Description

Caterpillar CP-563E, CS-563E, CS-573E, CS-583E 2002 Service Manual

You are staring at a compactor that won’t vibrate. The bypass valve is suspect, the piston pump could be out of neutral, or maybe the charge relief valve just needs a tweak. Without the factory numbers, you are guessing — and guessing on a Caterpillar vibratory system costs you billable hours and parts that were fine. I have been in this trade long enough to know that when the drum stops compacting, the last thing you need is a generic diagram from some third-party website. This 72-page Caterpillar CP-563E, CS-563E, CS-573E, CS-583E 2002 Service Manual is the OEM document Caterpillar issued under publication KENR3606. It is not a reprint or a compilation. It came from the factory in December 2002, and it covers machines from serial numbers ASA1-Up, CEB1-Up, BWE1-Up, CNG1-Up, DAJ1-Up, CNN1-Up, CNT1-Up, and CNX1-Up. If your iron fits those prefixes, this is the only paper you should have on the bench.

Vibratory System Specifications – Pages 4 through 15

This section lays out the component groups you need to identify before you pull a wrench. The vibratory lines group, piston pump, support and vibratory drive, piston motor, bypass valve return manifold, vibratory support, drum group (smooth and padded), eccentric weight housing and shaft groups, vibratory gauge group, and the speed and vibratory module group. Each subsection includes the OEM part references and assembly notes. If you need to know which O-ring goes into the return manifold, or the correct clearance on the eccentric weight shaft, this is where you start. The manual expects you to have the machine in front of you and a clean work surface. I have seen too many guys skip the vibratory support section and then wonder why the bearings hum after reassembly. Do not be that guy.

Systems Operation: Hydraulic and Electrical Flow (Pages 16–42)

Page 16 kicks off with an introduction to the vibratory system, followed by features, system operation, location of electrical and hydraulic components, the vibratory electrical system, piston pump operation, support and vibratory drive, piston motor, bypass valve, and two schematics. The electrical schematic on page 41 and the hydraulic schematic on page 42 are the ones you will tab with sticky notes. When the magnetic sensor gives erratic readings or the tachometer stops displaying frequency, you trace back through those diagrams. Do not trust aftermarket schematics — they often swap wire colors or miss the ground path. Caterpillar’s engineers drew these, and they match the harness in your machine. If you are working on a CS-573E or CS-583E with a padded drum, pay attention to the drum group details on page 12 and the eccentric weight housing group on page 13. That area sees the most wear when the bypass valve sticks.

Testing and Adjusting: Real Procedures from Page 43

The troubleshooting visual inspection checklist on page 43 is the first thing I run through on any dead roller. From there, the manual takes you through vibratory system troubleshooting, machine preparation, hydraulic oil contamination test, charge relief valve test and adjust, piston pump neutral test and adjust, main relief valve test and adjust, hydraulic control neutral test, case drain flow for piston motor, vibratory frequency test and adjust, tachometer calibration, and magnetic sensor test and adjust. Each procedure includes the required pressure gauge ranges and the exact sequence for bleeding air from the charge circuit. For example, the piston pump neutral adjustment on page 50 requires a 0–4000 psi gauge and a 5/16-inch hex wrench. The frequency test on page 60 asks for a magnetic pickup and a multimeter capable of reading hertz. If you do not have those tools, do not start the procedure.

Why Factory Torque Specs Matter on Vibratory Compactors

Every bolted joint in the vibratory system has a specific torque value written in the manual. I have seen a CP-563E lose its eccentric weight because a mechanic used a generic torque chart from a tool truck poster. That repair cost the shop three days of downtime and a new housing. The manual does not list generic ranges; it gives the value for each fastener on the piston pump, motor mounting bolts, and the vibratory support. If the spec says 95 lb-ft, you do not stop at 90. You also do not add thread locker unless the procedure calls for it. This is the difference between a compactor that runs for 5000 hours and one that comes back at 500. For the price of this manual, you buy insurance against that phone call.

Audience: Who Needs This Manual

If you operate a single CS-563E in a rental fleet or maintain a fleet of Caterpillar rollers for a paving contractor, you need this. It is also for the independent mechanic who gets called out to a jobsite where the drum pulses instead of vibrating. The manual assumes you have basic hydraulic knowledge — pressure gauges, flow meters, and a willingness to follow a procedure in order. It is not a training manual for people who have never seen a piston pump. If you are new to compactors, pair this with a Manual Transmission understanding of basic hydraulic circuits, then come back to the vibratory system. The step order matters: you test charge pressure before you touch the main relief valve, and you set pump neutral before you check motor case drain. Beginners who skip to the frequency adjustment end up chasing symptoms instead of causes.

Source Validity: OEM Print vs Aftermarket Copies

This file is a direct scan of the original Caterpillar publication KENR3606, dated December 2002. It is not a recreated PDF with missing pages or blurred schematics. Every page from the table of contents through the index on page 69 is present. I have compared this against an aftermarket version that claimed to cover the CS-573E — that version had the wrong relief valve settings and omitted the magnetic sensor adjustment entirely. Stick with the factory document. The Caterpillar CP-563E CS-563E CS-573E CS-583E 2002 Service Manual is the same one you would get from the dealer catalog. No guesswork. No third-party translations.

Related Manuals for the Caterpillar Fleet

If you also work on the propulsion side, the Caterpillar CS-563E, 500E Technical Manual – OEM Specs for Propulsion & Vibratio covers the drive train and steering circuits. For shops that need tool numbers and special service tool part numbers, the Caterpillar C175, 3600, C8.7, C12.9 2016 Service Manual – Factory Tool Catalog lists the required pullers, adapters, and gauges. And for understanding how a Manual Transmission works in related equipment, the same principles apply to the piston motor speed control.

FAQ: Two Questions You Might Have

Does this manual cover the CS-573E model?

Yes. It covers CP-563E, CS-563E, CS-573E, and CS-583E.

What torque values are listed for the piston pump mounting bolts?

The manual provides specific torque values for every bolted joint in the piston pump and vibratory system. I am not going to type a number here because the correct value depends on which fastener you are turning — the pump-to-support bolts, the motor flange bolts, and the eccentric weight housing bolts all have different specs. Page 6 and the testing section refer to torques that must be applied in the correct sequence. Using a generic torque chart can distort the pump housing or cause gear misalignment. If you have the manual open to the piston pump section, you will see the exact ft-lb value and the tightening pattern. That is the only number you should follow. Generic manuals that claim to cover multiple models often round values up or down. This one does not.

72 pages. Factory spec. No extra fluff. Access the Factory Manual now and keep it on the tablet in the shop. Your vibratory system will thank you the next time the drum stops compacting.