PSP FOR INSTALLING A NEW BREATHER AND HOSES TO REDUCE OIL LEAKAGE ON CERTAIN CP-563 AND CS-563 COMPACTORS - PS4562 - MAI LED US AND CANADA, CACO, CFEL, COSA, LIMITED COFA - REVISED 03/92 Caterpillar

March 13, 1991
(Revised March 1992)
U-43
A-34
AU-29.1
E-33
O-37
PRODUCT SUPPORT PROGRAM FOR INSTALLING A NEW BREATHER AND HOSES TO REDUCE OIL
LEAKAGE ON CERTAIN CP-563 AND CS-563 COMPACTORS
5057   PS4562
NOTE: This Program can be administered either before or after a
failure. In either case the decision whether to apply the Program
is made by the dealer. When reporting the repair, use "PS4562"
as Part Number, "7755" as Group Number, and "96" as Description
Code.
NOTE: This Revised Service Letter replaces the March 13, 1991 Service
Letter. A change was made to the Termination Date.

June 30, 1992

Hose movement and turbulence from the flexdrive coupling may cause oil
leakage around the breather or vibratory motor adapters on certain CP-563 and
CS-563 Compactors

Model Identification Number
CP-563 1YJ55-119
CS-563 8XF45-194

1 - 1G5239 Breather
2 - 3K0360 Seal
2 - 7M8485 Seal
220 - 9S0247 Hose (XT3) (quantity is in inches)
2 - 6V8398 Seal
4 - 6V9746 Seal
4 - 6V9969 Coupling Assembly

Install the new parts as described in the attached procedure.

Product Caterpillar Dealer Suggested Customer Suggested
smu/age Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
whichever (D/N) (Cost)  (C/L) (Sell)
comes
first
0-2000 100% 6 0 0 0 0
0-24 mo
2001-3000 33 1/3% 3 0 1.5 50% 1.5
25-36 mo
NOTE: This is a 6-hour job.

Handle the parts in accordance with your Warranty Bulletin on warranty parts
handling.
Attach. (1-Rework Procedure)
Rework Procedure
1. Fabricate 2-1G5240 Hoses to replace the two existing vibratory hoses.
Fabricate each of the hoses from 2-6V9969 Coupling Assemblies and 110
inches of 9S0247 Hydraulic Hose. See Illustration 2.
2. To allow for easier access to the vibratory motor hoses, remove the side
covers on the right hand side of the compactor.
If equipped with a platform, follow the procedure in the Disassembly and
Assembly section of the Service Manual (KENR1627) and raise the
platform.
If equipped with a cab, do the following:
A) Remove the two small bolts under the platform of the cab.
B) Remove the two small bolts from the cab floor that hold the cab to
the compactor frame.
C) Remove the two large bolts inside the cab behind the operator and
the two large bolts with spacers under the platform for the cab
pivot mount.
D) Install the two larger bolts into the center hole on the front side
of each cab frame pivot. Be sure to install the spacer between the
cab platform and frame to help keep the cab aligned when raising and
lowering.
E) Using the handle inside the cab, raise the cab by use of the pump
located on the right hand side of the compactor. After the cab is
raised, install the two bolts that were removed in Step A.
NOTE: See the Operation And Maintenance Manual, Form Number KEBU2858,
for additional information on raising and lowering the cab.
3. Remove the existing 7X9745 and 7X9746 Vibratory Motor Hoses. In order
to remove the hose fittings from the adapters in the vibratory cooling
block it may be necessary to remove the 984153 Charge Pressure Relief
Valve. Do not loosen the locking nut on the end of the valve as this
may affect the compactor's charge pressure setting. The hydrasorb
clamps and yoke plate will have to be loosened to aid in replacing the
hoses.
NOTE: Extra care should be taken to prevent contamination of the closed
loop hydraulic system. Lines, fittings and adapters should be
plugged and capped when they are exposed to the environment.
4. Prior to connecting the hoses to the vibratory motor, both 6V9182 Elbows
should be rotated 45 degrees from their current position. Install the
new hoses beginning with the one towards the inside of the compactor on
the vibratory cooling block. This line is routed to the bottom, "Port
A", of the 7X8133 Vibratory Motor. Install the outermost hose and route
it to the top, "Port B", of the 7X8133 Vibratory Motor. The two ports,
one on either side of the motor, are for case return and can be
interchanged. See Illustration 1 for hose and o-ring seal locations.
NOTE: Some compactors may have left the factory with the high and low
amplitude reversed. Having "Port B" in the upper position will
insure proper weight rotation and subsequently the correct
amplitude selection.
Proper weight rotation can be verified by measuring the vibratory
pressure at the high amplitude quick disconnect pressure tap at the
vibratory cooling manifold. Refer to page 26 of the Systems Operation
and Testing, KENR1588, Vibratory System for location identification.
With the vibratory in high amplitude, the relief valve setting should be
2500-4000 psi. If this is the reading observed at the outermost
pressure tap and the high amplitude is selected, then the amplitude and
rotation is correct. If the reading is approximately the same as the
charge pressure, then the motor will need to be reversed to have the "B"
port at the top.
5. Install the charge relief valve, hydrasorb clamps, and yoke plate.
6. Lower the cab or platform, and install the hardware at their original
locations.
7. Replace the 9X0761 Breather with the 1G5239 Breather. See Illustration
3.
8. Start the compactor and inspect for leaks.
****** IMAGE: SEBE4535.01001.001
CAPTION: Illustration 1 - Vibratory Motor And Hose Installation
****** IMAGE: SEBE4535.01001.002
CAPTION: Illustration 2 - Fabrication of 1G5240 Hose
****** IMAGE: SEBE4535.01001.003
CAPTION: Illustration 3 - 1G5239 Breather Installation