Cp-663E Caterpillar Vibratory Compactor Operation and Maintenance Manual by quality service repair manual

Product:VIBRATORYCOMPACTOR

Model:CP-663EVIBRATORYCOMPACTORDAF

Configuration:CS-663ECP-663EVibratoryCompactorDAF00001-UP(MACHINE)POWEREDBY3056EEngine

OperationandMaintenanceManual

CS-563E,CP-563E,CS-573E,CP-573E,CS-583E,CP-583E,CS-663E,CP-663EandCS683EVibratorySoilCompactors

MediaNumber-KEBU7513-14PublicationDate-01/08/2011DateUpdated-12/04/2019

Foreword

SMCS-6606-025-NS;6606-081-NS

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

s03548206

Washhandsafterhandlingcomponentsthatmaycontainlead.

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).

FriDec102:06:14UTC+05302023

Product:VIBRATORYCOMPACTOR

Model:CP-663EVIBRATORYCOMPACTORDAF

Configuration:CS-663ECP-663EVibratoryCompactorDAF00001-UP(MACHINE)POWEREDBY3056EEngine

OperationandMaintenanceManual

CS-563E,CP-563E,CS-573E,CP-573E,CS-583E,CP-583E,CS-663E,CP-663EandCS683EVibratorySoilCompactors

MediaNumber-KEBU7513-14PublicationDate-01/08/2011DateUpdated-12/04/2019

AccessDoorsandCovers

SMCS-7251;7263;7273-572;7273-573;7273

i01927142

Usethehandleinordertounlatchthehoodfortheengine.Thiswillallowaccesstotheengineand majorcomponents.

FriDec102:16:16UTC+05302023

Product:VIBRATORYCOMPACTOR

Model:CP-663EVIBRATORYCOMPACTORDAF

Configuration:CS-663ECP-663EVibratoryCompactorDAF00001-UP(MACHINE)POWEREDBY3056EEngine

OperationandMaintenanceManual

CS-563E,CP-563E,CS-573E,CP-573E,CS-583E,CP-583E,CS-663E,CP-663EandCS683EVibratorySoilCompactors

MediaNumber-KEBU7513-14PublicationDate-01/08/2011DateUpdated-12/04/2019

AxleOil(Rear)-Change

SMCS-3260-044;3278-044

S/N-ASB1-UP

S/N-ASF1-UP

S/N-ASG1-UP

S/N-DAD1-UP

S/N-DAF1-UP

S/N-DAG1-UP

S/N-MCP1-UP

i01830459

1.Removethedifferentialdrainplug.Theplugislocatedonthefrontsideofthedifferentialcase atthebottom.

Note:Draintheoilintoasuitablecontainer.Disposeoftheusedoilinanappropriatemanner.

2.Removethedifferentiallevel/fillplug.Thedifferentiallevel/fillplugislocatedonthebackside ofthedifferentialcase.

3.Cleanthedrainplugandinstallthedrainplug.Addtheproperoiltothedifferential.Maintain theleveloftheoiltothebottomoftheholeforthedifferentiallevel/fillplug.Refertothe OperationandMaintenanceManual,"LubricantViscositiesandCapacities(Refill)"sectionfor moreinformation.

4.Cleanthefillerplug.Installthefillerplug.

FriDec102:19:13UTC+05302023

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

Product:VIBRATORYCOMPACTOR

Model:CP-663EVIBRATORYCOMPACTORDAF

Configuration:CS-663ECP-663EVibratoryCompactorDAF00001-UP(MACHINE)POWEREDBY3056EEngine

OperationandMaintenanceManual

CS-563E,CP-563E,CS-573E,CP-573E,CS-583E,CP-583E,CS-663E,CP-663EandCS683EVibratorySoilCompactors

MediaNumber-KEBU7513-14PublicationDate-01/08/2011DateUpdated-12/04/2019

AxleOilLevel(Rear)-Check

SMCS-3260-535-FLV;3278-535

Note:Alwayschecktheoillevelwhenthemachineisparkedonalevelsurface.

Note:Thedifferentiallevel/fillplugislocatedonthebacksideoftherearaxle.

1.Removethelevel/fillplug.Maintaintheoilleveltothebottomofthelevel/fillplugopening.If necessary,addoil.

Note:Whenyouaddoil,allowtheoiltosettleinordertoverifytheoillevel.

2.Cleanthelevel/fillplug.Installtheplug.

FriDec102:20:02UTC+05302023

Product:VIBRATORYCOMPACTOR

Model:CP-663EVIBRATORYCOMPACTORDAF

Configuration:CS-663ECP-663EVibratoryCompactorDAF00001-UP(MACHINE)POWEREDBY3056EEngine

OperationandMaintenanceManual

CS-563E,CP-563E,CS-573E,CP-573E,CS-583E,CP-583E,CS-663E,CP-663EandCS683EVibratorySoilCompactors

MediaNumber-KEBU7513-14PublicationDate-01/08/2011DateUpdated-12/04/2019

AxleOilSample-Obtain

SMCS-3260-008;3278-008;7542

Obtainanoilsampleofthedifferentialoilthroughtheoillevel/fillplug.Theoillevel/fillplugis locatedonthebacksideoftherearaxle.

RefertotheSpecialPublication,SEBU6250,"CaterpillarMachineFluidsRecommendations"and refertotheOperationandMaintenanceManual,"SamplingIntervalandLocationofSamplingValve" formoreinformation.RefertoSpecialPublication,PEGJ0047,"HowToTakeAGoodOilSample" formoreinformationaboutobtaininganoilsample.

FriDec102:20:13UTC+05302023

Product:VIBRATORYCOMPACTOR

Model:CP-663EVIBRATORYCOMPACTORDAF

Configuration:CS-663ECP-663EVibratoryCompactorDAF00001-UP(MACHINE)POWEREDBY3056EEngine

OperationandMaintenanceManual

CS-563E,CP-563E,CS-573E,CP-573E,CS-583E,CP-583E,CS-663E,CP-663EandCS683EVibratorySoilCompactors

MediaNumber-KEBU7513-14PublicationDate-01/08/2011DateUpdated-12/04/2019

BackupAlarm-Test

SMCS-7406-081

Thebackupalarmislocatedattherearofthemachine.

TurntheenginestartswitchtotheONpositioninordertoperformthetest.

MovethepropelcontrollevertotheREVERSEposition.

Thebackupalarmshouldstarttosoundimmediately.Thebackupalarmwillcontinuetosounduntil thetransmissioncontrolleverismovedtotheSTOPpositionortotheFORWARDposition.

i02855591

Ifthebackupalarmdoesnotsound,makethenecessaryrepairsimmediately.Donotoperatea machinewithoutabackupalarm.

FriDec102:20:24UTC+05302023

Product:VIBRATORYCOMPACTOR

Model:CP-663EVIBRATORYCOMPACTORDAF

Configuration:CS-663ECP-663EVibratoryCompactorDAF00001-UP(MACHINE)POWEREDBY3056EEngine

OperationandMaintenanceManual

CS-563E,CP-563E,CS-573E,CP-573E,CS-583E,CP-583E,CS-663E,CP-663EandCS683EVibratorySoilCompactors

MediaNumber-KEBU7513-14PublicationDate-01/08/2011DateUpdated-12/04/2019

Battery-Clean/Check

SMCS-1401-070;1401-535;1402-070;1402-535

Note:Thebatteriesthataresuppliedwiththemachinesaremaintenancefreebatteries.Youdonot needtochecktheleveloftheelectrolyteinthemaintenancefreebatteries.

Tightenthebatteryretainersonbothofthebatteries.Tightenthebatteryretainersatevery1000hours. Checkthefollowingitemsatevery1000hours.Ifnecessary,checkthefollowingitemsmoreoften.

•Cleanthetopofthebatterieswithacleancloth.

•Cleanthebatteryterminals.Asneeded,coatthebatteryterminalswithpetroleumjelly.

FriDec102:20:39UTC+05302023

Product:VIBRATORYCOMPACTOR

Model:CP-663EVIBRATORYCOMPACTORDAF

Configuration:CS-663ECP-663EVibratoryCompactorDAF00001-UP(MACHINE)POWEREDBY3056EEngine

OperationandMaintenanceManual

CS-563E,CP-563E,CS-573E,CP-573E,CS-583E,CP-583E,CS-663E,CP-663EandCS683EVibratorySoilCompactors

MediaNumber-KEBU7513-14PublicationDate-01/08/2011DateUpdated-12/04/2019 i07746330

Battery-Recycle

SMCS-1401-561

Alwaysrecycleabattery.Neverdiscardabattery.

Alwaysreturnusedbatteriestooneofthefollowinglocations:

•Abatterysupplier

•Anauthorizedbatterycollectionfacility

•Recyclingfacility

FriDec102:20:49UTC+05302023

Product:VIBRATORYCOMPACTOR

Model:CP-663EVIBRATORYCOMPACTORDAF

Configuration:CS-663ECP-663EVibratoryCompactorDAF00001-UP(MACHINE)POWEREDBY3056EEngine

OperationandMaintenanceManual

CS-563E,CP-563E,CS-573E,CP-573E,CS-583E,CP-583E,CS-663E,CP-663EandCS683EVibratorySoilCompactors

MediaNumber-KEBU7513-14PublicationDate-01/08/2011DateUpdated-12/04/2019

BatteryorBatteryCable-Inspect/Replace

SMCS-1401-040;1401-510;1402-040;1402-510

1.TurntheenginestartswitchtotheOFFposition.TurnallswitchestotheOFFposition.

2.TurnthebatterydisconnectswitchtotheOFFposition.Removethebatterydisconnectswitch key.

3.Openthebatterycompartments.Thereisonecompartmentoneachsideofthemachine.

4.Atthebatterydisconnectswitch,disconnectthenegativebatterycablethatisconnectedtothe frame.

Note:Donotallowthedisconnectedbatterycablestocontactthedisconnectswitch.Donot allowthedisconnectedbatterycablestocontacttheothercables.Donotallowthedisconnected batterycablestocontacttheoppositeterminalofeitherbattery.

5.Disconnectthenegativebatterycableatthebattery.

6.Disconnectthebatterycablefromthefirstbattery.

7.Removethenegativebatterycablefromthesecondbattery.Thiswillallowyoutoremovethe cable.

8.Removethe+batterycablefromthesecondbattery.Inordertoremovethecablethatconnects thetwobatteries,youmustremovetwoclamps.Thetwoclampsarelocatedundertheradiator attherearofthemachine.

9.Removethecablefromthestartermotor.

10.Performthenecessaryrepairs.Replacethecablesorthebatteries,asneeded.

11.Reversetheabovestepsinordertoreconnectthebatteries.

12.Connectthebatterycableatthebatterydisconnectswitch.

13.Installthebatterydisconnectswitchkey.TurnthebatterydisconnectswitchtotheONposition.

14.Installthebatterycompartmentcovers.

FriDec102:21:01UTC+05302023

Product:VIBRATORYCOMPACTOR

Model:CP-663EVIBRATORYCOMPACTORDAF

Configuration:CS-663ECP-663EVibratoryCompactorDAF00001-UP(MACHINE)POWEREDBY3056EEngine

OperationandMaintenanceManual

CS-563E,CP-563E,CS-573E,CP-573E,CS-583E,CP-583E,CS-663E,CP-663EandCS683EVibratorySoilCompactors

MediaNumber-KEBU7513-14PublicationDate-01/08/2011DateUpdated-12/04/2019

Belts-Inspect/Adjust/Replace

SMCS-1357-510;1357-025;1357-040

Yourenginecanbeequippedwithafandrivebeltandwithaccessorydrivebelts.Yourenginecan alsobeequippedwithanalternatorbelt.Formaximumengineperformanceandmaximumutilization ofyourengine,inspectthebeltsforwearandforcracking.Checkthebelttension.Adjustthebelt tensioninordertominimizebeltslippage.Beltslippagewilldecreasethebeltlife.Beltslippagewill alsocausepoorperformanceofthealternatorandofanydrivenequipment.

Ifnewbeltsareinstalled,recheckthebeltadjustmentafter30minutesofoperation.Iftwobeltsor morearerequiredforanapplication,replacethebeltsinbeltsets.Ifonlyonebeltofamatchedsetis replaced,thenewbeltwillcarrymoreload.Thisisduetothefactthattheolderbeltsarestretched. Theadditionalloadonthenewbeltcouldcausethenewbelttobreak.

Opentheenginecompartment.

AlternatorBelt

i01850022

1.Tocheckthebelttension,apply110N(25lb)offorcemidwaybetweenthepulleys.Correctly adjustedbeltswilldeflect14to20mm(1/2to3/4inch).

2.Inordertoadjustthealternatorbelt,loosenbracketbolt(1)andmountingbolt(2)onthe alternatorbracket.

3.Toachievethecorrectadjustment,movethealternatorinwardormovethealternatoroutward, asrequired.

4.Ifnecessary,useaprybarinsquarehole(3)inthealternatorbracket.

5.Tightenmountingbolt(2)andbracketbolt(1).

6.Ifnewbeltsareinstalled,checkthebeltandadjustmentagainafter30minutesofengine operationattheratedspeed.

7.Checkthepositionofthefanshroud.Adjustthepositionofthefanshroudsothatthefanwill notrubagainsttheshroud.Maintaina9.4mm(0.38inch)clearancebetweenthefanandthe shroud.

AirConditionerBelt(IfEquipped)

1.Stoptheengineinordertoinspecttheairconditionerbelt.

2.Inspecttheconditionoftheairconditionerbeltandtheadjustmentoftheairconditionerbelt. Theairconditionerbeltshoulddeflect14to20mm(0.55to0.79inch)under110N(25lb)of force.

Illustration3g00763247

3.Loosencompressorbracketmountingbolt(1).Loosenadjustinglocknut(2).

4.Movethecompressoruntilthecorrectbelttensionisreached.

5.Movethecompressoruntilthecorrectbelttensionisreached.Tightenadjustinglocknut(2). Tightencompressorbracketmountingbolt(1).

6.Recheckthebeltdeflection.Iftheamountofdeflectionisincorrect,repeatStep3toStep5.

7.Starttheengine.Ifpoorcoolingisstillexperienced,turnofftheairconditioner.Stopthe engine.NotifyyourCaterpillardealerforairconditionersystemservice.

Product:VIBRATORYCOMPACTOR

Model:CP-663EVIBRATORYCOMPACTORDAF

Configuration:CS-663ECP-663EVibratoryCompactorDAF00001-UP(MACHINE)POWEREDBY3056EEngine

OperationandMaintenanceManual

CS-563E,CP-563E,CS-573E,CP-573E,CS-583E,CP-583E,CS-663E,CP-663EandCS683EVibratorySoilCompactors

MediaNumber-KEBU7513-14PublicationDate-01/08/2011DateUpdated-12/04/2019

CabAirFilter-Clean/Replace

SMCS-7311-070;7311-510-FI;7311-040;7311-070-FI;7342-510-FI;7342-510;7342-070-FI; 7342-070;7521

Thecabairfilterislocatedtotheleftoftheseat.

Illustration1g00645572

1.Removetwohandknobs(1).

2.Toremovetheairfilters,pullupwardonhandle(2).

Illustration2g00645580

3.Cleanairfilters(3)withamaximumof200kPa(30psi).

4.Afteryoucleantheairfilters,inspecttheairfilters.Iftheairfiltersaredamagedorbadly contaminated,usenewairfilters.

5.Installthefiltersinthereverseorderoftheabovesteps.

FriDec102:22:38UTC+05302023

Product:VIBRATORYCOMPACTOR

Model:CP-663EVIBRATORYCOMPACTORDAF

Configuration:CS-663ECP-663EVibratoryCompactorDAF00001-UP(MACHINE)POWEREDBY3056EEngine

OperationandMaintenanceManual

CS-563E,CP-563E,CS-573E,CP-573E,CS-583E,CP-583E,CS-663E,CP-663EandCS683EVibratorySoilCompactors

MediaNumber-KEBU7513-14PublicationDate-01/08/2011DateUpdated-12/04/2019

Capacities(Refill)

SMCS-1000;6320;7000;7560

(1)Add0.5L(0.5qt)of197-0017AxleandBrakeOilAdditivewhenyouchangetheoilintheaxlecenterhousing. (2)Therearetwofinaldriveplanetariesfortheaxle.Thecapacityshownisforonedrive. (3)Therearetwoeccentricweighthousings.Thecapacityshownisforonehousing.

(4)Thedrumcoolingoilisforcoolingpurposesonly.Themaintenanceintervaldoesnotrequirethedrumcoolingoilto bechanged. Table2

(1)Add0.5L(0.5qt)of197-0017AxleandBrakeOilAdditivewhenyouchangetheoilintheaxlecenterhousing.

(2)Therearetwofinaldriveplanetariesfortheaxle.Thecapacityshownisforonedrive.

(3)Therearetwoeccentricweighthousings.Thecapacityshownisforonehousing.

(4)Thedrumcoolingoilisforcoolingpurposesonly.Themaintenanceintervaldoesnotrequirethedrumcoolingoilto bechanged.

FriDec102:17:26UTC+05302023

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