Cb-64 Caterpillar Vibratory Compactor Operation and Maintenance Manual by quality service repair manual

Product:VIBRATORYCOMPACTOR

Model:CB-64VIBRATORYCOMPACTORDJM

Configuration:CB64VibratoryCompactorDJM00001-UP(MACHINE)POWEREDBYC4.4(MECH)Engine

OperationandMaintenanceManual CB54andCB64VibratoryAsphaltCompactors

MediaNumber-KEBU7548-04PublicationDate-01/02/2015DateUpdated-28/03/2019

Foreword

CaliforniaProposition65Warning

DieselengineexhaustandsomeofitsconstituentsareknowntotheStateofCaliforniatocause cancer,birthdefects,andotherreproductiveharm.

WARNING-Thisproductcanexpose youtochemicalsincludingethylene glycol,whichisknowntotheStateof Californiatocausebirthdefectsorother reproductiveharm.Formoreinformation goto:

www.P65Warnings.ca.gov

Donotingestthischemical.Washhandsafterhandlingtoavoidincidentalingestion.

WARNING-Thisproductcanexpose youtochemicalsincludingleadandlead compounds,whichareknowntotheState ofCaliforniatocausecancer,birthdefects, orotherreproductiveharm.Formore informationgoto:

www.P65Warnings.ca.gov

Washhandsafterhandlingcomponentsthatmaycontainlead.

s03548206

LiteratureInformation

Thismanualshouldbestoredintheoperator'scompartmentintheliteratureholderorseatback literaturestoragearea.

Thismanualcontainssafetyinformation,operationinstructions,transportationinformation, lubricationinformation,andmaintenanceinformation.

Somephotographsorillustrationsinthispublicationshowdetailsorattachmentsthatcanbedifferent fromyourmachine.Guardsandcoversmighthavebeenremovedforillustrativepurposes.

Continuingimprovementandadvancementofproductdesignmighthavecausedchangestoyour machinewhicharenotincludedinthispublication.Read,study,andkeepthismanualwiththe machine.

Wheneveraquestionarisesregardingyourmachine,orthispublication,pleaseconsultyourCat dealerforthelatestavailableinformation.

Safety

Thesafetysectionlistsbasicsafetyprecautions.Inaddition,thissectionidentifiesthetextand locationsofwarningsignsandlabelsusedonthemachine.

Readandunderstandthebasicprecautionslistedinthesafetysectionbeforeoperatingorperforming lubrication,maintenance,andrepaironthismachine.

Operation

Theoperationsectionisareferenceforthenewoperatorandarefresherfortheexperiencedoperator. Thissectionincludesadiscussionofgauges,switches,machinecontrols,attachmentcontrols, transportation,andtowinginformation.

Photographsandillustrationsguidetheoperatorthroughcorrectproceduresofchecking,starting, operating,andstoppingthemachine.

Operatingtechniquesoutlinedinthispublicationarebasic.Skillandtechniquesdevelopasthe operatorgainsknowledgeofthemachineanditscapabilities.

Maintenance

Themaintenancesectionisaguidetoequipmentcare.TheMaintenanceIntervalSchedule(MIS)lists theitemstobemaintainedataspecificserviceinterval.Itemswithoutspecificintervalsarelisted underthe"WhenRequired"serviceinterval.TheMaintenanceIntervalScheduleliststhepage numberforthestep-by-stepinstructionsrequiredtoaccomplishthescheduledmaintenance.Usethe MaintenanceIntervalScheduleasanindexor"onesafesource"forallmaintenanceprocedures.

MaintenanceIntervals

Usetheservicehourmetertodetermineservicingintervals.Calendarintervalsshown(daily,weekly, monthly,etc.)canbeusedinsteadofservicehourmeterintervalsifthecalendarintervalsprovide moreconvenientservicingschedulesandapproximatetheindicatedservicehourmeterreading. Performtherecommendedserviceattheintervalthatoccursfirst.

Undersevere,dusty,orwetoperatingconditions,morefrequentlubricationthanisspecifiedinthe maintenanceintervalschartmightbenecessary.

Performserviceonitemsatmultiplesoftheoriginalrequirement.Forexample,atevery500service hoursor3months,alsoservicethoseitemslistedunderevery250servicehoursormonthlyandevery 10servicehoursordaily.

CertifiedEngineMaintenance

Propermaintenanceandrepairareessentialtokeeptheengineandmachinesystemsoperating correctly.Astheheavy-dutyoff-roaddieselengineowner,youareresponsiblefortheperformanceof therequiredmaintenancelistedintheOwnerManual,OperationandMaintenanceManual,and ServiceManual.

Itisprohibitedforanypersonengagedinthebusinessofrepairing,servicing,selling,leasing,or tradingenginesormachinestoremove,alter,ortorenderinoperative,anyemission-relateddeviceor elementofdesigninstalledonorinanengineormachinethatisincompliancewithallapplicable regulationsoftheintendedcountrytowhichithasbeenshipped.Certainelementsofthemachineand enginesuchastheexhaustsystem,fuelsystem,electricalsystem,intakeairsystem,andcooling systemmaybeemission-relatedandshouldnotbealteredunlessapprovedbyCaterpillar.

MachineCapacity

Additionalattachmentsormodificationsmayexceedmachinedesigncapacitywhichcanadversely affectperformancecharacteristics.Includedwouldbestabilityandsystemcertificationssuchas brakes,steering,androlloverprotectivestructures(ROPS).ContactyourCatdealerforfurther information.

ProductIdentificationNumber

EffectiveFirstQuarter2001theProductIdentificationNumber(PIN)haschangedfrom8to17 characters.Toprovideuniformequipmentidentification,constructionequipmentmanufacturersare movingtocomplywiththelatestversionoftheproductidentificationnumberingstandard.Non-road machinePINsaredefinedbyISO10261.ThenewPINformatwillapplytoallmachinesand generatorsets.ThePINplatesandframemarkingwilldisplaythe17characterPIN.Thenewformat willlooklikethefollowing:

Illustration1g03891925

Where:

1.WorldManufacturingCode(characters1-3)

2.MachineDescriptor(characters4-8)

3.CheckCharacter(character9)

4.MachineIndicatorSection(MIS)orProductSequenceNumber(characters10-17).Thesewere previouslyreferredtoastheSerialNumber.

MachinesandgeneratorsetsproducedbeforeFirstQuarter2001willmaintaintheir8characterPIN format.

Componentssuchasengines,transmissions,axles,andworktoolswillcontinuetousean8character SerialNumber(S/N).

SatOct1400:04:30UTC+05302023

Product:VIBRATORYCOMPACTOR

Model:CB-64VIBRATORYCOMPACTORDJM

Configuration:CB64VibratoryCompactorDJM00001-UP(MACHINE)POWEREDBYC4.4(MECH)Engine

OperationandMaintenanceManual

CB54andCB64VibratoryAsphaltCompactors

MediaNumber-KEBU7548-04PublicationDate-01/02/2015DateUpdated-28/03/2019

EngineAirFilterSecondaryElement-Replace

SMCS-1054-510-SE

NOTICE

Alwaysreplacethesecondaryfilterelement.Neverattempttoreuseit bycleaning.

Thesecondaryfilterelementshouldbereplacedatthetimethe primaryelementisservicedforthethirdtime.

Thesecondaryfilterelementshouldalsobereplacediftheyellow pistoninthefilterelementindicatorenterstheredzoneafter installationofacleanprimaryelement,oriftheexhaustsmokeisstill black.

1.Opentheengineaccessdoorontherightsideofthemachine.

i01928619

Illustration1g00101864

2.Removetheaircleanerhousingcover(1).

3.Removetheprimaryfilterelement(2)fromtheaircleanerhousing.

Illustration2g00038606

4.Removethesecondaryfilterelement.

5.Covertheairinletopening.Cleantheinsideoftheaircleanerhousing.

6.Inspectthegasketbetweentheairinletpipeandtheaircleanerhousing.Replacethegasket ifthegasketisdamaged.

7.Uncovertheairinletopening.Installanewsecondaryelement.

8.Installtheprimaryelementandtheaircleanerhousingcover.

9.Resetthefilterelementindicator.

10.Closetheengineaccessdoor.

SatOct1400:14:35UTC+05302023

Product:VIBRATORYCOMPACTOR

Model:CB-64VIBRATORYCOMPACTORDJM

Configuration:CB64VibratoryCompactorDJM00001-UP(MACHINE)POWEREDBYC4.4(MECH)Engine

OperationandMaintenanceManual

CB54andCB64VibratoryAsphaltCompactors

MediaNumber-KEBU7548-04PublicationDate-01/02/2015DateUpdated-28/03/2019 i03288621

EngineAirFilterServiceIndicator-Inspect

SMCS-7452-040

1.Theairfilterelementindicatorislocatedunderthehoodontheleftsideofthemachine. Openthehood.RefertotheOperationandMaintenanceManual,"AccessDoorsand Covers"forthelocationofthehood.

2.Starttheengine.

3.Runtheengineathighidle.

4.Iftheyellowpistonintheengineairfilterserviceindicatorenterstheredzone,servicethe aircleaner.

5.Stoptheengine.

Note:SeetheOperationandMaintenanceManual,"EngineAirFilterPrimaryElementClean/Replace".SeetheOperationandMaintenanceManual,"EngineAirFilterSecondary Element-Replace".

This is the sample of the manual Click on the download link for complete Manual

6.Inordertoresettheairfilterelementindicator,pushdownonthebuttonontopofthe indicator.

7.Closethehood.

SatOct1400:14:20UTC+05302023

Product:VIBRATORYCOMPACTOR

Model:CB-64VIBRATORYCOMPACTORDJM

Configuration:CB64VibratoryCompactorDJM00001-UP(MACHINE)POWEREDBYC4.4(MECH)Engine

OperationandMaintenanceManual

CB54andCB64VibratoryAsphaltCompactors

MediaNumber-KEBU7548-04PublicationDate-01/02/2015DateUpdated-28/03/2019 i01404793

EngineCompartment-Clean

SMCS-1000-070

NOTICE

Beforesprayingtheenginecompartmentwithhighpressurewater turnofftheengineandallowtheenginetocool.Donotspraywater directlyonahotfuelinjectionpumpordamagemayoccur.

Useacommerciallyavailableenginedegreaserinordertocleantheenginecompartment.Use cautionandminimizethewateraroundbearingsandelectricalconnections.

Product:VIBRATORYCOMPACTOR

Model:CB-64VIBRATORYCOMPACTORDJM

Configuration:CB64VibratoryCompactorDJM00001-UP(MACHINE)POWEREDBYC4.4(MECH)Engine

OperationandMaintenanceManual

CB54andCB64VibratoryAsphaltCompactors

MediaNumber-KEBU7548-04PublicationDate-01/02/2015DateUpdated-28/03/2019

EngineMounts-Inspect

SMCS-1152-040

Openthehoodinordertochecktheenginemounts.

Therearethreeenginemountsthatneedtobechecked.

Enginevibrationcanbecausedbyimpropermountingoftheengine.Enginevibrationcanbe causedbylooseenginemountsordeterioratedenginemounts.

Inspecttheenginemountsfordeterioration.

Replaceanyenginemountthatisdeteriorated.

Inspecttheenginemountsforcorrectbolttorque.

Tightenthemountsifthemountsareloose.

SeeyourCaterpillardealerforfurtherinformationandinstructionsforyourmachine.

SatOct1400:14:00UTC+05302023

i01796194

Product:VIBRATORYCOMPACTOR

Model:CB-64VIBRATORYCOMPACTORDJM

Configuration:CB64VibratoryCompactorDJM00001-UP(MACHINE)POWEREDBYC4.4(MECH)Engine

OperationandMaintenanceManual

CB54andCB64VibratoryAsphaltCompactors

MediaNumber-KEBU7548-03PublicationDate-01/02/2015DateUpdated-17/02/2015

EngineAirFilterPrimaryElement-Clean/Replace

SMCS-1054-070-PY;1054-510-PY

NOTICE

Servicetheaircleaneronlywiththeenginestopped.Enginedamage couldresult.

Servicetheaircleanerfilterelementwhentheyellowpistonontheengineairfilterservice indicatorenterstheredzoneortheindicatorreads63.5cm(25inch)ofwater.Referto OperationandMaintenanceManual,"EngineAirFilterServiceIndicator-Inspect".

i01953476

1.Removecover(1)fortheairfilterhousing.

2.Removeprimaryfilterelement(2)fromtheairfilterhousing.

3.Cleantheinsideoftheairfilterhousing.

4.Ifthemachineisequippedwithavacuatorvalve,cleanthevacuatorvalveonthecoverforthe airfilterhousing.

5.Installacleanprimaryairfilterelement.Installthecoverfortheairfilterhousing.

Note:Referto"CleaningPrimaryAirFilterElements".

6.Resettheengineairfilterserviceindicator.

7.Closetheaccessdoor.

Iftheyellowpistonintheindicatormovesintotheredzoneafterstartingtheengineortheexhaust smokeisstillblackafterinstallationofacleanprimaryfilterelement,installanewprimaryfilter element.Ifthepistonremainsintheredzonereplacethesecondaryelement.

CleaningPrimaryAirFilterElements

Caterpillarrecommendscertifiedairfiltercleaningservicesavailable atparticipatingCaterpillardealers.TheCaterpillarcleaningprocess

usesprovenprocedurestoassureconsistentqualityandsufficientfilter life.

Observethefollowingguidelinesifyouattempttocleanthefilter element:

Donottaporstrikethefilterelementinordertoremovedust.

Donotwashthefilterelement.

Uselowpressurecompressedairinordertoremovethedustfromthe filterelement.Airpressuremustnotexceed207kPa(30psi).Directthe airflowupthepleatsanddownthepleatsfromtheinsideofthefilter element.Takeextremecareinordertoavoiddamagetothepleats.

Donotuseairfilterswithdamagedpleats,gaskets,orseals.Dirt enteringtheenginewillcausedamagetoenginecomponents.

Theprimaryairfilterelementcanbeuseduptosixtimesiftheelementisproperlycleanedandifthe elementisproperlyinspected.Whentheprimaryairfilterelementiscleaned,checkforripsortearsin thefiltermaterial.Theprimaryairfilterelementshouldbereplacedatleastonetimeperyear.This replacementshouldbeperformedregardlessofthenumberofcleanings.

NOTICE

Donotcleantheairfilterelementsbybumpingortapping.Thiscould damagetheseals.Donotuseelementswithdamagedpleats,gaskets,or seals.Damagedelementswillallowdirttopassthrough.Engine damagecouldresult.

Visuallyinspecttheprimaryairfilterelementsbeforecleaning.Inspecttheairfilterelementsfor damagetotheseal,thegaskets,andtheoutercover.Discardanydamagedairfilterelements.

Therearetwocommonmethodsthatareusedtocleanprimaryairfilterelements:

•Pressurizedair

•Vacuumcleaning

PressurizedAir

Pressurizedaircanbeusedtocleanprimaryairfilterelementsthathavenotbeencleanedmorethan twotimes.Pressurizedairwillnotremovedepositsofcarbonandoil.Usefiltered,dryairwitha maximumpressureof207kPa(30psi).

Note:Whentheprimaryairfilterelementsarecleaned,alwaysbeginwiththecleanside(inside)in ordertoforcedirtparticlestowardthedirtyside(outside).

Aimthehosesothattheairflowsinsidetheelementalongthelengthofthefilterinordertohelp preventdamagetothepaperpleats.Donotaimthestreamofairdirectlyattheprimaryairfilter element.Dirtcouldbeforcedfurtherintothepleats.

VacuumCleaning

Vacuumcleaningisanothermethodforcleaningprimaryairfilterelementswhichrequiredaily cleaningbecauseofadry,dustyenvironment.Cleaningwithpressurizedairisrecommendedpriorto vacuumcleaning.Vacuumcleaningwillnotremovedepositsofcarbonandoil.

InspectingthePrimaryAirFilterElements

Inspecttheclean,dryprimaryairfilterelement.Usea60wattbluelightinadarkroomorinasimilar facility.Placethebluelightintheprimaryairfilterelement.Rotatetheprimaryairfilterelement. Inspecttheprimaryairfilterelementfortearsand/orholes.Inspecttheprimaryairfilterelementfor lightthatmayshowthroughthefiltermaterial.Ifitisnecessaryinordertoconfirmtheresult, comparetheprimaryairfilterelementtoanewprimaryairfilterelementthathasthesamepart number.

Donotuseaprimaryairfilterelementthathasanytearsand/orholesinthefiltermaterial.Donotuse aprimaryairfilterelementwithdamagedpleats,gasketsorseals.Discarddamagedprimaryairfilter elements.

StoringPrimaryAirFilterElements

Ifaprimaryairfilterelementthatpassesinspectionwillnotbeused,theprimaryairfilterelementcan bestoredforfutureuse.

Illustration4g00281694

Donotusepaint,awaterproofcover,orplasticasaprotectivecoveringforstorage.Anairflow restrictionmayresult.Toprotectagainstdirtanddamage,wraptheprimaryairfilterelementsin VolatileCorrosionInhibited(VCI)paper.

Placetheprimaryairfilterelementintoaboxforstorage.Foridentification,marktheoutsideofthe boxandmarktheprimaryairfilterelement.Includethefollowinginformation:

•Dateofcleaning

•Numberofcleanings

Storetheboxinadrylocation.

AllRightsReserved.

PrivateNetworkForSISLicensees.

SatOct1400:13:52UTC+05302023

Product:VIBRATORYCOMPACTOR

Model:CB-64VIBRATORYCOMPACTORDJM

Configuration:CB64VibratoryCompactorDJM00001-UP(MACHINE)POWEREDBYC4.4(MECH)Engine

OperationandMaintenanceManual

CB54andCB64VibratoryAsphaltCompactors

MediaNumber-KEBU7548-04PublicationDate-01/02/2015DateUpdated-28/03/2019 i03288766

EngineOilLevel-Check

SMCS-1348-535-FLV NOTICE

Donotunderfilloroverfillenginecrankcasewithoil.Eithercondition cancauseenginedamage.

Stoptheengineinordertochecktheoillevel.DONOTchecktheoillevelwhentheengineis running.

Parkthemachineonalevelsurface.

1.Openthehood.RefertotheOperationandMaintenanceManual,"AccesDoorsandCovers" forthelocationofthehood.

2.Removeengineoillevelgauge(1).Wipetheengineoillevelgaugewithacleancloth. Inserttheengineoillevelgauge.Removetheengineoillevelgaugeandnotetheoillevel. Inserttheengineoillevelgauge.

Note:RefertotheOperationandMaintenanceManual,"LubricantViscositiesand Capacities(Refill)"forthecorrectamountofoilthatisusedwhentheoilischanged.The correctamountofoildeterminesthecorrectleveloftheoilintheFULLrangeonengineoil levelgauge(1).

NOTICE

Donotoverfillthecrankcase.Theoillevelmustnotreachthetopof theFULLrangemarkorabovetheFULLrangemark.

Illustration2g00367841

3.Maintaintheoillevelonengineoillevelgauge(1)betweentheFULLRANGEmarkand theADDOILmark.Addoiliftheoillevelistoolow.

Note:OperatingyourenginewiththeoillevelabovetheFULLmarkintheFULLRange couldcausethecrankshafttodipintotheoil.Thiscouldresultinexcessivelyhighoperating temperatures.Thehighoperatingtemperaturescouldresultinreducedlubricating characteristicsoftheoil.Thiscouldcausedamagetothebearingsandlossofenginepower.

4.Removetheoilfillercap(2).

5.Ifoilisrequired,addtherequiredamount.

6.Cleantheoilfillercap.Installtheoilfillercap.

7.Closethehood.

ForadditionalbasicenginemaintenanceinformationrefertoOperationandMaintenanceManual, SEBU8180,"C4.4IndustrialEngineOMM".

SatOct1400:13:46UTC+05302023

Product:VIBRATORYCOMPACTOR

Model:CB-64VIBRATORYCOMPACTORDJM

Configuration:CB64VibratoryCompactorDJM00001-UP(MACHINE)POWEREDBYC4.4(MECH)Engine

OperationandMaintenanceManual

MediaNumber-KEBU7548-03PublicationDate-01/02/2015DateUpdated-17/02/2015 i03434143

EccentricWeightHousingOilLevel-Check

SMCS-6606-535-FLV

Thereisaneccentricweighthousingintheleftfrontdrum.Thereisaneccentricweighthousingin therightreardrum.

Illustration1g01086108

1.Rotatethedrumuntilindicatorbar(1)isatthebottomofthedrum.Thesightgauge(3)willbe atthebottomofthehousing.

2.Observethelevelofoilinthesightgauge.Theoillevelshouldbevisibleinthecenterofthe sightgauge.

3.Ifthelubricantlevelislow,removefill/drainplug(2)attheteno'clockposition.

4.Addthecorrectamountofoil.RefertotheMaintenanceManual,"LubricationViscosities"and MaintenanceManual,"Capacities(Refill)".Maintaintheleveloftheoiltothemiddleofthe sightgauge.

5.Cleanfill/drainplug(2).Installfill/drainplug(2).

Note:Donotoverfilltheeccentricweighthousing.Iftheeccentricweighthousingisoverfilled theexcessoilmustbedrainedout.Aneccentricweighthousingthathasbeenoverfilledcan leadtoexcessiveheatgenerationandlossofvibratorysystemperformance.

SatOct1400:13:43UTC+05302023

Product:VIBRATORYCOMPACTOR

Model:CB-64VIBRATORYCOMPACTORDJM

Configuration:CB64VibratoryCompactorDJM00001-UP(MACHINE)POWEREDBYC4.4(MECH)Engine

OperationandMaintenanceManual

CB54andCB64VibratoryAsphaltCompactors

MediaNumber-KEBU7548-04PublicationDate-01/02/2015DateUpdated-28/03/2019

EngineOilSample-Obtain

SMCS-1000-008

Hotoilandhotcomponentscancausepersonalinjury.Donotallowhot oilorhotcomponentstocontacttheskin.

ObtaintheSampleandtheAnalysis

CaterpillarrecommendsthatyouuseS·O·Soilanalysisatscheduledintervalsinordertomonitor theconditionoftheengineandtomonitorthemaintenancerequirementsoftheengine.

Eachoilsampleshouldbetakenwhentheoiliswarmandwhentheoiliswellmixed.Thesample shouldbetakenatthistimeinordertoensurethatthesampleisrepresentativeoftheoilinthe crankcase.

ObtaintheS·O·SSample

UseoneofthefollowingmethodsinordertoobtainanS·O·Ssample:

•Usetheoilsamplingvalve.

•Usea1U-5718VacuumPumporuseanequivalentpumpthatisinsertedintothesump.

Caterpillarrecommendsthatyouusetheoilsamplingvalveinordertoobtainoilsamples.The qualityandtheconsistencyofthesamplesisbetterwhenthesamplingvalveisused.Iftheengine isnotequippedwithasamplingvalve,theuseofa1U-5718VacuumPumpispreferred.

Toavoidcontaminationoftheoilsamples,thetoolsandthesuppliesthatareusedforobtainingoil samplesmustbeclean.

RefertoSpecialPublication,PEHP6001formoreinformationonobtainingagoodoilsample. ConsultyourCaterpillardealerforcompleteinformationandassistanceinestablishinganS·O·S programforyourengine.

1.Theoilsamplingvalveislocatedunderthehood.Openthehood.RefertotheOperationand MaintenanceManual,"AccessDoorsandCovers"forthelocationofthehood.

Illustration1g01676713

2.Openthesamplingvalve.Obtainanoilsampleinasuitablecontainerandclosethe samplingvalve.

3.Sealthecontainerandlabelthecontainer.SendthesampletoyourCaterpillardealerfor analysis.

4.Closethehood.

SatOct1400:13:37UTC+05302023

This is the sample of the manual Click on the download link for complete Manual