CP/CS-323 VIBRATORY COMPACTORS VEHICLE SYSTEMS Caterpillar

Drum Motor

Usage:

Remove & Install Drum Motor

Start By:

a. remove drum

1. Position the drum vertically.

2. Remove eight bolts (1).

3. Install tooling (A) on motor mount (2). Attach a hoist and lift the drum drive motor out of the drum. The weight of the motor is 1100 kg (500 lb).

NOTE: Install in reverse order.

End By:

a. install drum

Disassemble Drum Motor

Start By;

a. remove drum

b. remove drum drive motor

1. Set the motor on blocks as shown. Remove the motor mount from the motor.

2. Using tooling (B) and a hoist, turn the motor over on the blocks. Using tooling (A), remove the drive and seal weldement.

3. Set the motor on end cap (20) with crankshaft (6) up.

NOTE: Inspect the keyway for burrs or sharp edges. Remove burrs or sharp edges to prevent damage to the shaft seal when the front cover is removed.

4. Grind off the lock and remove three bolts (9), end plate (10) and key (38).

NOTE: If jack screw hole threads are are stripped, the motor can not be disassembled.

5. Run a bottoming tap into the jack screw holes in front cover (2) and use clean shop air to clean the holes out.

6. Remove front cover cap screws (1).

7. Turn two socket cap screws into the jack holes in the front cover until they bottom out. Alternately turn the cap screws in about one half turn at a time so the front cover comes up evenly.

8. Carefully remove front cover (2) so seal (7) and the shims [called out as (3), (4), (5) and (6) are not damaged.

9. Inspect O-ring seal (7). Replace if required.

10. Using tooling (F) and a press, remove shaft seal (39).

11. Remove top rod retaining ring (30) and lift connecting rods (28) from the bottom retaining ring and push the connecting rods up into the cylinder bores.

12. Remove crankshaft assembly (9) from the motor. The weight of the crankshaft is 23 kg (50 lb).

13. Remove bottom retaining rings (30).

NOTE: Remove the bearings only if necessary. If the bearings are replaced, the bearing cups must also be replaced.

14. If the bearings are not damaged, do not perform Step 15, proceed to Step 16. If necessary, remove bearings (8) and (16) with tooling (C).

15. Using tooling (D), remove the rear bearing cup from the motor case. Remove the front bearing cup from the front cover.

16. Remove each of the piston-connecting rod assemblies by pulling them back into the crankcase and lifting them out.

NOTE: Mark the piston-connecting rod assemblies as to their original location for assembly purposes. Keep the piston with the original connecting rod.

17. Remove snap ring (29) with tool (E) and separate piston (31) from connecting rod (28). Using a screwdriver exactly fitting the slot in the restrictor screw, remove restrictor screw (26) from the connecting rod. Repeat for each of the piston-connecting rod assemblies.

18. Remove Oldham's coupling (13) from the end of valve spool (18) by wedging a round file in the end of the valve spool, lifting the spool until it can be grasped by hand and lifted out. If the valve spool can not be removed in this manner, end cap (21) will need to be removed and the spool will have to be tapped out.

NOTE: Normally further disassembly is not required unless the cylinder heads are leaking or the valve housing bore is scored. If the valve housing bore is scored, the motor case must be replaced. For cylinder head disassembly, perform Steps 19 & 20.

19. If the cylinder heads are leaking, remove bolts (32) and cylinder head (33).

20. Remove back-up ring (34) and O-ring seal (35). Inspect for wear or damage and replace as required.

Assemble Drum Motor

NOTE: Check all seals for wear or damage. Replace as required.

1. If bearings (7) and (16) were removed, install new bearings using a press.

2. If the cylinder heads were not removed, proceed to Step 7.

3. Place the motor on wooden blocks.

4. Remove restrictor screw (27). If there is a filter, remove and discard the filter. Filters are no longer necessary.

5. Install restrictor screw (27) with Loctite.

6. Install O-ring seal (35), backup ring (34) and cylinder head (33) with bolts (32). Tighten the bolts to a torque of 74 N·m (55 lb ft).

7. Install valve rings (19) on valve spool (18) with the ring gaps 180° apart. Install valve spool (18) into the bore.

8. Install O-ring seal (20). Install end cap (21) with bolts (22).

9. Both the end of valve spool (18) and crankshaft (12) are stamped with the letters TDC and an arrow pointing up. Mark the case at the spot where the arrow on the valve spool points up.

10. Attach connecting rods (28) to pistons (31) with snap rings (29) using tool (B).

11. Install the piston assemblies into the cylinder bores. The piston assemblies should slip in easily without using force.

12. Drop in bottom retaining rings (30) and lift the two connecting rods nearest the mark on the crankcase over the retaining rings and push the pistons into the bores.

13. Center coupling (13) in the slot in valve spool (18).

14. Turn crankshaft (12) so it is Top Dead Center (TDC) and the arrow point is towards the mark on the motor case and install it into the motor.

15. Slowly rotate shaft (12) back and forth until it engages in coupling (13). Lift the other three connecting rods (28) over bottom retaining rings (30) and drop on top ring (30). Rotate the shaft. It should turn freely.

NOTE: If the crankshaft, motor case or the bearings have been replaced, re-shimming of the motor will be necessary. If re-shimming is not required, proceed to Step 17.

16. Motors are shimmed so the preload is 0.05 to 0.10 mm (0.002 to 0.004 in). Shims are removed to reduce end play and added to increase the end play. To determine the end play:

a. Remove all of the shims.

b. Bolt down the front cover.

c. Using a feeler gauge, measure the gape between the plate and the motor case.

d. Add or remove shims until the end play is within specs.

17. Using a press and a ring that is slightly smaller than the shaft seal, install a new shaft seal (39) in cover plate (2) so the open end of the seal faces in.

18. Make sure the surfaces of cover (2) and the motor case are smooth and free of dirt and debris. Check to make sure the shims are smooth and not damaged. Install shims (3) on front cover (2).

19. Install O-ring seal (7) firmly against the shims.

20. Install two cap screws (1) equal distance into two of the tapped holes in front cover (2).

NOTE: Take care when installing cover (2) not to damage the splines on the crankshaft.

21. Install cover (2) onto the motor taking care not to damage the shaft seal. Tap the cover with a soft mallet to start the cover into the housing.

22. Remove the bolts from the tapped holes. Install all cap screws (1) by hand. Tighten them in a cross pattern to pull cover (2) down evenly.

23. Turn the shaft by hand. If the shaft won't turn, shims will need to be added.

24. Tighten cap screws (1) to 74 N·m (55 lb ft).

25. Make sure the keyway is free of debris, burrs or sharp edges.

26. Install key (38) and end plate (10) with three bolts (9).