five wires (25) from the starter.

30. Remove the nut, and remove cover (26) from the starter.

31. Remove the remaining two wires from the starter.

32. Disconnect hose assemblies (27) and (28) from the vibratory pump. Cap and plug immediately.

33. Disconnect two hose assemblies (29) from the vibratory pump. Cap and plug immediately.

34. Disconnect two electrical connectors (30).

35. Disconnect hose assemblies (31) and (32) from the propel pumps. Cap and plug immediately.

36. Disconnect hose assemblies (33), (36), (37) and (39) from the propel pumps. Cap and plug immediately.

37. Remove the cotter pin and pin that fastens control cable (38) to the propel pump. Loosen the jam nut and remove control cable (38) from the bracket. Move the control cable out of the way.

38. Mark electrical connectors (34) for assembly purposes. Remove the screws that fasten electrical connectors (34) to the control valves on the propel pumps. Remove the electrical connectors from the propel pumps.

39. Remove the cable ties that fasten wiring harness (35) to the pumps. Move the wiring harness out of the way.

40. Attach a Tooling (A) and a hoist to the engine as shown. Remove four mounting bolts (41), and remove engine (40) and the pumps as a unit from the machine. The weight of the engine and pumps as a unit is approximately 726 kg (1600 lb).

NOTE: For the installation of the engine, reverse the removal steps.

NOTE: After the engine has been installed, fill the cooling system with coolant to the correct level. Fill the hydraulic oil system with hydraulic oil to the correct level. See the Operation & Maintenance Manual, Form No. KEBU7503, for the correct procedures.

End By:

a. * tilt operators platform or lower cab

*This procedure is in the Machine Systems Disassembly & Assembly module, Form No. KENR7037.

Product: VIBRATORY COMPACTOR

Model: CP-563D VIBRATORY COMPACTOR 9ZW

Configuration: CS-563D CP-563D Vibratory Compactors 9ZW00001-UP (MACHINE) POWERED BY 3116 Engine

Disassembly and Assembly

3116 ENGINE SUPPLEMENT FOR CP-563D, CS-563D, & CS-583D VIBR

Media Number -KENR7023-02

Fan Motor

SMCS - 1386-017; 1386-010

Publication Date -01/02/2001

Date Updated -28/06/2002

Remove & Install Fan Motor

1. Open the engine enclosure.

2. Move the disconnect switch to the OFF position.

NOTE: Identify all hydraulic lines as they are removed for reinstallation purposes. Cap and plug all lines and fittings to prevent any contaminants from entering the system.

3. Release the pressure in the hydraulic system by slowly loosening the fill cap located on the top of the hydraulic oil tank.

4. Drain the hydraulic oil from the hydraulic oil tank. The capacity of the hydraulic oil tank is 80 liters (21.1 U.S. gallons).

5. Disconnect three hose assemblies (4) from fan motor (2). Cap and plug immediately.

6. Remove the bolt that fastens clamp (5) to guard (3).

7. Remove the two bolts and brace (7) from between the hydraulic oil tank and the radiator.

8. Remove four bolts (6). Remove the three bolts that fasten guard (3) to the left side of shroud (8).

9. Remove the three bolts, and remove shroud (8) from left side of the radiator, and remove the shroud.

10. Remove the remaining two bolts (1), and remove fan motor (2) and guard (3) from the left side of the machine.

10. Remove four bolts (10), and remove fan (9) from fan motor (2).

11. Remove two bolts (11), and remove fan motor (2) from guard (3).

NOTE: For installation of the fan motor, reverse the removal steps.

NOTE: After the fan motor has been installed, fill hydraulic oil system with hydraulic oil to the correct level. See the Operation & Maintenance Manual, Form No. KEBU7503, for the correct procedures.

Disassemble & Assemble Fan Motor

Start By:

a. remove fan motor

1. Remove nut (2), and remove adapter (1) and the woodruff key.

2. Remove four bolts (3), and remove end cover (4) from the housing.

3. Remove relief valve (5) and check valve (6) from end cover (4).

4. Remove O-ring seals (7) and back-up ring (8) from relief valve (5). Check the O-ring seals and back-up ring for wear or damage, and replace if necessary.

5. Remove O-ring seals (9) and back-up ring (10) from check valve (6). Check the O-ring seals and back-up ring for wear or damage, and replace if necessary.

6. Remove housing (11) and thrust plate (12) from the shaft cover.

7. Remove seal (13) from thrust plate (12). Check the seal for wear or damage, and replace if necessary.

8. If necessary, remove four dowel pins (14) from housing (11).

9. Remove two seals (15) from housing (11). Check the seals for wear or damage, and replace if necessary.

10. Remove drive gear (16), idler gear (18) and thrust plate (19) from shaft cover (17).

11. Remove the seal from thrust plate (19). Check the seal for wear or damage, and replace if necessary.

12. Remove retaining ring (20) and lip-type seal (21) from shaft cover (17). Check the lip-type seal for wear or damage, and replace if necessary.

NOTE: For assembly of the fan motor, reverse the disassembly steps.

End By:

a. install fan motor

Product: VIBRATORY COMPACTOR

Model: CP-563D VIBRATORY COMPACTOR 9ZW

Configuration: CS-563D CP-563D Vibratory Compactors 9ZW00001-UP (MACHINE) POWERED BY 3116 Engine

Disassembly and Assembly

3116 ENGINE SUPPLEMENT FOR CP-563D, CS-563D, & CS-583D VIBR

Media Number -KENR7023-02

Fuel Tank

SMCS - 1273-010

Publication Date -01/02/2001

Date Updated -28/06/2002

Remove & Install Fuel Tank

Start By:

a. remove radiator, hydraulic oil cooler & hydraulic oil tank

1. Drain the fuel from the the fuel tank into a suitable container. The capacity of the full fuel tank is 100 liters (26 U. S. gallons).

2. Disconnect fuel lines (3) from fuel tank (7). Cap and plug immediately.

3. Identify all electrical wires for installation purposes. Disconnect two electrical wires (2) from the fuel level sending unit.

4. Remove clamps (1) and (6) that fasten the wiring harness and battery cable to the fuel tank.

5. Remove clamp (5) that fastens the hose assemblies and battery cable to the fuel tank.

6. Remove battery cable (9) from both batteries. Move battery cable and electrical wires out of the way.

7. Remove the eight bolts and four brackets (4). Use two people to lift the fuel tank from the machine. The weight of the fuel tank is 25 kg (55 lb).

NOTE: For the installation of the fuel tank, reverse the removal steps.

NOTE: After the fuel tank has been installed, fill it with fuel. See the Operation & Maintenance Manual, Form No. KEBU7503, for the correct procedures.

End By:

a. install radiator, hydraulic oil cooler & hydraulic oil tank

Fri Feb 23 22:46:43 UTC+0530 2024

Product: VIBRATORY COMPACTOR

Model: CP-563D VIBRATORY COMPACTOR 9ZW

Configuration: CS-563D CP-563D Vibratory Compactors 9ZW00001-UP (MACHINE) POWERED BY 3116 Engine

Disassembly and Assembly

3116 ENGINE SUPPLEMENT FOR CP-563D, CS-563D, & CS-583D VIBR

Media Number -KENR7023-02 Publication Date -01/02/2001 Date Updated -28/06/2002

Radiator, Hydraulic Oil Cooler & Hydraulic Oil Tank

SMCS - 1353; 1374; 5056-01; 5056-017

Remove & Install Radiator, Hydraulic Oil Cooler & Hydraulic Oil Tank

1. Open the engine enclosure.

2. Move the disconnect switch to the OFF position.

3. Drain the radiator. The capacity of the cooling system is 30.0 liters (8 U.S. gallons).

At operating temperatures, the oil tank is hot and under pressure. Hot oil can cause burns. Remove the fill plug only when the engine is

stopped and when the fill plug is cool enough to touch with your bare hands.

NOTE: Identify all hydraulic lines as they are removed for reinstallation purposes. Cap and plug all lines and fittings to prevent any contaminants from entering the system.

4. Release the pressure in the hydraulic system by slowly loosening the fill cap located on the top of the hydraulic oil tank.

5. Drain the hydraulic oil from the hydraulic oil tank. The capacity of the hydraulic oil tank is 80 liters (21.1 U.S. gallons).

NOTE: Use steps 6 through 13 only if the machine is equipped with air conditioning.

6. Loosen the clamp, and remove coolant hose (4) from the top of the hydraulic oil tank frame.

7. Remove rivet (1) and hose (6) from seal (7).

8. Remove two clamps (5) from hose (3).

9. Remove the two bolts that hold air dryer (2) to the hydraulic oil tank. Move the air dryer out of the way.

10. Disconnect hose (8) from the top of the radiator and move out of the way.

11. Remove clamp (11) from hose (6).

12. Remove bolt (13) from support bracket (12) and remove hose (6). Install bolt (13) after removing hose (6).

13. Remove four bolts (9) from the radiator and move air condenser (10) out of the way.

14. Remove the nut that fastens disconnect switch (14) to the hydraulic oil tank frame. Remove the bolt and clamp (17) from the hydraulic oil tank frame. Move the disconnect switch and cables out of the way.

15. Loosen clamp (16). Remove the two bolts, and remove fuel tube (15) from the hose and the hydraulic oil tank frame. Cover the opening to the fuel tank.

16. Remove the two bolts that fasten water separator (20) to the hydraulic oil tank frame.

17. Disconnect two hose assemblies (18) from the fan motor. Cap and plug immediately. Remove the bolt and clamp (21) that fastens the two hose assemblies to the fan guard.

18. Disconnect two hose assemblies (22) from the hydraulic oil tank. Cap and plug immediately.

19. Remove oil level indicator (19).

20. Disconnect electrical connector (23).

21. Loosen the hose clamp, and remove coolant hose (24) from the engine.

22. Disconnect hose assemblies (25) from the hydraulic oil tank. Cap and plug immediately.

23. Disconnect two electrical connectors (26).

24. Remove bolts (27) and remove the battery cable from the hydraulic oil tank frame.

25. Remove the remaining two bolts that fasten air cleaner bracket (28) to the hydraulic oil tank.

26. Attach Tooling (A) to the hydraulic oil tank frame. Attach a suitable hoist and lifting chains to Tooling (A).

27. Remove four bolts (30), and remove hydraulic oil tank (29), radiator and hydraulic oil cooler as a unit from the machine. The weight of the hydraulic oil tank, radiator and hydraulic oil cooler as a unit is approximately 227 kg (500 lb).

NOTE: For the installation of the radiator, hydraulic oil cooler and hydraulic oil tank, reverse the removal steps.

NOTE: After the radiator, hydraulic oil cooler and hydraulic oil tank have been installed, fill the cooling system with coolant to the correct level. Fill the hydraulic oil system with hydraulic oil to the correct level. See the Operation & Maintenance Manual, Form No. KEBU7503, for the correct procedures.

Disassemble & Assemble Radiator, Hydraulic Oil Cooler & Hydraulic Oil Tank

Start By:

a. remove radiator, hydraulic oil cooler & hydraulic oil tank

1. Remove four bolts (1) from support brace (2) and remove the support brace.

2. Loosen the two clamps and remove coolant hose (3) from hydraulic oil tank (4) and radiator (5).

3. Disconnect hose assembly (6) from the hydraulic oil tank. Cap and plug immediately.

4. Disconnect two hose assemblies (7) from hydraulic oil cooler (9). Cap and plug immediately.

5. Remove four bolts (8) and remove hydraulic oil cooler (9) from radiator (5).

6. Remove the bolts that fasten two braces (10) to hydraulic oil tank (4) and hydraulic oil tank frame (5).

7. Attach lifting straps and a hoist to hydraulic oil tank (4) as shown.

8. Remove four bolts (12) from hydraulic oil tank frame (11). Remove hydraulic oil tank (4) from the hydraulic oil tank frame. The weight of the hydraulic oil tank is 60 kg (132 lb).

9. Position the hydraulic oil tank frame as shown. Remove remaining five bolts (13) and remove fan guard assembly (14).

10. Remove eight nuts and spacers (15) and remove radiator shroud (16).

11. Remove four bolts (18), and remove fan (17) from fan motor (20).

12. Remove two bolts (21), and remove fan motor (20) from guard (19).

13. Attach Tool (A) and a suitable hoist to radiator (8).

14. Remove eight nuts and spacers (22) and remove radiator (5) from hydraulic oil tank frame (11). The weight of the radiator is 82 kg (180 lb).

NOTE: For assembly of the radiator, hydraulic oil cooler and hydraulic oil tank, reverse the disassembly steps.

End By:

Network For SIS Licensees. Fri Feb 23 22:46:17 UTC+0530 2024

Product: VIBRATORY COMPACTOR

Model: CP-563D VIBRATORY COMPACTOR 9ZW

Configuration: CS-563D CP-563D Vibratory Compactors 9ZW00001-UP (MACHINE) POWERED BY 3116 Engine

Disassembly and Assembly

3116 ENGINE SUPPLEMENT FOR CP-563D, CS-563D, & CS-583D VIBR

Media Number -KENR7023-02

Starter

SMCS - 1518-010

Publication Date -01/02/2001

Date Updated -28/06/2002

Remove & Install Starter

1. Open the engine enclosure.

2. Move the disconnect switch to the OFF position.

NOTE: Identify all electrical wires for installation purposes.

3. Remove five wires (1) from the starter.

4. Remove nut (2), and remove cover (3) from the starter.

5. Remove wires (4) from starter (6).

6. Attach a lifting strap and hoist to starter (6). Remove three bolts (5), and remove starter (6) from the engine. The weight of the starter is approximately 27 kg (60 lb).