TM 5-3895-379-23-2

*TM 5-3895-379-23-2
TECHNICAL MANUAL FIELD MAINTENANCE FOR
ROLLER, MOTORIZED, VIBRATING TANDEM STEEL DRUMS CATERPILLAR MODEL CB534B NSN 3895-01-396-2822 CATERPILLAR MODEL CB534C NSN 3895-01-502-4005
* SUPERSEDURE NOTICE - This manual supersedes TM 5-3895-379-23, dated 15 July 2005. DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.
HEADQUARTERS, DEPARTMENT OF THE ARMY 04 SEPTEMBER 2012

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TM 5-3895-379-23-2
WARNING SUMMARY
This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of this equipment. Failure to observe these precautions could result in serious injury or death to personnel. Also included are explanations of safety and hazardous materials icons used within the technical manual. FIRST AID DATA For information on first aid, refer to FM 4-25.11. EXPLANATION OF SAFETY WARNING ICONS
EAR PROTECTION - Headphones over ears shows that noise level will harm ears.
ELECTRICAL - Electrical wire to arm with electricity symbol running through human body shows that shock hazard is present.
FLYING PARTICLES - Arrows bouncing off face with face shield shows that particles flying through the air will harm face.
HEAVY PARTS - Hand with heavy object on top shows that heavy parts can crush and harm.
HEAVY PARTS - Heavy object on human figure shows that heavy parts present a danger to life or limb.
HELMET PROTECTION - Arrow bouncing off head with helmet shows that falling parts present a danger.
HOT AREA - Hand over object radiating heat shows that part is hot and can burn.
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WARNING SUMMARY - Continued

EXPLANATION OF SAFETY WARNING ICONS - Continued
SLICK FLOOR - Wavy line on floor with legs prone shows that slick floor presents a danger for falling.
GENERAL SAFETY WARNINGS DESCRIPTION
WARNING
COMPRESSED AIR Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air against human skin. Failure to follow this warning may causes injury or death. Make sure air stream is directed away from user and other personnel in the area. To prevent injury, user must wear protective goggles or face shield.
WARNING
ELECTRICAL SYSTEM MAINTENANCE Turn battery disconnect switch to OFF before working on any electrical system component. Failure to follow this warning could result in personal injury or damage to equipment.
WARNING
HEARING PROTECTION Your hearing can be PERMANENTLY DAMAGED if you are exposed to constant high noise levels of 85 dB or greater. Hearing protection is required when operating machine or when working on machine while it is operating. Failure to wear hearing protection may cause hearing loss.
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GENERAL SAFETY WARNINGS DESCRIPTION - Continued
WARNING
HOT COMPONENTS Hot oil or metal parts can cause severe burns. Wear insulated gloves, long sleeves and eye protection when working with heated parts.
WARNING
HYDRAULIC SYSTEM PRESSURE DO NOT remove hydraulic tank filler cap or disconnect or remove hydraulic system line or fitting unless hydraulic system pressure has been relieved. Hydraulic system pressure can be over 2,500 psi (17,237 kPa), even with engine and pump OFF. To relieve pressure, lower all hydraulic attachments to loosen hydraulic tank filler cap. After maintenance, tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing injury or death. At operating temperature hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulics. Failure to do so could result in injury.
WARNING
MACHINE OPERATION This machine must be operated only by authorized personnel who have satisfactorily completed a program of training which must include familiarity with safe operating procedures, characteristics and knowledge of applicable codes, regulations and facilities directives. Untrained personnel subject themselves and others to the possibility of death or injury from the improper operation of this machine. Understand the equipment, its functions, and controls before operation.
TM 5-3895-379-23-2

WARNING
PRESSURIZED COOLING SYSTEM DO NOT service cooling system unless engine has been allowed to cool down. This is a pressurized cooling system and escaping steam or hot coolant may cause serious burns. DO NOT remove radiator cap when engine is hot. Allow engine to cool down. Loosen cap to first stop and let any pressure out of cooling system, then remove cap. Failure to follow this warning may cause serious burns. Wear effective eye, glove, and skin protection when handling coolants. Failure to do this may cause injury.
WARNING
LIFTING HEAVY PARTS Lifting equipment used for lifting machine must be in good condition and of suitable load capacity. Failure to follow this warning may cause injury or death, or damage to equipment. Improper use of lifting equipment and improper attachment to machine can result in injury, or equipment damage. Observe all standard rules of safety. Use caution when handling heavy parts. Provide adequate support and assistance during procedure. Ensure that any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may cause injury or death.
WARNING
PROTECTIVE HEAD GEAR Operators and maintainers must wear protective head gear. Failure of operators and maintainers to wear protective head gear may result in serious injury or death.
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WARNING
OPERATION AND MAINTENANCE Do not operate or maintain this machine unless you have read and understand the instructions and warnings in the operation and maintenance sections of this manual. Failure to follow the instructions or heed the warnings could result in injury or death. EXPLANATION OF HAZARDOUS MATERIALS ICONS
BIOLOGICAL - Abstract symbol bug shows that a material may contain bacteria or viruses that present a danger to life or health.
CHEMICAL - Drops of liquid on hand shows that the material will cause burns or irritation to human skin or tissue.
EYE PROTECTION - Person with goggles shows that the material will injure the eyes.
FIRE - Flame shows that a material may ignite and cause burns.
RADIATION - Three circular wedges shows that the material emits radioactive energy and can injure human tissue.
VAPOR - Human figure in a cloud shows that material vapors present a danger to life or health.
TM 5-3895-379-23-2

HAZARDOUS MATERIALS DESCRIPTIONS
WARNING
BATTERIES To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. Do not smoke, use open flame, make sparks, or create other ignition sources around batteries. If a battery is giving off gases, it can explode and cause injury to personnel. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts battery terminal, a direct short will result in instant heating, damage to equipment, and injury. Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makes contact with skin, eyes, or clothing, take immediate action to stop corrosive burning effects. Failure to follow these procedures may cause injury or death. Eyes. Flush with cold water for no less than 15 minutes and seek medical attention immediately. Skin. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required. Internal. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Seek medical attention immediately. Clothing/Equipment. Wash area with large amounts of cold water. Neutralize acid with baking soda or household ammonia.
TM 5-3895-379-23-2

HAZARDOUS MATERIALS DESCRIPTIONS - Continued
WARNING
CARBON MONOXIDE (EXHAUST GAS) CAN KILL! Carbon monoxide is a colorless, odorless, DEADLY POISONOUS gas and when breathed deprives body of oxygen and causes SUFFOCATION. Breathing air with carbon monoxide produces symptoms of headache, dizziness, loss of muscular control, a sleepy feeling, and coma. Permanent BRAIN DAMAGE or DEATH can result from severe exposure. Carbon monoxide occurs in exhaust fumes of internal combustion engines. Carbon monoxide can become dangerously concentrated under condition of inadequate ventilation. The following precautions must be observed to ensure safety of personnel when engine of roller is operated: DO NOT operate roller engine in enclosed areas. DO NOT idle roller engine without adequate ventilation. DO NOT drive roller with inspection plates or cover plates removed. BE ALERT for exhaust poisoning symptoms. They are: Headache. Dizziness. Sleepiness. Loss of muscular control.
If you see another person with exhaust poisoning symptoms: Remove person from area. Expose to fresh air. Keep person warm. Do not permit physical exercise. Administer cardiopulmonary resuscitation (CPR), if necessary. Notify a medic.
BE AWARE. The field protective mask for Nuclear-Biological-Chemical (NBC) protection will not protect you from carbon monoxide poisoning. The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation!
TM 5-3895-379-23-2

WARNING
DRY CLEANING SOLVENT Cleaning compound, solvent MIL-PRF-680 Type III is an environmentally compliant and low toxic material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. NOTE: P-D-680 Type II is no longer in use and has been replaced by MIL-PRF-680 Type III.
WARNING
ETHER COLD START SYSTEM Ether fuel is extremely flammable and toxic. DO NOT smoke and make sure you are in a well-ventilated area away from heat, open flames, or sparks. Wear eye protection. Avoid contact with skin and eyes and avoid breathing ether fumes. If fluid enters or fumes irritate the eyes, wash immediately with large quantities of clean water for 15 minutes. Seek medical attention immediately if ether is inhaled or causes eye irritation. Failure to follow this warning may cause injury or death.
WARNING
EYE PROTECTION Eye protection must be worn when performing maintenance where components or particles could fly out during procedure. Failure to take precautions could cause injury to personnel. Some components are under spring tension. Wear eye protection and use caution when disassembling them, to avoid injury.
TM 5-3895-379-23-2

WARNING
FUEL HANDLING DO NOT smoke or permit any open flame in area of machine while you are servicing diesel fuel system. Be sure hose nozzle is grounded against filler tube during refueling to prevent static electricity. Failure to follow this warning may cause injury to personnel, or equipment damage. DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing damage to machine and injury or death to personnel. Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing.
WARNING
HAZARDOUS WASTE DISPOSAL When servicing this machine, performing maintenance, or disposing of materials such as engine coolant, hydraulic fluid, lubricants, battery acids or batteries, and CARC paint, consult your unit/local hazardous waste disposal center or safety office for local regulatory guidance. If further information is needed, please contact The Army Environmental Hotline at 1-800-872-3845.
WARNING
NBC EXPOSURE If NBC exposure is suspect, personnel wearing protective equipment should handle all air cleaner media. Consult your NBC Officer or NBC NCO for appropriate handling or disposal procedures. NBC contaminated filters must be handled using adequate precautions (FM-21-40) and must be disposed of by trained personnel.
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LIST OF EFFECTIVE PAGES/WORK PACKAGES

NOTE: This publication supersedes TM 5-3895-379-23 dated 15 July 2005. Zero in the Change No. column indicates an original page or work package. Date of issue for the original manual is: Original 04 September 2012
TOTAL NUMBER OF VOLUMES IS 2, TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 168 AND TOTAL NUMBER OF WORK PACKAGES IS 291 CONSISTING OF THE FOLLOWING: Page/WP No. VOLUME 2 Front Cover (2 pages) a -i/j blank (10 pages) i - xxiii/xxiv blank (24 pages) Chapter 5 Title Page (2 pages) WP 0222 (14 pages) WP 0223 (6 pages) WP 0224 (8 pages) WP 0225 (6 pages) WP 0226 (4 pages) WP 0227 (8 pages) WP 0228 (12 pages) WP 0229 (4 pages) WP 0230 (4 pages) WP 0231 (10 pages) WP 0232 (4 pages) WP 0233 (4 pages) WP 0234 (6 pages) WP 0235 (8 pages) WP 0236 (14 pages) WP 0237 (2 pages) WP 0238 (2 pages) WP 0239 (2 pages) WP 0240 (6 pages) WP 0241 (2 pages) WP 0242 (6 pages) WP 0243 (2 pages) WP 0244 (22 pages) WP 0245 (2 pages) WP 0246 (2 pages) WP 0247 (6 pages) WP 0248 (2 pages) WP 0249 (4 pages) WP 0250 (6 pages) WP 0251 (4 pages) WP 0252 (6 pages) WP 0253 (4 pages) WP 0254 (6 pages) WP 0255 (4 pages) WP 0256 (4 pages) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Page/WP No. WP 0257 (4 pages) WP 0258 (6 pages) WP 0259 (6 pages) WP 0260 (10 pages) WP 0261 (6 pages) WP 0262 (4 pages) WP 0263 (8 pages) WP 0264 (22 pages) WP 0265 (16 pages) WP 0266 (4 pages) WP 0267 (10 pages) WP 0268 (4 pages) WP 0269 (10 pages) WP 0270 (6 pages) WP 0271 (4 pages) WP 0272 (8 pages) WP 0273 (6 pages) WP 0274 (6 pages) WP 0275 (4 pages) WP 0276 (4 pages) WP 0277 (8 pages) WP 0278 (6 pages) WP 0279 (8 pages) WP 0280 (8 pages) WP 0281 (6 pages) WP 0282 (2 pages) WP 0283 (30 pages) WP 0284 (38 pages) Chapter 6 Title Page (2 pages) WP 0285 (2 pages) WP 0286 (4 pages) WP 0287 (22 pages) WP 0288 (8 pages) WP 0289 (4 pages) WP 0290 (8 pages) WP 0291 (12 pages) Index-1 - Index-8 (8 pages) Inside Back Cover Back Cover Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
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*TM 5-3895-379-23-2
HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON, D.C., 04 SEPTEMBER 2012 TECHNICAL MANUAL FIELD MAINTENANCE FOR
ROLLER MOTORIZED, VIBRATING TANDEM STEEL DRUMS CATERPILLAR MODEL CB534B NSN 3895-01-396-2822 CATERPILLAR MODEL CB534C NSN 3895-01-502-4005
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication. If you find any errors, or if you would like to recommend any improvements to the procedures in this publication, please let us know. The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet on the TACOM Unique Logistics Support Applications (TULSA) Web site. The Internet address is https://tulsa.tacom.army.mil. Access to all applications requires CAC authentication, and you must complete the Access Request form the first time you use it. The DA Form 2028 is located under the TULSA Applications on the left-hand navigation bar. Fill out the form and click on SUBMIT. Using this form on the TULSA Web site will enable us to respond more quickly to your comments and to better manage the DA Form 2028 program. You may also mail, e-mail, or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP/ TECH PUBS, MS 727, 6501 E. 11 Mile Road, Warren, MI 48397-5000. The e-mail address is tacomlcmc.daform2028@us.army.mil. The fax number is DSN 786-1856 or Commercial (586) 282-1856. A reply will be furnished to you.
*SUPERSEDURE NOTICE - This manual supersedes TM 5-3895-379-23, dated 15 July 2005. DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.
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TABLE OF CONTENTS
Page No. WP Sequence No. Volume 2 Chapter 5 - MAINTENANCE INSTRUCTIONS FOR CB534B or CB534C ROLLER, MOTORIZED, VIBRATING TANDEM STEEL DRUMS NSN 3895-01-396-2822 AND 3895-01-502-4005 STEERING CONTROL UNIT (SCU) MAINTENANCE................................................................................ WP 0222 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Steering Control Unit (SCU) Removal.................................................................................. 0222-2 Steering Control Unit (SCU) Removal.................................................................................. 0222-4 Steering Control Unit (SCU) Disassembly............................................................................ 0222-4 Steering Control Unit (SCU) Disassembly............................................................................ 0222-5 Steering Control Unit (SCU) Disassembly............................................................................ 0222-5 Steering Control Unit (SCU) Disassembly............................................................................ 0222-6 Steering Control Unit (SCU) Disassembly............................................................................ 0222-6 Steering Control Unit (SCU) Disassembly............................................................................ 0222-7 Steering Control Unit (SCU) Disassembly............................................................................ 0222-7 Steering Control Unit (SCU) Assembly................................................................................ 0222-8 Steering Control Unit (SCU) Assembly................................................................................ 0222-9 Steering Control Unit (SCU) Assembly................................................................................ 0222-9 Steering Control Unit (SCU) Assembly.............................................................................. 0222-10 Steering Control Unit (SCU) Assembly.............................................................................. 0222-11 Steering Control Unit (SCU) Assembly.............................................................................. 0222-11 Steering Control Unit (SCU) Assembly.............................................................................. 0222-12 Steering Control Unit (SCU) Installation............................................................................. 0222-13 Steering Control Unit (SCU) Installation............................................................................. 0222-13
POWER STEERING PUMP REPLACEMENT............................................................................................. WP 0223 Figure 1. Figure 2. Figure 3. Figure 4. Power Steering Pump Removal........................................................................................... 0223-1 Power Steering Pump Removal........................................................................................... 0223-2 Power Steering Pump Removal........................................................................................... 0223-2 Power Steering Pump Removal........................................................................................... 0223-3
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TABLE OF CONTENTS - Continued

Page No. WP Sequence No. Figure 5. Figure 6. Figure 7. Power Steering Pump Installation........................................................................................ 0223-3 Power Steering Pump Installation........................................................................................ 0223-4 Power Steering Pump Installation........................................................................................ 0223-4
STEERING HOSES, LINES, AND FITTINGS REPLACEMENT.................................................................. WP 0224 Figure 1. Figure 2. Figure 3. Figure 4. Steering Hoses, Lines, and Fittings Removal...................................................................... 0224-3 Steering Hoses, Lines, and Fittings Removal...................................................................... 0224-4 Steering Hoses, Lines, and Fittings Installation................................................................... 0224-5 Steering Hoses, Lines, and Fittings Installation................................................................... 0224-6
HYDRAULIC STEERING CYLINDERS REPLACEMENT........................................................................... WP 0225 Figure 1. Figure 2. Figure 3. Figure 4. Hydraulic Steering Cylinders Removal................................................................................. 0225-2 Hydraulic Steering Cylinders Removal................................................................................. 0225-3 Hydraulic Steering Cylinders Installation.............................................................................. 0225-4 Hydraulic Steering Cylinders Installation.............................................................................. 0225-5
STEERING CYLINDER REPAIR................................................................................................................. WP 0226 Figure 1. Figure 2. Steering Cylinder Disassembly............................................................................................ 0226-2 Steering Cylinder Assembly................................................................................................. 0226-3
STEERING PIVOT REPLACEMENT........................................................................................................... WP 0227 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Steering Pivot Removal........................................................................................................ 0227-2 Steering Pivot Removal........................................................................................................ 0227-3 Steering Pivot Removal........................................................................................................ 0227-3 Steering Pivot Removal........................................................................................................ 0227-4 Steering Pivot Removal........................................................................................................ 0227-5 Steering Pivot Installation..................................................................................................... 0227-6 Steering Pivot Installation..................................................................................................... 0227-7 Steering Pivot Installation..................................................................................................... 0227-7 Steering Pivot Installation..................................................................................................... 0227-8
YOKE REPLACEMENT............................................................................................................................... WP 0228
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Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Yoke Removal...................................................................................................................... 0228-1 Yoke Removal...................................................................................................................... 0228-2 Yoke Removal...................................................................................................................... 0228-3 Yoke Removal...................................................................................................................... 0228-3 Yoke Removal...................................................................................................................... 0228-4 Yoke Installation................................................................................................................... 0228-4 Yoke Installation................................................................................................................... 0228-5 Yoke Installation................................................................................................................... 0228-6 Yoke Installation................................................................................................................... 0228-7 Yoke Installation................................................................................................................... 0228-7 Vertical Steer Pivot Clearance Check.................................................................................. 0228-8 Vertical Steer Pivot Clearance Check.................................................................................. 0228-9 Horizontal Steer Pivot Clearance Check............................................................................ 0228-10 Oscillation Bearing Clearance Check................................................................................. 0228-11
FRONT AND REAR SUPPORTS (BUMPERS) REPLACEMENT............................................................... WP 0229 Figure 1. Figure 2. Front and Rear Support (Bumpers) Removal....................................................................... 0229-2 Front and Rear Support (Bumpers) Installation.................................................................... 0229-3
DECONTAMINATION KIT BRACKET REPLACEMENT............................................................................. WP 0230 Figure 1. Figure 2. Decontamination Kit Bracket Removal................................................................................. 0230-2 Decontamination Kit Bracket Installation.............................................................................. 0230-3
DOOR ASSEMBLY MAINTENANCE........................................................................................................... WP 0231 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Door Assembly Removal...................................................................................................... 0231-2 Door Assembly Removal...................................................................................................... 0231-3 Door Assembly Disassembly................................................................................................ 0231-4 Door Assembly Disassembly................................................................................................ 0231-5 Door Assembly Disassembly................................................................................................ 0231-5 Door Assembly..................................................................................................................... 0231-6
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Page No. WP Sequence No. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Door Assembly..................................................................................................................... 0231-6 Door Assembly..................................................................................................................... 0231-7 Door Assembly Installation................................................................................................... 0231-8 Door Assembly Installation................................................................................................... 0231-9 Door Assembly Installation................................................................................................... 0231-9
LEFT AND RIGHT-SIDE HANDRAIL ASSEMBLIES REPLACEMENT....................................................... WP 0232 Figure 1. Figure 2. Left and Right-side Handrail Assemblies Removal.............................................................. 0232-2 Left and Right-side Handrail Assemblies Installation........................................................... 0232-3
FRONT HANDRAIL ASSEMBLY REPLACEMENT..................................................................................... WP 0233 Figure 1. Figure 2. Front Handrail Assembly Removal....................................................................................... 0233-2 Front Handrail Assembly Installation.................................................................................... 0233-3
ROLLOVER PROTECTION STRUCTURE (ROPS) ASSEMBLY REPLACEMENT.................................... WP 0234 Figure 1. Figure 2. Figure 3. Figure 4. Rollover Protection Structure (ROPS) Assembly Removal.................................................. 0234-2 Rollover Protection Structure (ROPS) Assembly Removal.................................................. 0234-3 Rollover Protection Structure (ROPS) Assembly Installation............................................... 0234-4 Rollover Protection Structure (ROPS) Assembly Installation............................................... 0234-5
RAISE/LOWER OPERATOR PLATFORM ASSEMBLY.............................................................................. WP 0235 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Raise Operator Platform Assembly...................................................................................... 0235-2 Raise Operator Platform Assembly...................................................................................... 0235-3 Raise Operator Platform Assembly...................................................................................... 0235-5 Lower Operator Platform Assembly..................................................................................... 0235-6 Lower Operator Platform Assembly..................................................................................... 0235-7 Lower Operator Platform Assembly..................................................................................... 0235-7
OPERATOR PLATFORM AND OPERATOR STATION REPLACEMENT.................................................. WP 0236 Figure 1. Figure 2. Figure 3. Operator Platform and Operator Station Removal............................................................... 0236-2 Operator Platform and Operator Station Removal............................................................... 0236-3 Operator Platform and Operator Station Removal............................................................... 0236-3
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Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Operator Platform and Operator Station Removal............................................................... 0236-4 Operator Platform and Operator Station Removal............................................................... 0236-4 Operator Platform and Operator Station Removal............................................................... 0236-5 Operator Platform and Operator Station Removal............................................................... 0236-5 Operator Platform and Operator Station Removal............................................................... 0236-6 Operator Platform and Operator Station Removal............................................................... 0236-6 Operator Platform and Operator Station Removal............................................................... 0236-7 Operator Platform and Operator Station Removal............................................................... 0236-8 Operator Platform and Operator Station Installation............................................................ 0236-9 Operator Platform and Operator Station Installation............................................................ 0236-9 Operator Platform and Operator Station Installation.......................................................... 0236-10 Operator Platform and Operator Station Installation.......................................................... 0236-10 Operator Platform and Operator Station Installation.......................................................... 0236-11 Operator Platform and Operator Station Installation.......................................................... 0236-11 Operator Platform and Operator Station Installation.......................................................... 0236-12 Operator Platform and Operator Station Installation.......................................................... 0236-12 Operator Platform and Operator Station Installation.......................................................... 0236-13 Operator Platform and Operator Station Installation.......................................................... 0236-13
ROTATE LOCK REPLACEMENT................................................................................................................ WP 0237 Figure 1. Figure 2. Rotate Lock Removal........................................................................................................... 0237-1 Rotate Lock Installation........................................................................................................ 0237-2
OPERATOR PLATFORM MOUNT REPLACEMENT.................................................................................. WP 0238 Figure 1. Figure 2. Operator Platform Mount Removal....................................................................................... 0238-1 Operator Platform Mount Removal....................................................................................... 0238-2
VANDAL GUARD REPLACEMENT............................................................................................................. WP 0239 Figure 1. Figure 2. Vandal Guard Removal........................................................................................................ 0239-1 Vandal Guard Installation..................................................................................................... 0239-2
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Page No. WP Sequence No. SEAT BELT AND LANYARD REPLACEMENT........................................................................................... WP 0240 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Seat Belt and Lanyard Removal........................................................................................... 0240-2 Seat Belt and Lanyard Removal........................................................................................... 0240-3 Seat Belt and Lanyard Removal........................................................................................... 0240-3 Seat Belt and Lanyard Installation........................................................................................ 0240-4 Seat Belt and Lanyard Installation........................................................................................ 0240-5 Seat Belt and Lanyard Installation........................................................................................ 0240-5 Seat Belt and Lanyard Installation........................................................................................ 0240-6
SEAT ASSEMBLY REPLACEMENT........................................................................................................... WP 0241 Figure 1. Figure 2. Seat Assembly Removal...................................................................................................... 0241-1 Seat Assembly Installation................................................................................................... 0241-2
SEAT ASSEMBLY REPAIR......................................................................................................................... WP 0242 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Seat Assembly Disassembly................................................................................................ 0242-1 Seat Assembly Disassembly................................................................................................ 0242-2 Seat Assembly Disassembly................................................................................................ 0242-3 Seat Assembly Assembly..................................................................................................... 0242-3 Seat Assembly Assembly..................................................................................................... 0242-4 Seat Assembly Assembly..................................................................................................... 0242-5
SEAT SUSPENSION REPLACEMENT....................................................................................................... WP 0243 Figure 1. Figure 2. Seat Suspension Removal................................................................................................... 0243-1 Seat Suspension Installation................................................................................................ 0243-2
SEAT SUSPENSION REPAIR..................................................................................................................... WP 0244 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Seat Suspension Disassembly............................................................................................. 0244-1 Seat Suspension Disassembly............................................................................................. 0244-2 Seat Suspension Disassembly............................................................................................. 0244-3 Seat Suspension Disassembly............................................................................................. 0244-3 Seat Suspension Disassembly............................................................................................. 0244-4
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Page No. WP Sequence No. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Seat Suspension Disassembly............................................................................................. 0244-5 Seat Suspension Disassembly............................................................................................. 0244-5 Seat Suspension Disassembly............................................................................................. 0244-6 Seat Suspension Disassembly............................................................................................. 0244-7 Seat Suspension Disassembly............................................................................................. 0244-8 Seat Suspension Disassembly............................................................................................. 0244-9 Seat Suspension Disassembly............................................................................................. 0244-9 Seat Suspension Disassembly........................................................................................... 0244-10 Seat Suspension Assembly................................................................................................ 0244-10 Seat Suspension Assembly................................................................................................ 0244-11 Seat Suspension Assembly................................................................................................ 0244-12 Seat Suspension Assembly................................................................................................ 0244-12 Seat Suspension Assembly................................................................................................ 0244-13 Seat Suspension Assembly................................................................................................ 0244-14 Seat Suspension Assembly................................................................................................ 0244-14 Seat Suspension Assembly................................................................................................ 0244-15 Seat Suspension Assembly................................................................................................ 0244-16 Seat Suspension Assembly................................................................................................ 0244-17 Seat Suspension Assembly................................................................................................ 0244-18 Seat Suspension Assembly................................................................................................ 0244-19 Seat Suspension Assembly................................................................................................ 0244-19 Seat Suspension Assembly................................................................................................ 0244-20 Seat Suspension Assembly................................................................................................ 0244-20
TOOLBOX REPLACEMENT........................................................................................................................ WP 0245 Figure 1. Figure 2. Toolbox Removal................................................................................................................. 0245-1 Toolbox Installation.............................................................................................................. 0245-2
RIFLE MOUNTING BRACKET REPLACEMENT........................................................................................ WP 0246
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Page No. WP Sequence No. Figure 1. Figure 2. Rifle Mounting Bracket Removal.......................................................................................... 0246-1 Rifle Mounting Bracket Installation....................................................................................... 0246-2
ENGINE BLOCK HEATING ELEMENT REPLACEMENT........................................................................... WP 0247 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Engine Block Heating Element Removal.............................................................................. 0247-2 Engine Block Heating Element Removal.............................................................................. 0247-3 Engine Block Heating Element Removal.............................................................................. 0247-3 Engine Block Heating Element Installation........................................................................... 0247-4 Engine Block Heating Element Installation........................................................................... 0247-4 Engine Block Heating Element Installation........................................................................... 0247-5
VEHICLE CLASSIFICATION SIGN KIT REPLACEMENT........................................................................... WP 0248 Figure 1. Figure 2. Vehicle Classification Sign Kit Removal............................................................................... 0248-1 Vehicle Classification Sign Kit Installation............................................................................ 0248-2
DATA PLATE AND DECAL REPLACEMENT............................................................................................. WP 0249 Figure 1. Figure 2. Figure 3. Figure 4. Data Plate Removal............................................................................................................. 0249-2 Data Plate Installation.......................................................................................................... 0249-3 Decal Removal..................................................................................................................... 0249-3 Decal Installation.................................................................................................................. 0249-4
HYDRAULIC VIBRATORY TESTS.............................................................................................................. WP 0250 Figure 1. Figure 2. Figure 3. Hydraulic Vibratory Adjustment............................................................................................ 0250-2 Hydraulic Vibratory Adjustment............................................................................................ 0250-3 Hydraulic Vibratory Test....................................................................................................... 0250-4
VIBRATORY CONTROL SOLENOID REPLACEMENT.............................................................................. WP 0251 Figure 1. Figure 2. Vibratory Control Solenoid Removal.................................................................................... 0251-2 Vibratory Control Solenoid Installation................................................................................. 0251-3
VIBRATORY MOTOR REPLACEMENT...................................................................................................... WP 0252 Figure 1. Figure 2. Vibratory Motor Removal...................................................................................................... 0252-2 Vibratory Motor Removal...................................................................................................... 0252-3
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Page No. WP Sequence No. Figure 3. Figure 4. Vibratory Motor Installation................................................................................................... 0252-4 Vibratory Motor Installation................................................................................................... 0252-5
VIBRATORY COOLING/CONTROL VALVE REPAIR................................................................................. WP 0253 Figure 1. Figure 2. Figure 3. Figure 4. Vibratory Cooling/Control Valve Removal............................................................................ 0253-2 Vibratory Cooling/Control Valve Removal............................................................................ 0253-3 Vibratory Cooling/Control Valve Assembly........................................................................... 0253-3 Vibratory Cooling/Control Valve Assembly........................................................................... 0253-4
VIBRATORY COOLING/CONTROL VALVE REPLACEMENT................................................................... WP 0254 Figure 1. Figure 2. Vibratory Cooling/Control Valve Removal............................................................................ 0254-3 Vibratory Cooling/Control Valve Installation......................................................................... 0254-4
HYDRAULIC OIL SAMPLING VALVE REPLACEMENT............................................................................. WP 0255 Figure 1. Figure 2. Figure 3. Figure 4. Hydraulic Oil Sampling Valve Removal................................................................................ 0255-2 Hydraulic Oil Sampling Valve Removal................................................................................ 0255-3 Hydraulic Oil Sampling Valve Installation............................................................................. 0255-3 Hydraulic Oil Sampling Valve Installation............................................................................. 0255-4
HYDRAULIC OIL SAMPLING...................................................................................................................... WP 0256 Figure 1. Hydraulic Oil Sampling......................................................................................................... 0256-3
HYDRAULIC OIL FILTER REPLACEMENT................................................................................................ WP 0257 Figure 1. Figure 2. Hydraulic Oil Filter Removal................................................................................................. 0257-2 Hydraulic Oil Filter Installation.............................................................................................. 0257-3
HYDRAULIC FILTER ASSEMBLY REPLACEMENT.................................................................................. WP 0258 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Hydraulic Filter Assembly Removal...................................................................................... 0258-2 Hydraulic Filter Assembly Removal...................................................................................... 0258-3 Hydraulic Filter Assembly Removal...................................................................................... 0258-3 Hydraulic Filter Assembly Installation................................................................................... 0258-4 Hydraulic Filter Assembly Installation................................................................................... 0258-5 Hydraulic Filter Assembly Installation................................................................................... 0258-5
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Page No. WP Sequence No. HYDRAULIC HOSES, LINES, AND FITTINGS REPLACEMENT............................................................... WP 0259 Figure 1. Figure 2. Hydraulic Hoses, Lines, and Fittings Removal..................................................................... 0259-3 Hydraulic Hoses, Lines, and Fittings Installation.................................................................. 0259-5
HYDRAULIC OIL COOLER AND FAN SHROUD REPLACEMENT............................................................ WP 0260 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Hydraulic Oil Cooler and Fan Shroud Removal................................................................... 0260-2 Hydraulic Oil Cooler and Fan Shroud Removal................................................................... 0260-3 Hydraulic Oil Cooler and Fan Shroud Removal................................................................... 0260-3 Hydraulic Oil Cooler and Fan Shroud Removal................................................................... 0260-4 Hydraulic Oil Cooler and Fan Shroud Removal................................................................... 0260-5 Hydraulic Oil Cooler and Fan Shroud Removal................................................................... 0260-6 Hydraulic Oil Cooler and Fan Shroud Installation................................................................ 0260-6 Hydraulic Oil Cooler and Fan Shroud Installation................................................................ 0260-7 Hydraulic Oil Cooler and Fan Shroud Installation................................................................ 0260-8 Hydraulic Oil Cooler and Fan Shroud Installation................................................................ 0260-8 Hydraulic Oil Cooler and Fan Shroud Installation................................................................ 0260-9 Hydraulic Oil Cooler and Fan Shroud Installation.............................................................. 0260-10
HYDRAULIC OIL CAP ASSEMBLY MAINTENANCE................................................................................. WP 0261 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Hydraulic Oil Cap Assembly Removal.................................................................................. 0261-1 Hydraulic Oil Cap Disassembly............................................................................................ 0261-2 Hydraulic Oil Cap Assembly Cleaning and Inspection......................................................... 0261-3 Hydraulic Oil Cap Assembly Cleaning and Inspection......................................................... 0261-4 Hydraulic Oil Cap Assembly Installation............................................................................... 0261-5 Hydraulic Oil Cap Assembly................................................................................................. 0261-5
VIBRATORY BEARING RESERVOIR SERVICE........................................................................................ WP 0262 Figure 1. Figure 2. Figure 3. Vibratory Bearing Reservoir Drain........................................................................................ 0262-1 Vibratory Bearing Reservoir Drain........................................................................................ 0262-2 Vibratory Bearing Reservoir Fill............................................................................................ 0262-3
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Page No. WP Sequence No. DRUM SCRAPER REPLACEMENT............................................................................................................ WP 0263 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Drum Scraper Removal........................................................................................................ 0263-2 Drum Scraper Removal........................................................................................................ 0263-3 Drum Scraper Removal........................................................................................................ 0263-3 Drum Scraper Removal........................................................................................................ 0263-4 Drum Scraper Installation..................................................................................................... 0263-5 Drum Scraper Installation..................................................................................................... 0263-5 Drum Scraper Installation..................................................................................................... 0263-6 Drum Scraper Installation..................................................................................................... 0263-6 Drum Scraper Installation..................................................................................................... 0263-7 Drum Scraper Adjustment.................................................................................................... 0263-8
DRUM ASSEMBLY REPAIR....................................................................................................................... WP 0264 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Drum Disassembly............................................................................................................... 0264-3 Drum Disassembly............................................................................................................... 0264-5 Drum Disassembly............................................................................................................... 0264-6 Drum Eccentric Disassembly............................................................................................... 0264-7 Drum Eccentric Disassembly............................................................................................... 0264-9 Drum Eccentric Disassembly............................................................................................. 0264-11 Drum Eccentric Assembly.................................................................................................. 0264-13 Drum Eccentric Assembly.................................................................................................. 0264-15 Drum Assembly.................................................................................................................. 0264-17 Drum Assembly.................................................................................................................. 0264-19 Drum Assembly.................................................................................................................. 0264-20
DRUM ASSEMBLY REPLACEMENT.......................................................................................................... WP 0265 Figure 1. Figure 2. Figure 3. Drum Assembly Removal..................................................................................................... 0265-2 Drum Assembly Removal..................................................................................................... 0265-3 Drum Assembly Removal..................................................................................................... 0265-3
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Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Drum Assembly Removal..................................................................................................... 0265-4 Drum Assembly Removal..................................................................................................... 0265-5 Drum Assembly Removal..................................................................................................... 0265-6 Drum Assembly Removal..................................................................................................... 0265-7 Drum Assembly Removal..................................................................................................... 0265-9 Drum Assembly Installation................................................................................................ 0265-11 Drum Assembly Installation................................................................................................ 0265-11 Drum Assembly Installation................................................................................................ 0265-12 Drum Assembly Installation................................................................................................ 0265-13 Drum Assembly Installation................................................................................................ 0265-14 Drum Assembly Installation................................................................................................ 0265-14 Drum Assembly Installation................................................................................................ 0265-15 Drum Assembly Installation................................................................................................ 0265-16
RESILIENT DRUM MOUNTS REPLACEMENT.......................................................................................... WP 0266 Figure 1. Figure 2. Resilient Drum Mounts Removal.......................................................................................... 0266-2 Resilient Drum Mounts Installation....................................................................................... 0266-3
WATER SPRAY PIPE ASSEMBLY MAINTENANCE.................................................................................. WP 0267 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Water Spray Pipe Assembly Removal................................................................................. 0267-2 Water Spray Pipe Assembly Removal................................................................................. 0267-3 Water Spray Pipe Assembly Removal................................................................................. 0267-3 Water Spray Pipe Disassembly............................................................................................ 0267-4 Water Spray Pipe Assembly................................................................................................. 0267-5 Water Spray Pipe Assembly Installation.............................................................................. 0267-6 Water Spray Pipe Assembly Installation.............................................................................. 0267-6 Water Spray Pipe Assembly Installation.............................................................................. 0267-7 Water Spray Pipe Adjustment.............................................................................................. 0267-8 Water Spray Pipe Adjustment.............................................................................................. 0267-9
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Page No. WP Sequence No. WATER LEVEL GAUGE REPLACEMENT.................................................................................................. WP 0268 Figure 1. Figure 2. Water Level Gauge Removal............................................................................................... 0268-2 Water Level Gauge Installation............................................................................................ 0268-3
WATER TANK REPLACEMENT................................................................................................................. WP 0269 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Water Tank Removal............................................................................................................ 0269-2 Water Tank Removal............................................................................................................ 0269-3 Water Tank Removal............................................................................................................ 0269-4 Water Tank Removal............................................................................................................ 0269-5 Water Tank Removal............................................................................................................ 0269-5 Water Tank Installation......................................................................................................... 0269-6 Water Tank Installation......................................................................................................... 0269-6 Water Tank Installation......................................................................................................... 0269-7 Water Tank Installation......................................................................................................... 0269-8 Water Tank Installation......................................................................................................... 0269-9
WATER SPRAY PUMP REPLACEMENT................................................................................................... WP 0270 Figure 1. Figure 2. Figure 3. Figure 4. Water Spray Pump Removal................................................................................................ 0270-2 Water Spray Pump Removal................................................................................................ 0270-3 Water Spray Pump Installation............................................................................................. 0270-4 Water Spray Pump Installation............................................................................................. 0270-5
WATER SPRAY STRAINER ASSEMBLY REPAIR..................................................................................... WP 0271 Figure 1. Figure 2. Water Spray Strainer Removal............................................................................................. 0271-2 Water Spray Strainer Assembly........................................................................................... 0271-4
WATER SPRAY STRAINER ASSEMBLY REPLACEMENT....................................................................... WP 0272 Figure 1. Figure 2. Figure 3. Figure 4. Water Spray Strainer Removal............................................................................................. 0272-2 Water Spray Strainer Removal............................................................................................. 0272-3 Water Spray Strainer Disassembly...................................................................................... 0272-4 Water Spray Strainer Assembly........................................................................................... 0272-5
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Page No. WP Sequence No. Figure 5. Figure 6. Water Spray Strainer Installation.......................................................................................... 0272-6 Water Spray Strainer Installation.......................................................................................... 0272-7
WATER SPRAY TUBES AND FITTINGS REPLACEMENT........................................................................ WP 0273 Figure 1. Figure 2. Figure 3. Table 1. Figure 4. Water Spray Tubes and Fittings Replacement..................................................................... 0273-2 Water Spray Tubes and Fittings Replacement..................................................................... 0273-3 Water Spray Tubes and Fittings Replacement..................................................................... 0273-3 Water Lines.......................................................................................................................... 0273-4 Water Lines Replacement.................................................................................................... 0273-5
WATER SPRAY CHECK VALVE REPLACEMENT..................................................................................... WP 0274 Figure 1. Figure 2. Figure 3. Figure 4. Water Spray Check Valve Removal..................................................................................... 0274-2 Water Spray Check Valve Removal..................................................................................... 0274-3 Water Spray Check Valve Installation.................................................................................. 0274-4 Water Spray Check Valve Installation.................................................................................. 0274-5
WATER SPRAY SCREEN ASSEMBLY MAINTENANCE (CB534C).......................................................... WP 0275 Figure 1. Figure 2. Figure 3. Figure 4. Water Spray Screen Assembly Removal............................................................................. 0275-1 Water Spray Screen Assembly Removal............................................................................. 0275-2 Water Spray Screen Assembly Installation.......................................................................... 0275-3 Water Spray Screen Assembly Installation.......................................................................... 0275-4
WATER TANK STRAINER ASSEMBLY REPLACEMENT.......................................................................... WP 0276 Figure 1. Figure 2. Water Tank Strainer Assembly Removal............................................................................. 0276-2 Water Tank Strainer Assembly Installation.......................................................................... 0276-3
DRAIN COCK AND TEE REPLACEMENT.................................................................................................. WP 0277 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Drain Cock and Tee Removal.............................................................................................. 0277-2 Drain Cock and Tee Removal.............................................................................................. 0277-3 Drain Cock and Tee Removal.............................................................................................. 0277-3 Drain Cock and Tee Removal.............................................................................................. 0277-4 Drain Cock and Tee Installation........................................................................................... 0277-5
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Page No. WP Sequence No. Figure 6. Figure 7. Figure 8. Drain Cock and Tee Installation........................................................................................... 0277-6 Drain Cock and Tee Installation........................................................................................... 0277-6 Drain Cock and Tee Installation........................................................................................... 0277-7
SIDE DRAIN COCK AND VALVE REPLACEMENT.................................................................................... WP 0278 Figure 1. Figure 2. Figure 3. Figure 4. Side Drain Cock and Valve Removal................................................................................... 0278-2 Side Drain Cock and Valve Removal................................................................................... 0278-3 Side Drain Cock and Valve Installation................................................................................ 0278-4 Side Drain Cock and Valve Installation................................................................................ 0278-5
GENERAL MAINTENANCE INSTRUCTIONS............................................................................................. WP 0279 ELECTRICAL GENERAL MAINTENANCE INSTRUCTIONS..................................................................... WP 0280 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Electrical General Maintenance Instructions........................................................................ 0280-3 Electrical General Maintenance Instructions........................................................................ 0280-4 Electrical General Maintenance Instructions........................................................................ 0280-5 Electrical General Maintenance Instructions........................................................................ 0280-6 Electrical General Maintenance Instructions........................................................................ 0280-7
PREPARATION FOR STORAGE AND SHIPMENT.................................................................................... WP 0281 LUBRICATION INSTRUCTIONS................................................................................................................. WP 0282 ILLUSTRATED LIST OF MANUFACTURED ITEMS................................................................................... WP 0283 Table 1. Figure 1. Table 2. Table 3. Table 4. Table 5. Table 6. Table 7. Table 8. Manufactured Items Part Number Index.............................................................................. 0283-1 Battery Cable........................................................................................................................ 0283-2 Battery Cables and Components......................................................................................... 0283-2 Engine Wiring Harness......................................................................................................... 0283-3 Main Wiring Harness............................................................................................................ 0283-8 Front Wiring Harness......................................................................................................... 0283-20 Rear Wiring Harness.......................................................................................................... 0283-21 Harness Assembly............................................................................................................. 0283-22 Instrument Wiring Harness................................................................................................. 0283-23
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Page No. WP Sequence No. Table 9. Table 10. Table 11. Table 12. Water Spray Lines.............................................................................................................. 0283-28 Rear Harness Tubing......................................................................................................... 0283-29 Front Harness Tubing......................................................................................................... 0283-29 Edging Channel.................................................................................................................. 0283-29
GENERAL TORQUE LIMITS....................................................................................................................... WP 0284 Figure 1. Figure 2. Figure 3. Table 1. Figure 4. Table 2. Figure 5. Figure 6. Figure 7. Table 3. Figure 8. Table 4. Figure 9. Table 5. Figure 10. Figure 11. Figure 12. Figure 13. Table 6. Figure 14. Table 7. Table 8. Bolt and Thread Gage.......................................................................................................... 0284-1 Thread Pitch Gage............................................................................................................... 0284-2 Torque Correction Formula.................................................................................................. 0284-3 Wet Flange Nut Torque Limits.............................................................................................. 0284-4 Wet Flange Nut.................................................................................................................... 0284-4 Wet Socket Head Screw Torque Limits................................................................................ 0284-4 Socket Head Capscrew........................................................................................................ 0284-4 Socket Head Capscrew........................................................................................................ 0284-5 Metric Screw Head and Nut Markings.................................................................................. 0284-5 Metric Screw Torque Values................................................................................................ 0284-5 Additional Metric Screws...................................................................................................... 0284-7 Metric Screw Torque Values................................................................................................ 0284-7 Unified Inch Screw Markings................................................................................................ 0284-8 Unified Inch Screw Torque Values....................................................................................... 0284-8 Outside Diameter Measurement........................................................................................ 0284-10 Inside Diameter Measurement........................................................................................... 0284-10 Sealing Surface Angle Measurement................................................................................. 0284-11 37 Degree Flare and 30 Degree Cone Seat Connectors................................................... 0284-11 Straight Fitting or Special Nut Torque Values.................................................................... 0284-11 O-Ring Boss Straight and Adjustable Fittings.................................................................... 0284-12 Straight Fitting or Special Nut Torque Values*................................................................... 0284-13 O-Ring Boss Straight and Adjustable Fitting Stud End Nut Torque Values....................... 0284-13
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Page No. WP Sequence No. Table 9. Table 10. Figure 15. Figure 16. Table 11. Figure 17. Table 12. Table 13. Figure 18. Table 14. Table 15. Figure 19. Table 16. Table 17. Figure 20. Table 18. Table 19. Figure 21. Table 20. Figure 22. Table 21. Figure 23. Table 22. Figure 24. Table 23. O-Ring Boss Straight and Adjustable Fitting Stud End Nut Torque Values....................... 0284-14 O-Ring Boss Straight Nut Torque Values........................................................................... 0284-15 Straight Thread................................................................................................................... 0284-15 Tapered Thread.................................................................................................................. 0284-16 Straight or Tapered Threads Torque Values a................................................................... 0284-16 Flat Face O-Ring Seal........................................................................................................ 0284-17 Flat Face O-Ring Seal Fitting Torque Values*................................................................... 0284-18 Stud End O-Ring Seal Torque Values for Straight and Adjustable Fittings*...................... 0284-18 O-Ring Face Seals............................................................................................................. 0284-19 O-Ring Face Seal Fittings with SAE Inch Hex Nut and Stud End Torque Values.............. 0284-20 O-Ring Face Seal Fittings with SAE Inch Hex Nut and Stud End Torque Values.............. 0284-21 O-Ring Face Seal Fittings with Metric Hex Nut and Stud End for Standard Pressure............................................................................................................................. 0284-22 O-Ring Face Seal Fittings with Metric Hex Nut and Stud End Torque Values................... 0284-22 O-Ring Straight, Adjustable, and External Hex Plug with Metric Stud End Torque Values.................................................................................................................... 0284-24 O-Ring Face Seal Fitting with Metric Hex Nut and Stud End for High-Pressure Service............................................................................................................................... 0284-25 O-Ring Face Seal Fittings with Metric Hex Nut and Stud End Torque Values................... 0284-26 O-Ring Straight, Adjustable, and External Hex Plug with Metric Stud End for High-Pressure Torque Values............................................................................................ 0284-27 Metric Series Four Bolt Flange Fitting................................................................................ 0284-29 Metric Series Four Bolt Flange Fitting Torque Values a..................................................... 0284-30 Inch Series Four Bolt Flange Fitting................................................................................... 0284-31 Inch Series Four Bolt Flange Fitting Torque Values........................................................... 0284-32 Inch Series Four Bolt Flange Fitting for High-Pressure Service......................................... 0284-33 Inch Series Four Bolt Flange Fitting for High-Pressure Service Torque Values................ 0284-33 Non-Restricted Banjo (Adjustable) Fittings........................................................................ 0284-34 Non-Restricted Banjo (Adjustable) Metric Fittings Torque Values..................................... 0284-35
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Page No. WP Sequence No. Table 24. Figure 25. Table 25. Non-Restricted Banjo (Adjustable) Inch Fittings Torque Values........................................ 0284-36 Metric 24 Degree O-Ring Seal DIN 20078......................................................................... 0284-37 Metric 24 Degree O-Ring Seal DIN 20078 Torque Values................................................. 0284-37
Chapter 6 - SUPPORTING INFORMATION CB534B or CB534C ROLLER, MOTORIZED, VIBRATING TANDEM STEEL DRUMS NSN 3895-01-396-2822 AND 3895-01-502-4005 REFERENCES............................................................................................................................................ WP 0285 INTRODUCTION FOR STANDARD TWO-LEVEL MAC............................................................................. WP 0286 MAINTENANCE ALLOCATION CHART (MAC) SUMMARY....................................................................... WP 0287 Table 1. Table 2. Table 3. Maintenance Allocation Chart (MAC) Summary................................................................... 0287-1 MAC Tools.......................................................................................................................... 0287-18 Remarks for the CB534 Roller........................................................................................... 0287-21
EXPENDABLE/DURABLE ITEMS LIST...................................................................................................... WP 0288 Table 1. Expendable/Durable Supplies and Materials List................................................................. 0288-2
TOOL IDENTIFICATION LIST..................................................................................................................... WP 0289 Table 1. Tool Identification List........................................................................................................... 0289-1
MANDATORY REPLACEMENT PARTS LIST............................................................................................ WP 0290 Table 1. MANDATORY REPLACEMENT PARTS LIST..................................................................... 0290-1
SCHEMATICS............................................................................................................................................. WP 0291 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Electrical Schematic............................................................................................................. 0291-1 Electrical Schematic............................................................................................................. 0291-2 Electrical Schematic............................................................................................................. 0291-3 Electrical Schematic............................................................................................................. 0291-4 Electrical Schematic............................................................................................................. 0291-5 Electrical Schematic............................................................................................................. 0291-6 Electrical Schematic............................................................................................................. 0291-7 Electrical Schematic............................................................................................................. 0291-8 Electrical Schematic............................................................................................................. 0291-9 Electrical Schematic........................................................................................................... 0291-10
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Page No. WP Sequence No. Figure 11. Index Electrical Schematic........................................................................................................... 0291-11
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HOW TO USE THIS MANUAL
WARNINGS, CAUTIONS, AND NOTES Read all WARNINGS, CAUTIONS, and NOTES before performing any procedure. Warnings, cautions, notes, subject headings, and other essential information is printed in BOLD type, making them easier for the user to see. GENERAL INFORMATION This manual is divided into CHAPTERS and WORK PACKAGES. For a specific Chapter or Work Package, refer to the TABLE OF CONTENTS. VOLUME 2 CHAPTER 5 provides maintenance instructions. CHAPTER 6 provides supporting information. The supporting information includes tables listing References used in this manual, an Introduction to the Standard Two-level MAC, the Two-level MAC, a listing of Expendable and Durable Items, a Tool Identification list, and a Mandatory Replacement Parts list.
The illustrations throughout this manual contain numerical callouts pointing to various components mentioned in the procedural steps. Mandatory replacement parts must be discarded after removal and replaced with a new part, which is listed in the Materials/Parts section located at the beginning of the task. Prior to performing any maintenance functions on the Steel Wheel Roller, ALWAYS do the following: Read and follow all WARNINGS in all work packages. Read the Safety Summary. Read the Equipment Description and Data located in Chapter 1. Read completely through the maintenance procedure to familiarize yourself with the procedure and the affected parts before beginning work.
The RPSTL manual, TM 5-3895-379-23P, is to be used in conjunction with this manual to help find needed parts for procurement. RPSTL manual lists and authorized spares and repair parts; special tools, special Test, Measurement, and Diagnostic Equipment (TMDE); and other special support equipment required for performance of field maintenance on the Steel Wheel Roller. It authorizes the requisitioning, issue, and disposition of spares, repair parts, and special tools as indicated by the source, maintenance, and recoverability (SMR) codes. METRIC SYSTEM The equipment described herein contains metric components and requires metric, common, and special tools. Therefore, metric units and English units will be used throughout this publication. An English-to-Metric conversion table is included as the last page of this manual inside the back cover.
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CHAPTER 5 MAINTENANCE INSTRUCTIONS FOR CB534B or CB534C ROLLER, MOTORIZED, VIBRATING TANDEM STEEL DRUMS NSN 3895-01-396-2822 AND 3895-01-502-4005
TM 5-3895-379-23-2
0222
FIELD MAINTENANCE STEERING CONTROL UNIT (SCU) MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (WP 0289, Table 1, Item 23) Wrench, Torque, 0-300 in-lb (WP 0289, Table 1, Item 41) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0288, Table 1, Item 12) Cleaning Compound, Solvent (WP 0288, Table 1, Item 13, 14, 15) Cloth, Cleaning (WP 0288, Table 1, Item 16) Sealing Compound, Loctite 271 (WP 0288, Table 1, Item 62) Tag, Marker (WP 0288, Table 1, Item 70) Materials/Parts (cont.) Lockwasher (WP 0290, Table 1, Item 110) Qty: 4 O-Ring (WP 0290, Table 1, Item 130) Qty: 4 O-Ring (WP 0290, Table 1, Item 91) Qty: 2 Seal (WP 0290, Table 1, Item 85) Qty: 3 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 86, 87, and 102 Equipment Condition Steering wheel removed. (Volume 1, WP 0221)
0222-1
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0222
REMOVAL 1. Remove two bolts (Figure 1, Item 2) and cover (Figure 1, Item 1) from console (Figure 1, Item 3).
NOTE
Bolts (6) and (7) are not interchangeable. 2. 3. Remove four bolts (Figure 1, Item 6) and cover (Figure 1, Item 5) from steering column (Figure 1, Item 4). Remove three bolts (Figure 1, Item 7) that fasten console (Figure 1, Item 3) to steering column (Figure 1, Item 4) and move console out of the way.
M0688SWR
Figure 1. Steering Control Unit (SCU) Removal.
0222-2
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0222
REMOVAL - Continued
WARNING
Do NOT remove hydraulic tank filler cap or disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. To relieve pressure, SLOWLY loosen hydraulic tank filler cap. After maintenance, tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing injury or death.
CAUTION
Wipe area clean around all hydraulic connections to be opened during removal. Cap lines and plug openings after removing hydraulic lines. Contamination of hydraulic system could result in premature failure.
NOTE
Tag and mark all hoses to aid in installation. Use drain pan to catch any steering fluid that may drain from system. Dispose of oil IAW local policy and ordinances. Ensure all spills are cleaned up. 4. 5. Disconnect four hoses (Figure 2, Item 1), O-rings (Figure 2, Item 2) from steering control unit (Figure 2, Item 6). Discard O-rings. While holding steering control unit (Figure 2, Item 6), remove four bolts (Figure 2, Item 4) and lockwashers (Figure 2, Item 5) that fasten the steering control unit (Figure 2, Item 6) and steering column (Figure 2, Item 3) to the console (Figure 1, Item 3). Discard lockwashers.
NOTE
It may be necessary to use puller to remove steering control unit from steering column. 6. Remove steering control unit (Figure 2, Item 6) from splines on steering column (Figure 2, Item 3).
0222-3
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0222
REMOVAL - Continued
4, 5
M0659SWR
Figure 2. Steering Control Unit (SCU) Removal. END OF TASK DISASSEMBLY
NOTE
Be sure the outside of the steering control unit (SCU) is thoroughly clean and free of dirt and debris prior to disassembly. Make alignment marks on the valve body to aid in proper assembly. 1. 2. 3. 4. Remove seven capscrews (Figure 3, Item 1). Remove end cap (Figure 3, Item 2). Remove seal (Figure 3, Item 3) from end cap (Figure 3, Item 2). Discard seal. Remove gerotor housing (Figure 3, Item 4) and lift housing straight up.
4 1 2 2 3
M1151SWR
Figure 3.
Steering Control Unit (SCU) Disassembly.
0222-4
TM 5-3895-379-23-2
0222
DISASSEMBLY - Continued 5. Remove seal (Figure 4, Item 5) from gerotor housing (Figure 4, Item 4). Discard seal.
NOTE
Components of the gerotor assembly shown in photo. Gerotor housing and gerotor are not serviced separately. 6. Remove gerotor (Figure 4, Item 3), spacer (Figure 4, Item 7), drive (Figure 4, Item 8), and spacer plate (Figure 4, Item 6) as a unit.
7 1 2 3 4 5 6 3 5 6 4 8
8
M1152SWR
Figure 4. 7. 8.
Remove seal (Figure 5, Item 7). Discard seal. Remove spool (Figure 5, Item 8) and sleeve (Figure 5, Item 9) from control housing (Figure 5, Item 9). Replace spool and sleeve if necessary.
NOTE
Components of the gerotor assembly shown in photo. 9. Remove backup ring (Figure 5, Item 10), O-ring (Figure 5, Item 11), and O-ring (Figure 5, Item 14) (not shown), two bearing races (Figure 5, Item 13), and needle thrust bearing (Figure 5, Item 8) from spool (Figure 5, Item 5) and sleeve (Figure 5, Item 6). Replace bearing and races as an assembly, if necessary, and discard back-up ring and O-rings.
5, 6
5, 6
5, 6 8 9 3 4 8
M0665SWR
Figure 5.
0222-5
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0222
DISASSEMBLY - Continued 10. 11. Remove pin (Figure 6, Item 6) from spool (Figure 6, Item 2) and sleeve (Figure 6, Item 3) (slip fit). Separate control spool (Figure 6, Item 2) and sleeve (Figure 6, Item 3).
NOTE
Spring kit has four centering springs. Components of the gerotor assembly shown in photo. 12. Remove centering spring kit (Figure 6, Item 7) from control spool (Figure 6, Item 2).
1 2 2, 3 2 3
M0668SWR
Figure 6. 13. 14.
Remove retaining ring (Figure 7, Item 1) and gland bushing (Figure 7, Item 2) from the control housing (Figure 7, Item 3). Discard retaining ring. Remove dust seal (Figure 5, Item 4) from gland seal (Figure 5, Item 5). Turn seal gland bushing over and remove quad ring seal (Figure 5, Item 6). Discard dust seal and quad ring seal.
3 2 1
M0671SWR
Figure 7.
0222-6
TM 5-3895-379-23-2
0222
DISASSEMBLY - Continued 15. 16. Remove set screw (Figure 8, Item 2) from control housing (Figure 8, Item 3). Install 1/8 in. - 24 machine screw into the end of the check ball seat (Figure 8, Item 4). Remove the check ball (Figure 8, Item 4) seat with pliers.
M0672SWR
Figure 8.
NOTE
O-rings are different sizes. Note their location on the check ball seat prior to removal. Do not mix when re-installed. 17. 18. Remove check ball (Figure 9, Item 4) and check ball retainer (Figure 9, Item 5) from the control housing (Figure 9, Item 6). Remove O-rings (Figure 9, Items 2 and 3) from check ball seat (Figure 9, Item 1). Discard O-rings.
M0674SWR
Figure 9. END OF TASK
0222-7
TM 5-3895-379-23-2
0222
ASSEMBLY
NOTE
Be sure all parts of the steering control unit (SCU) are clean and free of dirt and debris. Clean all parts with cleaning compound and air dry or use cleaning cloth ONLY to clean dry parts. Replace any parts that have scratches or burrs that could result in leakage. Put a thin coat of clean lubricating oil on O-rings prior to installation. 1. 2. 3. 4. Install check ball retainer (Figure 10, Item 5) in control housing (Figure 10, Item 6). Be sure the retainer is straight and not tilted in the bore. Install check ball (Figure 10, Item 4). Install two new O-rings (Figure 10, Item 3) and (Figure 10, Item 2) in their original location on the check ball seat (Figure 10, Item 5). Install the check ball seat (Figure 10, Item 1) in center of control housing (Figure 10, Item 6), using an 1/8 in. -24 machine screw.
M0675SWR
Figure 10. Steering Control Unit (SCU) Assembly.
0222-8
TM 5-3895-379-23-2
0222
ASSEMBLY - Continued
NOTE
After installation, the set screw should be slightly below the outside surface of the center housing. 5. Install setscrew (Figure 11, Item 2) in control housing (Figure 11, Item 3) and tighten to 8 lb-in. (11 Nm).
M0676SWR
Figure 11. Steering Control Unit (SCU) Assembly. 6. Assemble gland bushing (Figure 12, Item 2). Install new dust seal (Figure 12, Item 4) in seal gland bushing (Figure 12, Item 5) with the flat or smooth side of seal facing bushing and turn seal gland bushing over. Install new quad ring seal (Figure 12, Item 6) in the seal gland bushing. Smooth seal in place with finger. Install gland bushing assembly (Figure 12, Item 2) in control housing (Figure 12, Item 3) and secure with new retaining ring (Figure 12, Item 1).
3 2 1 4 5 6
7.
M0677SWR
0222-9
TM 5-3895-379-23-2
0222
NOTE
Apply a thin coat of clean hydraulic oil on control spool and sleeve prior to installation. 8. Assemble control spool (Figure 13, Item 1) with control sleeve (Figure 13, Item 2). The spool should turn freely in the sleeve. Put the spring slots in each component in alignment. Some spool and sleeve sets may have alignment marks on them. In this case, align the marks. Install centering spring kit (Figure 13, Item 3) to control spool (Figure 13, Item 1). Be sure the springs are centered. Install pin (Figure 13, Item 4) that holds the spool (Figure 13, Item 1) and sleeve (Figure 13, Item 2) together and ensure pin is flush on each side of the spool and sleeve after installation.
1, 2 1 2 3
9.
M0678SWR
NOTE
When spool and sleeve assembly is installed in the control housing, be sure it is not tilted out of position. The assembly should be pushed gently into place with a slight rotating action, keeping pin nearly horizontal. The spool and sleeve assembly should be installed until it is flush with the meter end of the housing (side with fourteen holes in the end). Be sure pin does not drop into the discharge groove in the center housing. Be sure the spool and sleeve assembly turns freely in the center housing. 10. 11. 12. 13. Position center of spool (Figure 14, Item 5) and sleeve (Figure 14, Item 6) assembly in a vertical position. Install two bearing races (Figure 14, Item 4) and needle thrust bearing (Figure 14, Item 9). Install two new O-rings (Figure 14, Items 2 and 3) and back-up ring (Figure 14, Item 1) over the spool (Figure 14, Item 5) and sleeve (Figure 14, Item 6) with a twisting motion. Position steering control housing (Figure 14, Item 8) in a vertical position with the steering column facing down. Install spool (Figure 14, Item 5) and sleeve (Figure 14, Item 6) as an assembly into control housing. Install new seal (Figure 14, Item 7) in control housing (Figure 14, Item 8).
0222-10
TM 5-3895-379-23-2
0222
1 2 3 4 5, 6 7
5, 6
M0681SWR
NOTE
The steering control unit (SCU) must be timed, this required the correct relationship between pin, gerotor and housing. One end of pin will point to the largest clearance between the gerotor and gerotor housing. The other end of the pin points to the least clearance. Pin cannot be seen after drive is installed, so it will be necessary to make a mark on the gear end of the drive for proper alignment. Be sure the bolt holes in the spacer plate align with the tapped holes in the center housing. 14. Install spacer plate (Figure 15, Item 3).
NOTE
Be sure the slot in drive (Figure 15, Item 6) engages with pin (Figure 15, Item 3). 15. 16. 17. Install drive (Figure 15, Item 6) and spacer (Figure 15, Item 2) in gerotor (Figure 15, Item 1). Install new seal (Figure 15, Item 5) in gerotor housing (Figure 15, Item 4). Position gerotor housing (Figure 15, Item 4) on steering control unit.
2 1 4 5 3 6 4
M0684SWR
0222-11
TM 5-3895-379-23-2
0222
ASSEMBLY - Continued 18. 19. Install seal (Figure 16, Item 1) in end cap (Figure 16, Item 3). Install cap (Figure 16, Item 3) with seven screws (Figure 16, Item 2) on steering control unit (SCU). Tighten capscrews in sequence shown to 150 lb-in. (17 Nm) 275 lb-in. (31 Nm).
1
3
M1092SWR
Figure 16. Steering Control Unit (SCU) Assembly. 20. Install steering control unit (SCU). Refer to INSTALLATION in this work package.
END OF TASK INSTALLATION 1. 2. Spline the steering control unit (SCU) (Figure 17, Item 6) in steering column (Figure 17, Item 3). Install four new lockwashers (Figure 17, Item 5) and bolts (Figure 17, Item 4) to fasten steering control unit (Figure 17, Item 6) and steering column (Figure 17, Item 3) and console (Figure 18, Item 3). Tighten bolts to 10-25 lb-ft (14-34 Nm).
NOTE
Remove all caps and plugs from hoses prior to installation. Remove tags from hoses after hoses are connected correctly. 3. 4. Install new O-rings (Figure 17, Item 2) into four hoses (Figure 17, Item 1). Connect four hoses (Figure 17, Item 1) to steering control unit (Figure 17, Item 6).
0222-12
TM 5-3895-379-23-2
0222
INSTALLATION - Continued
6
Figure 17.
4, 5
M0687SWR
Steering Control Unit (SCU) Installation.
NOTE
Bolts (Figure 18, Item 6) and (Figure 18, Item 7) are not interchangeable. 5. 6. 7. Position console (Figure 18, Item 3) on steering column (Figure 18, Item 4) and install three bolts (Figure 18, Item 7). Position cover (Figure 18, Item 5) on steering column (Figure 18, Item 4) and install four bolts (Figure 18, Item 6). Position cover (Figure 18, Item 1) on console (Figure 18, Item 3) and install two bolts (Figure 18, Item 2).
7
M0688SWR
Steering Control Unit (SCU) Installation.
0222-13
TM 5-3895-379-23-2
0222
FOLLOW-ON MAINTENANCE 1. 2. Install steering wheel. (Volume 1, WP 0221) Operate roller and check for proper operation and leaks. (TM 5-3895-379-10)
END OF TASK END OF WORK PACKAGE
0222-14
TM 5-3895-379-23-2
0223
FIELD MAINTENANCE POWER STEERING PUMP REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (WP 0289, Table 1, Item 23) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0288, Table 1, Item 12) Tag, Marker (WP 0288, Table 1, Item 70) Gasket (WP 0290, Table 1, Item 59) Qty: 1 Lockwasher (WP 0290, Table 1, Item 67) Qty: Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 88 and 89 Equipment Condition Hydraulic oil drained. (Volume 1, WP 0124) Right-side door opened. (TM 5-3895-379-10) Engine coolant drained. (Volume 1, WP 0139) 1
REMOVAL
CAUTION
Wipe area clean around all hydraulic connections to be opened during removal. Cap lines and plug openings after removing hydraulic lines. Contamination of hydraulic sytem could result in premature failure.
NOTE
Tag and mark all hoses to ensure correct installation. Use drain pan to catch any steering fluid that may drain from system. Dispose of oil In Accordance With (IAW) local policy and ordinances. Ensure all spills are cleaned up. 1. Disconnect hose assembly (Figure 1, Item 2) from steering pump (Figure 1, Item 1).
M0689SWR
Figure 1.
Power Steering Pump Removal.
0223-1
TM 5-3895-379-23-2
0223
REMOVAL - Continued 2. Disconnect hose assembly (Figure 2, Item 2) from steering pump (Figure 2, Item 1).
1 2
M0690SWR
Figure 2. Power Steering Pump Removal. 3. 4. 5. 6. 7. Remove bolt (Figure 3, Item 2), washer (Figure 3, Item 3), and remove clamp (Figure 3, Item 4) from gauge rod (dipstick) assembly (Figure 3, Item 1). Loosen nut that fastens gauge rod (dipstick) tube (Figure 3, Item 1) to oil pan. Remove gauge rod tube. Remove bolt (Figure 3, Item 8), washer (Figure 3, Item 9), and remove hose clamp (Figure 3, Item 10) from tube (Figure 3, Item 5). Disconnect tube (Figure 3, Item 5) from engine oil cooler. Disconnect hose assembly (Figure 3, Item 6) from steering pump (Figure 3, Item 7).
2, 3, 4
M0691SWR
8, 9, 10
Figure 3. Power Steering Pump Removal. 8. Remove bolt (Figure 4, Item 1), washer (Figure 4, Item 2), five bolts (Figure 4, Item 4), and remove steering pump (Figure 4, Item 3) and gasket (Figure 4, Item 5) from engine. Discard gasket.
0223-2
TM 5-3895-379-23-2
0223
REMOVAL - Continued
1, 2
M0692SWR
Figure 4. END OF TASK INSTALLATION 1. 2.
Power Steering Pump Removal.
Position new gasket (Figure 5, Item 5) and steering pump (Figure 5, Item 3) on engine. Install five bolts (Figure 5, Item 4), new lockwasher (Figure 5, Item 2), and bolt (Figure 5, Item 1) securing steering pump (Figure 5, Item 3) to engine.
1, 2
M1188SWR
Figure 5.
Power Steering Pump Installation.
0223-3
TM 5-3895-379-23-2
0223
INSTALLATION - Continued 3. 4. 5. 6. Connect hose assembly (Figure 6, Item 6) to steering pump (Figure 6, Item 7). Position tube (Figure 6, Item 5) to engine oil cooler and install hose clamp (Figure 6, Item 10), washer (Figure 6, Item 9), and bolt (Figure 6, Item 8). Position gauge rod (dipstick) tube (Figure 6, Item 1) to oil pan and tighten nut that fastens the gauge rod (dipstick) tube. Install clamp (Figure 6, Item 4), washer (Figure 6, Item 3), and bolt (Figure 6, Item 2) to secure gauge rod (dipstick) tube (Figure 6, Item 1) to engine.
2, 3, 4
M1187SWR
8, 9, 10
Figure 6. 7.
Connect hose (Figure 7, Items 2 and 3) to steering pump (Figure 7, Item 1).
2, 3
M0693SWR
0223-4
TM 5-3895-379-23-2
0223
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Fill hydraulic oil tank to correct level. (Volume 1, WP 0124) Fill engine cooling system. (Volume 1, WP 0139) Close right-side door assembly. (TM 5-3895-379-10) Operate roller and check for proper installation. (TM 5-3895-379-10)
0223-5/6 blank
TM 5-3895-379-23-2
0224
FIELD MAINTENANCE STEERING HOSES, LINES, AND FITTINGS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (WP 0289, Table 1, Item 23) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0288, Table 1, Item 12) Rag, Wiping (WP 0288, Table 1, Item 60) Tag, Marker (WP 0288, Table 1, Item 70) Gasket (WP 0290, Table 1, Item 92) Qty: 1 O-Ring (WP 0290, Table 1, Item 130) Qty: 6 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 90, 91, and 102 WP 0222 Equipment Condition Engine off. (TM 5-3895-379-10) Battery disconnect switch in OFF position. (TM 5-3895-379-10) Operator platform assembly raised. (WP 0235) Right and left-side door assemblies opened. (TM 5-3895-379-10) Fuel/hydraulic oil tank drained. (Volume 1, WP 0124)
0224-1
TM 5-3895-379-23-2
0224
REMOVAL
WARNING
Fuel and oil are very slippery. Use drain pan to capture any fluid which may drain from lines. Dispose of In Accordance With (IAW) local policy and ordinances. Ensure all spills are cleaned up.
CAUTION
Wipe area clean around all hydraulic connections to be opened during removal. Cap lines and plug openings after removing lines. Contamination of hydraulic system could result in premature failure of the roller.
NOTE
Tag and mark all hydraulic lines and hoses to ensure correct installation. Inspect all hoses, lines, and fittings for cracks, bends, nicks, dents, stripped treads, and cuts. Replace all damaged parts. 1. 2. 3. 4. 5. 6. 7. 8. Disconnect four hose assemblies (Figure 1, Item 1) from steering control unit (SCU) (WP 0222). Remove bolt (Figure 1, Item 15), cover (Figure 1, Item 16), four clamps (Figure 1, Item 8), and plate (Figure 1, Item 17). Remove transfer (Figure 1, Item 18) and spring nut (Figure 1, Item 19). Raise operator platform assembly (WP 0235). Remove screw (Figure 1, Item 4), washer (Figure 1, Item 5), loop clamp (Figure 1, Item 6), retainer (Figure 1, Item 7), and clamps (Figure 1, Item 8) from frame. Disconnect hose assembly (Figure 1, Item 13) from steering pump (Figure 1, Item 14). Disconnect hose assemblies (Figure 1, Items 11 and 12) from tee fittings (Figure 1, Item 9). Remove O-rings (Figure 1, Item 10). Discard O-rings. Disconnect hose assembly (Figure 1, Item 3) from manifold (Figure 1, Item 2).
0224-2
TM 5-3895-379-23-2
0224
REMOVAL - Continued
1 19 18 17 8 16 15 2
14 13 12 11 8 7 6 3 9 10
4 5
M0694SWR
Figure 1.
Steering Hoses, Lines, and Fittings Removal.
0224-3
TM 5-3895-379-23-2
0224
REMOVAL - Continued 9. 10. 11. 12. 13. 14. 15. 16. 17. Disconnect hose assembly (Figure 2, Item 2) from steering pump (Figure 2, Item 1). Remove screw (Figure 2, Item 20), retainer (Figure 2, Item 21), two clamps (Figure 2, Item 22), and plate (Figure 2, Item 23) from hose assemblies (Figure 2, Items 18 and 19). Disconnect hose assemblies (Figure 2, Items 18 and 19) from hydraulic steering cylinder (Figure 2, Item 13). Disconnect hose assemblies (Figure 2, Items 18 and 19) from two tee fittings (Figure 2, Item 17). Remove two nuts (Figure 2, Item 16), tee fittings (Figure 2, Item 17), four O-rings (Figure 2, Item 15), and two hose assemblies (Figure 2, Items 10 and 12) from frame. Discard O-rings. Remove bolt (Figure 2, Item 14), cover (Figure 2, Item 11), two clamps (Figure 2, Item 24), and plate (Figure 2, Item 25) from hose assemblies (Figure 2, Items 10 and 12). Disconnect hose assemblies (Figure 2, Items 10 and 12) from hydraulic steering cylinder (Figure 2, Item 13). Remove two screws (Figure 2, Item 5), bracket (Figure 2, Item 4), two clamps (Figure 2, Item 3), and plate (Figure 2, Item 9) from hose assembly (Figure 2, Item 2). Disconnect hose assembly (Figure 2, Item 2) and remove elbow (Figure 2, Item 8) and gasket (Figure 2, Item 7) from hydraulic side of fuel/hydraulic tank (Figure 2, Item 6). Discard gasket.
1 23 22 21 19 20 15 17 16 2
5 4 3 6 7 8 9
15 10
24 25
13 18 19 18
15
17
16
15
14 13
12
11
10
M0695SWR
Steering Hoses, Lines, and Fittings Removal.
0224-4
TM 5-3895-379-23-2
0224
INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. Connect hose assembly (Figure 3, Item 2). Install elbow (Figure 3, Item 8) and new gasket (Figure 3, Item 7) to hydraulic side of fuel/hydraulic oil tank (Figure 3, Item 6). Install two screws (Figure 3, Item 5), bracket (Figure 3, Item 4), two clamps (Figure 3, Item 3), and plate (Figure 3, Item 9) to hose assembly (Figure 3, Item 2). Connect hose assemblies (Figure 3, Items 10 and 12) to hydraulic steering cylinder (Figure 3, Item 13). Install bolt (Figure 3, Item 14), cover (Figure 3, Item 11), two clamps (Figure 3, Item 24), and plate (Figure 3, Item 25) to hose assemblies (Figure 3, Items 10 and 12). Install two nuts (Figure 3, Item 16), tees (Figure 3, Item 17), four new O-rings (Figure 3, Item 15), and hose assemblies (Figure 3, Items 10 and 12) to frame. Connect hose assemblies (Figure 3, Items 18 and 19) to two tees (Figure 3, Item 17). Connect hose assemblies (Figure 3, Items 18 and 19) to hydraulic steering cylinder (Figure 3, Item 13). Install screw (Figure 3, Item 20), retainer (Figure 3, Item 21), two clamps (Figure 3, Item 22), and plate (Figure 3, Item 23) to hose assemblies (Figure 3, Items 18 and 19). Connect hose assembly (Figure 3, Item 2) to steering pump (Figure 3, Item 1).
1 23 22 21 19 20 15 17 16 2
5 4 3 6 7 8 9
15 10
24 25
13 18 19 18
15
17
16
15
14 13 12 11 10
M1219SWR
Figure 3. Steering Hoses, Lines, and Fittings Installation.
0224-5
TM 5-3895-379-23-2
0224
INSTALLATION - Continued 10. 11. 12. 13. 14. 15. 16. 17. Connect hose assembly (Figure 4, Item 3) to manifold (Figure 4, Item 2). Install new O-ring (Figure 4, Item 10) to each of two hose assemblies (Figure 4, Items 11 and 12) and connect to tee fittings (Figure 4, Item 9). Connect hose assembly (Figure 4, Item 13) to steering pump (Figure 4, Item 14). Install screw (Figure 4, Item 4), washer (Figure 4, Item 5), loop clamp (Figure 4, Item 6), retainer (Figure 4, Item 7), and fairlead clamps (Figure 4, Item 8) to frame. Lower operation platform assembly (WP 0235). Install transfer (Figure 4, Item 18) and spring nut (Figure 4, Item 19). Install bolt (Figure 4, Item 15), cover (Figure 4, Item 16), four clamps (Figure 4, Item 8), and plate (Figure 4, Item 17). Connect four hose assemblies (Figure 4, Item 1) to steering control unit (SCU) (WP 0222).
1 19 18 17 8 16 15 2
14 13 12 11 8 7 6 3 9 10
4 5
M0696SWR
Figure 4. Steering Hoses, Lines, and Fittings Installation. END OF TASK
0224-6
TM 5-3895-379-23-2
0224
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Close left and right-side door assemblies. (TM 5-3895-379-10) Lower operator platform. (WP 0235) Fill hydraulic side of fuel/hydraulic oil tank. (Volume 1, WP 0124) Start engine and check for proper operation and oil leaks. (TM 5-3895-379-10)
0224-7/8 blank
TM 5-3895-379-23-2
0225
FIELD MAINTENANCE HYDRAULIC STEERING CYLINDERS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (WP 0289, Table 1, Item 23) Wrench, Torque, 20-100 ft-lb (WP 0289, Table 1, Item 42) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0288, Table 1, Item 12) Rag, Wiping (WP 0288, Table 1, Item 60) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 93 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Left and right-door assemblies opened. (TM 5-3895-379-10)
0225-1
TM 5-3895-379-23-2
0225
REMOVAL
WARNING
Oil is very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury.
NOTE
Right and left hydraulic steering cylinders are replaced the same way. Left hydraulic steering cylinder is shown. Use drain pan to catch any oil that may drain from system. Dispose of oil In Accordance With (IAW) local policy and ordinances. Ensure all spills are cleaned up. Inspect all hoses, lines, and fittings for cracks, bends, nicks, dents, stripped threads, and cuts. If damaged, notify Direct Support. 1. 2. 3. Place drain pan with 1 gal (3.8 Liters) minimum capacity under hydraulic fittings (Figure 1, Items 1 and 4). Loosen fittings (Figure 1, Items 1 and 4) and remove hydraulic lines (Figure 1, Items 2 and 3) from hydraulic steering cylinder (Figure 1, Item 6). Cap hydraulic steering cylinder fittings (Figure 1, Item 5) and lines (Figure 1, Items 2 and 3).
1 2 3 4
6
M0697SWR
Figure 1. Hydraulic Steering Cylinders Removal.
0225-2
TM 5-3895-379-23-2
0225
REMOVAL - Continued 4. Remove two screws (Figure 2, Item 1), washers (Figure 2, Item 3), and spacers (Figure 2, Item 4) from frame assembly (Figure 2, Item 6) and yoke assembly (Figure 2, Item 9).
NOTE
The number of spacers used may vary from one roller to the next. 5. 6. 7. Remove two pin assemblies (Figure 2, Item 5) and hydraulic steering cylinder (Figure 2, Item 7) from frame assembly (Figure 2, Item 6) and yoke assembly (Figure 2, Item 9). Remove lubrication fitting (Figure 2, Item 2) from frame assembly (Figure 2, Item 6). Remove alignment bearing (Figure 2, Item 8) from yoke assembly (Figure 2, Item 9).
1 1 3 4 2 5
3 4 5 8 9 6
7
M0698SWR
Hydraulic Steering Cylinders Removal.
0225-3
TM 5-3895-379-23-2
0225
INSTALLATION 1. 2. 3. 4. 5. Install alignment bearing (Figure 3, Item 8) in yoke assembly (Figure 3, Item 9). Install lubrication fitting (Figure 3, Item 2) on frame assembly (Figure 3, Item 6). Position hydraulic steering cylinder (Figure 3, Item 7) on frame assembly (Figure 3, Item 6) and yoke assembly (Figure 3, Item 9). Install two pin assemblies (Figure 3, Item 5) in frame assembly (Figure 3, Item 6) and yoke assembly (Figure 3, Item 9). Install spacers (Figure 3, Item 4), washers (Figure 3, Item 3), and screws (Figure 3, Item 1) in frame assembly (Figure 3, Item 6) and yoke assembly (Figure 3, Item 9) to lock two pin assemblies (Figure 3, Item 5) in place. Tighten screws to 33-47 lb-ft (45-64 Nm).
1 1 3 4 2 5
3 4 5 8 9 6
7
Figure 3.
M1218SWR
Hydraulic Steering Cylinders Installation.
0225-4
TM 5-3895-379-23-2
0225
INSTALLATION - Continued 6. 7. Remove caps and install hydraulic lines (Figure 4, Items 2 and 3) on hydraulic steering cylinder fittings (Figure 4, Item 5). Tighten fittings (Figure 4, Items 1 and 4).
1 2 3 4
6
M1217SWR
Figure 4. Hydraulic Steering Cylinders Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Close right and left-side door assemblies. (TM 5-3895-379-10) Start engine, operate steering , and check for leaks. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0225-5/6 blank
TM 5-3895-379-23-2
0226
FIELD MAINTENANCE STEERING CYLINDER REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Wrench, Torque, 90-600 ft-lb (WP 0289, Table 1, Item 44) Materials/Parts Cleaning Compound, Solvent (WP 0288, Table 1, Item 13, 14, 15) Lubricating Oil, General Purpose (WP 0288, Table 1, Item 40, 41, 42, 43, 44, 45, 46, 47) Rag, Wiping (WP 0288, Table 1, Item 60) Washer, Lock (WP 0290, Table 1, Item 129) Qty: 2 O-Ring (WP 0290, Table 1, Item 27) Qty: 2 Materials/Parts (cont.) Wear Ring (WP 0290, Table 1, Item 28) Qty: O-Ring (WP 0290, Table 1, Item 37) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-10 TM 5-3895-379-23P, Figure 93 Equipment Condition Hydraulic steering cylinder removed. (WP 0225) 1
0226-1
TM 5-3895-379-23-2
0226
DISASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. Remove two bolts (Figure 1, Item 11), lockwashers (Figure 1, Item 12), slide cover (Figure 1, Item 15), and rod assembly (Figure 1, Item 10) partially out of cylinder assembly (Figure 1, Item 17). Discard lockwasher. Push head (Figure 1, Item 5) into cylinder assembly (Figure 1, Item 17) and remove lockwire ring (Figure 1, Item 8). Push head (Figure 1, Item 5) and rod assembly (Figure 1, Item 10) from cylinder assembly (Figure 1, Item 17). Remove nut (Figure 1, Item 1), piston (Figure 1, Item 2), and head (Figure 1, Item 5) from rod assembly (Figure 1, Item 10). Remove O-ring (Figure 1, Item 16) from rod assembly (Figure 1, Item 10). Discard O-ring. Remove wear ring (Figure 1, Item 4) and O-ring (Figure 1, Item 3) from piston (Figure 1, Item 2). Discard wear ring and O-ring. Remove O-ring (Figure 1, Item 6) and back-up ring (Figure 1, Item 7) from outside of head (Figure 1, Item 5). Discard O-ring and back-up ring. Remove lip-type seal (Figure 1, Item 9), O-ring (Figure 1, Item 14), and back-up ring (Figure 1, Item 13) from inside head (Figure 1, Item 5). Discard lip-type seal, O-ring, and back-up ring.
4 3
7 9
11, 12 17 16 15 14
Figure 1. Steering Cylinder Disassembly. END OF TASK
10
13
M0699SWR
0226-2
TM 5-3895-379-23-2
0226
ASSEMBLY
NOTE
Inspect all parts and bore of steering cylinder for cracks and damage. Replace if damage is found. During assembly of steering cylinder, apply a thin coat of clean oil on O-ring, back-up rings, and lip-type seals. 1. 2. 3. 4. 5. 6. 7. Install new back-up ring (Figure 2, Item 13), new O-ring (Figure 2, Item 14), and new lip-type seal (Figure 2, Item 9) on inside of head (Figure 2, Item 5). Install new back-up ring (Figure 2, Item 7) and new O-ring (Figure 2, Item 6) on outside of head (Figure 2, Item 5). Install new O-ring (Figure 2, Item 3) and new wear ring (Figure 2, Item 4) on piston (Figure 2, Item 2). Install new O-ring (Figure 2, Item 16) on rod assembly (Figure 2, Item 10) with nut (Figure 2, Item 1). Install piston (Figure 2, Item 2) and head (Figure 2, Item 5) on rod assembly (Figure 2, Item 10) with nut (Figure 2, Item 1). Tighten nut to 590 + 20 lb-ft (800 + 27 Nm). Slide head (Figure 2, Item 5) and rod assembly (Figure 2, Item 10) in cylinder assembly (Figure 2, Item 17) and install lockwire ring (Figure 2, Item 8). Install two new lockwashers (Figure 2, Item 12) and bolts (Figure 2, Item 11) and secure cover (Figure 2, Item 15) and rod assembly (Figure 2, Item 10) in cylinder (Figure 2, Item 17).
4 3
7 9
11, 12 17 16 15 14
Figure 2. END OF TASK Steering Cylinder Assembly.
10
13
M1305SWR
0226-3
TM 5-3895-379-23-2
0226
FOLLOW-ON MAINTENANCE 1. 2. Install hydraulic steering cylinder. (WP 0225) Operate roller and check for proper operation and leaks. (TM 5-3895-379-10)
0226-4
TM 5-3895-379-23-2
0227
FIELD MAINTENANCE STEERING PIVOT REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Jack, Dolly Type (WP 0289, Table 1, Item 21) Materials/Parts Cleaning Compound, Solvent (WP 0288, Table 1, Item 13, 14, 15) Grease, Automotive and Artillery (WP 0288, Table 1, Item 24, 25, 26, 27) Rag, Wiping (WP 0288, Table 1, Item 60) Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-10 TM 5-3895-379-23P, Figure 94 Equipment Condition Operator platform assembly raised. (WP 0235) Yoke removed. (WP 0228)
0227-1
TM 5-3895-379-23-2
0227
REMOVAL
WARNING
Use caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may cause injury or death. 1. Remove two bolts (Figure 1, Item 1), washers (Figure 1, Item 2), nuts (Figure 1, Item 5), and pins (Figure 1, Item 3) that fasten steering cylinder (Figure 1, Item 4) to steering pivot assembly (Figure 1, Item 6). Repeat Step (1) for other steering cylinder.
1, 2
6
Figure 1.
M0700SWR
Steering Pivot Removal.
0227-2
TM 5-3895-379-23-2
0227
REMOVAL - Continued 2. Remove two nuts (Figure 2, Item 1), washers (Figure 2, Item 2), and bolts (Figure 2, Item 3) that hold upper and lower pivot pins (Figure 2, Item 4) in place.
1, 2, 3
M0701SWR
Figure 2. 3.
Position floor jack under steering pivot assembly (Figure 3, Item 1) and fasten steering pivot assembly to floor jack.
M0702SWR
Figure 3.
0227-3
TM 5-3895-379-23-2
0227
REMOVAL - Continued 4. 5. Remove grease fittings (Figure 4, Item 4) from pivot pins (Figure 4, Item 3). Remove pivot pins (Figure 4, Item 3) from bores in rear frame (Figure 4, Item 1) and steering pivot assembly (Figure 4, Item 2).
WARNING
Use caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may cause injury or death.
NOTE
Note the quantity and location of shims used for upper and lower pivot pins. Weight of steering pivot assembly is 295 lb (134 kg). Inspect shims for damage and wear and replace as necessary. 6. Use lifting device and remove steering pivot assembly (Figure 4, Item 2) and shims from rear frame (Figure 4, Item 1).
3, 4
Figure 4.
2
M0703SWR
0227-4
TM 5-3895-379-23-2
0227
REMOVAL - Continued 7. If necessary, remove two bearings (Figure 5, Item 2), bearing (Figure 5, Item 3), and race (Figure 5, Item 4) from steering pivot assembly (Figure 5, Item 1). Inspect bearings and race for damage and wear and replace as necessary.
1 2
3, 4
M0704SWR
0227-5
TM 5-3895-379-23-2
0227
INSTALLATION
WARNING
CAUTION
Ensure steering pivot assembly, rear frame, bearing, and race surfaces are clean and dry prior to installation. Contamination of these systems could result in premature failure.
NOTE
Apply a sufficient amount of clean grease to bearings and race prior to installation. 1. If removed, install bearing (Figure 6, Item 3) and race (Figure 6, Item 4) as a unit and two bearings (Figure 6, Item 2) into steering pivot assembly (Figure 6, Item 1).
NOTE
Weight of steering pivot assembly is 295 lb (134 kg). 2. Use a lifting device and position steering pivot assembly (Figure 6, Item 1) on floor jack.
1 2
3, 4
M1186SWR
Figure 6.
Steering Pivot Installation.
0227-6
TM 5-3895-379-23-2
0227
INSTALLATION - Continued 3. 4. 5. 6. Position steering pivot assembly (Figure 6, Item 1) to rear of frame (Figure 7, Item 1). Install shims and steering pivot assembly (Figure 6, Item 1) on rear frame (Figure 7, Item 1). Install pivot pins (Figure 7, Item 3) in bores in rear frame (Figure 7, Item 1) and steering pivot assembly (Figure 6, Item 1). Install two grease fittings (Figure 7, Item 4) in pivot pins (Figure 7, Item 3).
3, 4
Figure 7. 7.
2
M1185SWR
Install two bolts (Figure 8, Item 3), washers (Figure 8, Item 2), and nuts (Figure 8, Item 1) to secure upper and lower pivot pins (Figure 8, Item 4) in place.
1, 2, 3
M1184SWR
Figure 8.
0227-7
TM 5-3895-379-23-2
0227
INSTALLATION - Continued 8. Install two washers (Figure 9, Item 2), bolts (Figure 9, Item 1), and nuts (Figure 9, Item 4) that fasten steering cylinder (Figure 9, Item 3) to steering pivot assembly (Figure 9, Item 5).
1, 2
5
Figure 9. 9. Repeat Step (8) for other steering cylinder.
M0705SWR
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Install yoke. (WP 0228) Lower operator platform assembly. (WP 0235) Operate roller and check for proper operation. (TM 5-3895-379-10)
0227-8
TM 5-3895-379-23-2
0228
FIELD MAINTENANCE YOKE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Gage Differential, Dial Indicating (WP 0289, Table 1, Item 9) Guide Screw (WP 0289, Table 1, Item 14) Lifting Device, Minimum Capacity 2,300 lb (1,044 kg) Straps, Lifting, Minimum Capacity 85 lb (39 kg) Materials/Parts Wooden Blocks Qty: Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figures 83, 95, and 124 Equipment Condition Drum scraper removed. (WP 0263) Drum assembly removed. (WP 0265)
REMOVAL 1. Remove two nuts (Figure 1, Item 1), bolts (Figure 1, Item 2), and clamp (Figure 1, Item 4) from both sides of yoke (Figure 1, Item 3). Move hose assemblies out of the way.
1, 2 3
4
M0706SWR
Figure 1.
Yoke Removal.
0228-1
TM 5-3895-379-23-2
0228
REMOVAL - Continued 2. Position wooden blocks (Figure 2, Item 1) under roller as shown.
M0708SWR
Figure 2.
Yoke Removal.
WARNING
Use caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may cause injury or death. 3. 4. Attach lifting straps and a lifting device to position yoke (Figure 3, Item 7) as shown. Install guide bolts (Figure 3, Item 1).
NOTE
Use marks on shims to note location for installation purposes. Shims are located between plate and pivot housing. 5. 6. With assistance, position bottom plate (Figure 3, Item 3) on yoke (Figure 3, Item 7). Remove four bolts (Figure 3, Item 5), washers (Figure 3, Item 6), and shims (Figure 3, Item 4) from bottom plate (Figure 3, Item 3). Inspect shims for damage or worn condition, replace as necessary.
NOTE
Use marks on shims to note location for installation purposes. 7. Remove two outside top bolts (Figure 3, Item 2) and install two M24 x 3.0 guide bolts (Figure 3, Item 1). Remove remaining two bolts (Figure 3, Item 2) and shims (Figure 3, Item 4).
0228-2
TM 5-3895-379-23-2
0228
REMOVAL - Continued
NOTE
Weight of plate is 85 lb (39 kg). 8. With assistance, remove plate (Figure 3, Item 3) from yoke (Figure 3, Item 7) and guide bolts (Figure 3, Item 1).
NOTE
Weight of yoke is 2,300 lb (1,044 kg). 9. With assistance, use lifting device to remove yoke (Figure 3, Item 7) from roller.
5, 6
M0709SWR
Figure 3. 10.
Yoke Removal.
Remove bearings (Figure 4, Item 1) from yoke (Figure 4, Item 2).
2
Figure 4. Yoke Removal.
M0711SWR
0228-3
TM 5-3895-379-23-2
0228
REMOVAL - Continued 11. If necessary, remove bearing race (Figure 5, Item 2) from bottom plate (Figure 5, Item 1).
1 2
M0712SWR
Figure 5. END OF TASK INSTALLATION
Yoke Removal.
NOTE
Apply a sufficient amount of clean grease to bearing and race prior to installation. 1. Install bearing race (Figure 6, Item 2) in bottom plate (Figure 6, Item 1) if it was removed.
1 2
M0713SWR
Figure 6.
Yoke Installation.
0228-4
TM 5-3895-379-23-2
0228
INSTALLATION - Continued 2. Install bearings (Figure 7, Item 1) on yoke (Figure 7, Item 2).
2
Figure 7. Yoke Installation.
M0711SWR
0228-5
TM 5-3895-379-23-2
0228
WARNING
Use caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may cause injury or death. 3. 4. Attach lifting straps using a lifting device to position yoke (Figure 8, Item 7) on roller. Install guide bolts (Figure 8, Item 1).
NOTE
Weight of plate is 85 lb (39 kg). Shims are positioned between plate and yoke. 5. 6. 7. With assistance, position bottom plate (Figure 8, Item 3) on yoke (Figure 8, Item 7). Install original amount of shims (Figure 8, Item 4) on bottom plate (Figure 8, Item 3) and install two bolts (Figure 8, Item 2). Remove guide bolts and install two top bolts (Figure 8, Item 2). Install original amount of shims (Figure 8, Item 4) on bottom plate (Figure 8, Item 3) and install washers (Figure 8, Item 6) and bolts (Figure 8, Item 5).
5, 6
M0715SWR
Figure 8.
Yoke Installation.
0228-6
TM 5-3895-379-23-2
0228
INSTALLATION - Continued 8. Remove wooden blocks (Figure 9, Item 1) from under roller and remove hoist and lifting straps.
M0718SWR
Figure 9. 9.
Yoke Installation.
Position hose assemblies and install two clamps (Figure 10, Item 4), bolts (Figure 10, Item 2), and nuts (Figure 10, Item 1) on both sides of yoke (Figure 10, Item 3).
1, 2 3
4
M0719SWR
Figure 10. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install drum assembly. (WP 0265) Install drum scraper. (WP 0263)
Yoke Installation.
END OF TASK
0228-7
TM 5-3895-379-23-2
0228
CHECK VERTICAL STEER PIVOT CLEARANCE
NOTE
After installation of the drum assembly, the clearance between vertical bushings and vertical pins must be checked. 1. 2. 3. 4. 5. Position roller on a hard, level surface. Stop engine and apply parking brake (TM 5-3895-379-10). Attach base of dial indicator (Figure 11, Item 1) to top of steering pivot housing as shown. Set dial indicator actuator on top of rear frame. Set dial indicator (Figure 11, Item 1) to zero. Put a hydraulic jack under rear frame at pivot assembly. Raise hydraulic jack to obtain greatest dial indicator (Figure 11, Item 1) reading. Record this dimension.
1
M0720SWR
Figure 11. Vertical Steer Pivot Clearance Check.
0228-8
TM 5-3895-379-23-2
0228
CHECK VERTICAL STEER PIVOT CLEARANCE - Continued
NOTE
When adding or removing shims, only top pivot point is shimmed. 6. With new bearings (Figure 12, Item 1) and shims (Figure 12, Item 3) installed, total movement should be 0.005 - 0.045 in. (0.13 - 1.14mm). On used roller, total vertical movement should not exceed 0.075 in. (1.91 mm). If movement is too great, clearance can be reduced by adding spacers at vertical pin joints. If movement is not enough, increase clearance by removing spacers at vertical pin joint. If proper clearance cannot be obtained with spacers, steer pivot housing should be disassembled. Bushings or any other worn components should be replaced.
7.
M0722SWR
Figure 12. Vertical Steer Pivot Clearance Check. END OF TASK
0228-9
TM 5-3895-379-23-2
0228
CHECK HORIZONTAL STEER PIVOT CLEARANCE 1. 2. 3. 4. 5. 6. 7. Position roller on a hard level surface. Stop engine and apply parking brake (TM 5-3895-379-10). Attach base of dial indicator (Figure 13, Item 1) to top of steering pivot housing. Set dial indicator actuator against front face of rear frame. Set dial indicator (Figure 13, Item 1) to zero. Put a hydraulic jack under rear frame at pivot assembly. Raise hydraulic jack and record reading on dial indicator (Figure 13, Item 1). With new bearings, bushings and pins, total recorded movement should be 0.004 - 0.030 in. (0.10 - 0.76mm). On used roller, total movement should not exceed 0.050 in. (1.27 mm). If movement is too much, steering pivot housing should be disassembled. Bushings, bearings and any other worn components should be replaced.
1
M0723SWR
Figure 13. Horizontal Steer Pivot Clearance Check. END OF TASK OSCILLATION BEARING CLEARANCE
NOTE
During assembly, it is recommended that this clearance measurement be made prior to installing drum into yoke. 1. 2. Put roller on hard level surface. Stop engine and apply parking brake (TM 5-3895-379-10). Attach base of dial indicator (Figure 14, Item 1) to steering pivot bearing plate. Set dial indicator actuator against front face of yoke center plate.
0228-10
TM 5-3895-379-23-2
0228
OSCILLATION BEARING CLEARANCE - Continued
WARNING
Ensure pry bar is in good condition and suitable for task. Keep hands clear of heavy parts supported and use caution while working with pry bar to avoid injury. 3. 4. 5. Insert a long, heavy pry bar between yoke assembly and steering pivot housing. Push hard on pry bar to move drum and yoke assembly as far forward as possible. With dial indicator (Figure 14, Item 1) actuator set against front face of yoke, set dial indicator to zero. Insert a long, heavy pry bar between yoke assembly and plate. Push hard on pry bar to move drum and yoke assembly back toward rear frame. Observe dial indicator (Figure 14, Item 1) and record reading.
NOTE
When removing or adding shims behind plate, remove or add equal amounts at top and bottom of plate. 6. Total movement should be 0.002 - 0.010 in. (0.05 - 0.25 mm) on a new assembly. The maximum reading for used assembly should be 0.020 in. (0.51 mm). If movement is too great, clearance can be reduced by removing shims from behind plate. If clearance is not enough, add shims to increase clearance.
NOTE
Inadequate bearing lubrication may result if zero end play or a preload condition is present. 7. If proper clearance cannot be obtained with removal or addition of shims, oscillation assembly should be disassembled. Bushings and any other worn or damaged components should be replaced.
1
M0724SWR
Figure 14. Oscillation Bearing Clearance Check. END OF TASK END OF WORK PACKAGE
0228-11/12 blank
TM 5-3895-379-23-2
0229
FIELD MAINTENANCE FRONT AND REAR SUPPORTS (BUMPERS) REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Lifting Device, Minimum Capacity 625 lb (286 kg) Link (WP 0289, Table 1, Item 22) Wrench, Torque, 90-600 ft-lb (WP 0289, Table 1, Item 44) Materials/Parts Strap, Tiedown, Electrical (WP 0288, Table 1, Item 67, 68, 69) Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figure 96 Equipment Condition Engine off. (TM 5-3895-379-10) Equipment Condition (cont.) Drums chocked. (TM 5-3895-379-10) Vehicle classification sign kit removed. (WP 0248) Front (or rear) water tank assembly removed. (WP 0269) Warning horn assembly removed. (Volume 1, WP 0186) Front (or rear) water spray strainer assembly removed. (WP 0276) Front (or rear) water spray pump removed. (WP 0270) Front (or rear) work light assemblies removed. (Volume 1, WP 0178) Front (or rear) water lines removed. (WP 0273) Front (or rear) scraper bar removed. (WP 0263)
0229-1
TM 5-3895-379-23-2
0229
REMOVAL
NOTE
Front and rear supports (bumpers) are replaced the same way. Rear bumper is shown. Remove electrical tiedown straps as necessary. Front side down, rear side similar. 1. Pull wiring harness (Figure 1, Item 1) though hole in backside of bumper assembly (Figure 1, Item 3) and position in a safe area.
WARNING
NOTE
Bumper assembly weighs 625 lb (283 kg). 2. 3. 4. Attach a lifting device to bumper assembly (Figure 1, Item 3). Remove six screws (Figure 1, Item 5) and washers (Figure 1, Item 2) from bumper assembly (Figure 1, Item 3). Operate lifting device while assistant guides bumper assembly (Figure 1, Item 3) away from yoke assembly (Figure 1, Item 4).
5 4 1
M0725SWR
Figure 1. Front and Rear Support (Bumpers) Removal. END OF TASK
0229-2
TM 5-3895-379-23-2
0229
INSTALLATION
WARNING
NOTE
Bumper weighs 625 lb (283 kg). Front side shown, rear side similar. 1. 2. 3. Attach a lifting device to bumper assembly (Figure 2, Item 3). Operate lifting device while assistant guides the bumper assembly (Figure 2, Item 3) into position on yoke assembly (Figure 2, Item 4). Install six screws (Figure 2, Item 5) and washers (Figure 2, Item 2) in yoke assembly (Figure 2, Item 4) and bumper assembly (Figure 2, Item 3). Tighten screws to 295-385 lb-ft (400-522 Nm).
NOTE
Replace electrical tiedown straps as required. 4. Pull wiring harness (Figure 2, Item 1) though hole in backside of bumper assembly (Figure 2, Item 3) and position for component installation.
5 4 1
M1183SWR
Front and Rear Support (Bumpers) Installation.
0229-3
TM 5-3895-379-23-2
0229
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Install front and/or rear scraper bar. (WP 0263) Install water lines. (WP 0273) Install work light assemblies. (Volume 1, WP 0178) Install water spray pump. (WP 0270) Install water spray strainer assembly. (WP 0276) Install warning horn assembly. (Volume 1, WP 0186) Install water tank assembly. (WP 0269) Install vehicle classification sign kit. (WP 0248) Start engine. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0229-4
TM 5-3895-379-23-2
0230
FIELD MAINTENANCE DECONTAMINATION KIT BRACKET REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (WP 0289, Table 1, Item 42) Personnel Required Construction Equipment Repairer 91L References TM 3895-379-23P, Figure 96 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Decontamination kit removed.
0230-1
TM 5-3895-379-23-2
0230
REMOVAL 1. Remove strap (Figure 1, Item 2) from bracket (Figure 1, Item 3).
WARNING
Use caution when handling heavy parts. Provide adequate support and use assistance during procedure. Failure to follow this warning may cause injury or death.
NOTE
Plate with decontamination kit bracket attached weighs 22 lb (10 kg). 2. 3. Remove four screws (Figure 1, Item 6), washers (Figure 1, Item 7), and plate (Figure 1, Item 8) from bumper assembly (Figure 1, Item 9). Remove four screws (Figure 1, Item 4), washers (Figure 1, Item 5), nuts (Figure 1, Item 1), and bracket (Figure 1, Item 3) from plate (Figure 1, Item 8).
1 2
6 5
M0726SWR
Figure 1. Decontamination Kit Bracket Removal. END OF TASK
0230-2
TM 5-3895-379-23-2
0230
INSTALLATION 1. 2. 3. Install bracket (Figure 2, Item 3), four washers (Figure 2, Item 5), screws (Figure 2, Item 4), and nuts (Figure 2, Item 1) on plate (Figure 2, Item 8). Tighten nuts to 15-25 lb-ft (20-34 Nm). Install plate (Figure 2, Item 8) on bumper assembly (Figure 2, Item 9) with four screws (Figure 2, Item 6) and washers (Figure 2, Item 7). Tighten screws to 15-25 lb-ft (20-34 Nm). Install strap (Figure 2, Item 2) in bracket (Figure 2, Item 3).
1 2
6 5
M1310SWR
Figure 2. Decontamination Kit Bracket Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install decontamination kit. Remove chocks. (TM 5-3895-379-10)
0230-3/4 blank
TM 5-3895-379-23-2
0231
FIELD MAINTENANCE DOOR ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Lifting Device, Minimum Capacity 100 lb (45 kg) Wrench, Torque, 0-300 in-lb (WP 0289, Table 1, Item 41) Wrench, Torque, 20-100 ft-lb (WP 0289, Table 1, Item 42) Materials/Parts Locknut (WP 0290, Table 1, Item 111) Qty: Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figures 99 and 100 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0231-1
TM 5-3895-379-23-2
0231
REMOVAL
NOTE
Right and left-side door assemblies are replaced the same way except where noted. Rightside door assembly is shown. 1. Open right-side door assembly (Figure 1, Item 4) (TM 5-3895-379-10).
WARNING
NOTE
Door assemblies weigh 100 lb (45 kg) each. 2. 3. Attach lifting device to door assembly (Figure 1, Item 4). Starting at bottom bolt and moving up, remove five bolts (Figure 1, Item 3), washers (Figure 1, Item 2), and door assembly (Figure 1, Item 4) from frame assembly (Figure 1, Item 1).
1 2
4
M0727SWR
Figure 1. Door Assembly Removal.
0231-2
TM 5-3895-379-23-2
0231
REMOVAL - Continued 4. 5. If damaged, remove four nuts (Figure 2, Item 12), washers (Figure 2, Item 11), bolts (Figure 2, Item 8), and two catches (Figure 2, Item 9) from support (Figure 2, Item 10). If damaged, remove four screws (Figure 2, Item 13), washers (Figure 2, Item 14), and two supports (Figure 2, Item 10) from yoke assembly (Figure 2, Item 1).
NOTE
Step (6) applies to right-side door assembly only. 6. If damaged, remove 12 nuts (Figure 2, Item 2), bolts (Figure 2, Item 4), washers (Figure 2, Item 3), four plates (Figure 2, Item 5), and air seals (Figure 2, Item 7) from door assembly (Figure 2, Item 6).
13 14 12 11 10 9 6 8 5
Figure 2. Door Assembly Removal.
M0728SWR
0231-3
TM 5-3895-379-23-2
0231
REMOVAL - Continued
END OF TASK DISASSEMBLY
NOTE
Right and left-side door assemblies are repaired the same way. Right-side door assembly is shown. Door assembly can be repaired with door installed on roller or with door assembly removed from roller. If door requires complete repair, door assembly must be removed from roller. 1. 2. If repairing door assembly (Figure 3, Item 1) while installed on roller, open door assembly (TM 5-3895-379-10). If damaged, remove nut (Figure 3, Item 2), bolt (Figure 3, Item 4), lanyard (Figure 3, Item 3), and washer (Figure 3, Item 5) from door assembly (Figure 3, Item 1).
1 2 3
4 5
M0730WR
Figure 3. Door Assembly Disassembly.
0231-4
TM 5-3895-379-23-2
0231
DISASSEMBLY - Continued 3. If damaged, remove two locknuts (Figure 4, Item 2), bolt (Figure 4, Item 5), screw (Figure 4, Item 6), washers (Figure 4, Item 4), and lock (Figure 4, Item 1) from door assembly (Figure 4, Item 3). Discard locknuts.
1
3 5 4
M0729SWR
Figure 4. 4.
Door Assembly Disassembly.
If damaged, remove four bolts (Figure 5, Item 5), washers (Figure 5, Item 4), two guides (Figure 5, Item 3), and latch assembly (Figure 5, Item 2) from door assembly (Figure 5, Item 1).
2 1 3 4 5
M0731SWR
Door Assembly Disassembly.
0231-5
TM 5-3895-379-23-2
0231
ASSEMBLY 1. If removed, install latch assembly (Figure 6, Item 2) and two guides (Figure 6, Item 3) on door assembly (Figure 6, Item 1) with four bolts (Figure 6, Item 5) and washers (Figure 6, Item 4). Tighten bolts to 15-25 lb-ft (20-34 Nm).
2 1 3 4 5
M1178SWR
Figure 6. 2.
Door Assembly.
If removed, install lock (Figure 7, Item 1) on door assembly (Figure 7, Item 3) with screw (Figure 7, Item 6), bolt (Figure 7, Item 5), two washers (Figure 7, Item 4), and new locknuts (Figure 7, Item 2). Tighten locknuts to 15-25 lb-ft (20-34 Nm).
1
3 5 4
M1177SWR
Figure 7.
Door Assembly.
0231-6
TM 5-3895-379-23-2
0231
ASSEMBLY - Continued 3. 4. 5. If removed, install lanyard (Figure 8, Item 3) on door assembly (Figure 8, Item 1) with washer (Figure 8, Item 5), bolt (Figure 8, Item 4), and nut (Figure 8, Item 2). Tighten nut to 84-132 lb-in. (9-15 Nm). If door assembly (Figure 8, Item 1) was repaired while installed on components roller, close door assembly. If door assembly (Figure 8, Item 1) was removed for repair, install door assembly. Refer to INSTALLATION in this work package.
4 1 2 3 5
M0732SWR
Door Assembly.
0231-7
TM 5-3895-379-23-2
0231
INSTALLATION
NOTE
Step (1) applies to right-side door assembly only. 1. If removed, install four air seals (Figure 9, Item 7) and plates (Figure 9, Item 5) on door assembly (Figure 9, Item 6) with 12 bolts (Figure 9, Item 4), washers (Figure 9, Item 3), and nuts (Figure 9, Item 2). Tighten nuts to 84-132 lb-in. (9-15 Nm). If removed, install two supports (Figure 9, Item 10) on yoke assembly (Figure 9, Item 5) with four washers (Figure 9, Item 14) and screws (Figure 9, Item 13). Tighten screws to 33-47 lb-ft (45-64 Nm). If removed, install two catches (Figure 9, Item 9) on support (Figure 9, Item 10) with four bolts (Figure 9, Item 8), washers (Figure 9, Item 11), and nuts (Figure 9, Item 12). Tighten nuts to 33-47 lb-ft (45-64 Nm).
2. 3.
13 14 12 11 10 9 6 8 5
Figure 9. Door Assembly Installation.
M1176SWR
WARNING
NOTE
Door assemblies weigh 100 lb (45 kg) each. 4. 5. Attach lifting device to door assembly (Figure 10, Item 4). Install door assembly (Figure 10, Item 4) on frame assembly (Figure 10, Item 1) with five washers (Figure 10, Item 2) and bolts (Figure 10, Item 3). Turn bolts until snug, but do not tighten bolts.
0231-8
TM 5-3895-379-23-2
0231
M0734SWR
Figure 10. 6.
Door Assembly Installation.
Align door assembly (Figure 11, Item 2) so that top of door is parallel with operator platform (Figure 11, Item 1) when closed. While assistant holds door assembly in place, tighten bolts to 33-47 lb-ft (45-64 Nm). Close door assembly (Figure 11, Item 2) (TM 5-3895-379-10).
7.
2
Figure 11. END OF TASK FOLLOW-ON MAINTENANCE Remove chocks. (TM 5-3895-379-10) END OF TASK END OF WORK PACKAGE Door Assembly Installation.
M0735SWR
0231-9/10 blank
TM 5-3895-379-23-2
0232
FIELD MAINTENANCE LEFT AND RIGHT-SIDE HANDRAIL ASSEMBLIES REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (WP 0289, Table 1, Item 42) Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figure 103 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Right and left-side door assemblies opened. (TM 5-3895-379-10)
0232-1
TM 5-3895-379-23-2
0232
REMOVAL
WARNING
CAUTION
Failure to hold handrail assembly in place during removal will allow handrail assembly to fall and become damaged.
NOTE
Right and left handrail assemblies are replaced the same way. Right handrail assembly is shown. Note position of handrail assembly before removal. Left handrail weighs 25 lb (11 kg). Right handrail weighs 17 lb (8 kg). 1. 2. While assistant holds handrail assembly (Figure 1, Item 2), remove four bolts (Figure 1, Item 4), washers (Figure 1, Item 3), and handrail assembly from two plate assemblies (Figure 1, Item 6). Remove eight nuts (Figure 1, Item 7), washers (Figure 1, Item 8), screws (Figure 1, Item 1), washers (Figure 1, Item 8), and two plate assemblies (Figure 1, Item 6) from platform assembly (Figure 1, Item 5).
2 1 3 4
5 6 8 7
M0736SWR
Left and Right-side Handrail Assemblies Removal.
0232-2
TM 5-3895-379-23-2
0232
INSTALLATION
WARNING
CAUTION
NOTE
Left handrail weighs 25 lb (11 kg). Right handrail weighs 17 lb (8 kg). 1. 2. With assistance, install handrail assembly (Figure 2, Item 2) in two plate assemblies (Figure 2, Item 6) with four washers (Figure 2, Item 3) and bolts (Figure 2, Item 4). Install two plate assemblies (Figure 2, Item 6) on platform assembly (Figure 2, Item 5) with eight washers (Figure 2, Item 8), screws (Figure 2, Item 1), washers (Figure 2, Item 8), and nuts (Figure 2, Item 7). Tighten nuts to 60 lb-ft (81 Nm).
1 4
5 6 8 7
M1182SWR
Left and Right-side Handrail Assemblies Installation.
0232-3
TM 5-3895-379-23-2
0232
FOLLOW-ON MAINTENANCE 1. 2. Close right and left-side door assemblies. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0232-4
TM 5-3895-379-23-2
0233
FIELD MAINTENANCE FRONT HANDRAIL ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (WP 0289, Table 1, Item 42) Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figure 103 Equipment Condition Rifle mounting bracket removed. (WP 0246)
0233-1
TM 5-3895-379-23-2
0233
REMOVAL
WARNING
CAUTION
NOTE
Front handrail assembly weighs 35 lb (16 kg). 1. While assistant holds front handrail assembly (Figure 1, Item 1), remove eight nuts (Figure 1, Item 4), washers (Figure 1, Item 3), screws (Figure 1, Item 2), and washers (Figure 1, Item 3) from left- and right-side of front handrail assembly. Remove four screws (Figure 1, Item 2), washers (Figure 1, Item 3), and front handrail assembly (Figure 1, Item 1) from platform assembly (Figure 1, Item 5).
2.
1 2 3
3 4
M0737SWR
Front Handrail Assembly Removal.
0233-2
TM 5-3895-379-23-2
0233
INSTALLATION With assistance, install handrail assembly (Figure 2, Item 1) on platform assembly (Figure 2, Item 5) with 12 washers (Figure 2, Item 3), screws (Figure 2, Item 2), eight washers (Figure 2, Item 3), and nuts (Figure 2, Item 4). Tighten nuts to 60 lb-ft (81 Nm).
2 3
5 3 4 CENTER RAIL ONLY

M0738SWR
Figure 2. Front Handrail Assembly Installation. END OF TASK FOLLOW-ON MAINTENANCE Install rifle mounting bracket. (WP 0246) END OF TASK END OF WORK PACKAGE
0233-3/4 blank
TM 5-3895-379-23-2
0234
FIELD MAINTENANCE ROLLOVER PROTECTION STRUCTURE (ROPS) ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Lifting Device, Minimum Capacity 880 lb (399 kg) Wrench, Torque, 20-100 ft-lb (WP 0289, Table 1, Item 42) Wrench, Torque, 90-600 ft-lb (WP 0289, Table 1, Item 44) Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figure 98 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0234-1
TM 5-3895-379-23-2
0234
REMOVAL
NOTE
The CB534B Roller has eight bolts. The CB534C Roller has four bolts. 1. 2. 3. With the aid of an assistant, remove bolts (Figure 1, Item 8), washers (Figure 1, Item 9), and rear handrail assembly (Figure 1, Item 5) from ROPS assembly (Figure 1, Item 4). Remove three bolts (Figure 1, Item 10) and washers (Figure 1, Item 11) from frame assembly (Figure 1, Item 12) and three handrail assemblies (Figure 1, Items 3, 6, and 7). With the aid of an assistant, remove six bolts (Figure 1, Item 2), washers (Figure 1, Item 1), and three side handrail assemblies (Figure 1, Items 3, 6, and 7) from ROPS assembly (Figure 1, Item 4).
2 4 8 5 9
7 3 6 7 7 5 4
12
11
10
M0739SWR
Figure 1.
Rollover Protection Structure (ROPS) Assembly Removal.
0234-2
TM 5-3895-379-23-2
0234
REMOVAL - Continued
WARNING
NOTE
ROPS assembly weighs 880 lb (399 kg). 4. Attach lifting device to ROPS assembly (Figure 2, Item 2).
NOTE
There are 11 remaining bolts attaching ROPS assembly to frame assembly. Leave one bolt in each side for stability. 5. 6. 7. 8. Remove nine bolts (Figure 2, Item 3) and washers (Figure 2, Item 4) from ROPS assembly (Figure 2, Item 2) and frame assembly (Figure 2, Item 1). Raise lifting device until tight. Remove remaining two bolts (Figure 2, Item 3) and washers (Figure 2, Item 4) from ROPS assembly (Figure 2, Item 2) and frame assembly (Figure 2, Item 1). While assistant operates lifting device, guide ROPS assembly (Figure 2, Item 2) from frame assembly (Figure 2, Item 1).
1 2
3 1
M0740SWR
Rollover Protection Structure (ROPS) Assembly Removal.
0234-3
TM 5-3895-379-23-2
0234
INSTALLATION
WARNING
NOTE
ROPS assembly weighs 880 lb (399 kg). 1. 2. Attach lifting device to ROPS assembly (Figure 3, Item 2). Position ROPS assembly (Figure 3, Item 2) on frame assembly (Figure 3, Item 1).
NOTE
Leave one bolt out of top rear hole on right-side for handrail assembly mounting and one bolt out of top rear hole and top front hole on left-side for handrail assembly mounting. Lifting device may be used to shift ROPS assembly for alignment. Apply oil to threads of bolts before installing. Failure to apply oil can result in improper torque. 3. 4. Install 11 bolts (Figure 3, Item 3) and washers (Figure 3, Item 4) in ROPS assembly (Figure 3, Item 2) and frame assembly (Figure 3, Item 1). Tighten bolts to 518-666 lb-ft (702-903 Nm). Remove lifting device from ROPS assembly (Figure 3, Item 2).
1 2
3 1
M1274SWR
Figure 3.
Rollover Protection Structure (ROPS) Assembly Installation.
0234-4
TM 5-3895-379-23-2
0234
INSTALLATION - Continued 5. 6. Install three handrail assemblies (Figure 4, Items 3, 6, and 7) on ROPS assembly (Figure 4, Item 4) with six washers (Figure 4, Item 1) and bolts (Figure 4, Item 2). Turn bolts until snug, but do not tighten bolts. Install three handrail assemblies (Figure 4, Items 3, 6, and 7) on ROPS assemby (Figure 4, Item 4) and frame assembly (Figure 4, Item 12) with three washers (Figure 4, Item 11) and bolts (Figure 4, Item 10). Tighten bolts to 518-666 lb-ft (702-903 Nm). Tighten six bolts (Figure 4, Item 2) to 65 lb-ft (88 Nm). Install rear handrail assembly (Figure 4, Item 5) on ROPS assembly (Figure 4, Item 4) with four washers (Figure 4, Item 9) and bolts (Figure 4, Item 8). Tighten bolts to 45 lb-ft (61 Nm).
7. 8.
2 4 8 5 9
7 3 6 7 7 5 4
12
11
10
M0741SWR
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE
Rollover Protection Structure (ROPS) Assembly Installation.
Remove chocks. (TM 5-3895-379-10) END OF TASK END OF WORK PACKAGE
0234-5/6 blank
TM 5-3895-379-23-2
0235
FIELD MAINTENANCE RAISE/LOWER OPERATOR PLATFORM ASSEMBLY
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Hoist, Wire Rope (WP 0289, Table 1, Item 15) Wrench, Torque, 20-100 ft-lb (WP 0289, Table 1, Item 42) Materials/Parts Locknut (WP 0290, Table 1, Item 70) Qty: Suitable Chain Qty: 2 Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figure 101 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Right and left-side door assemblies opened. (TM 5-3895-379-10) Handrails in stowed position. (TM 5-3895-379-10)
0235-1
TM 5-3895-379-23-2
0235
RAISE PLATFORM
WARNING
Use caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may cause injury or death. 1. 2. Move fore/aft lever (Figure 1, Item 2) right and adjust seat (Figure 1, Item 1) to full forward position. Release fore/aft lever. Pull pin assembly (Figure 1, Item 3) up and rotate operator station (Figure 1, Item 4) completely clockwise or counterclockwise. Release pin assembly ensuring that pin is securely seated in hole (Figure 1, Item 5) in operator platform.
1 2
4
M0742SWR
Figure 1.
Raise Operator Platform Assembly.
0235-2
TM 5-3895-379-23-2
0235
RAISE PLATFORM - Continued 3. Remove four nuts (Figure 2, Item 5), washers (Figure 2, Item 4), screws (Figure 2, Item 2), and washers (Figure 2, Item 3) from operator platform assembly (Figure 2, Item 1).
2 1 3 1 2 3
4 5
4 5
M0743SWR
Figure 2.
0235-3
TM 5-3895-379-23-2
0235
RAISE PLATFORM - Continued 4. 5. 6. Remove two locknuts (Figure 3, Item 3), washers (Figure 3, Item 6), and screws (Figure 3, Item 7) from stowage locations (Figure 3, Item 5) in frame assembly (Figure 3, Item 4). Discard locknuts. Attach short section of chain (Figure 3, Item 9) securely in each cutout in front of sides of yoke assembly (Figure 3, Item 8). Attach a wire rope hoist (Figure 3, Item 10) to each chain and to eyelets in handrail assemblies (Figure 3, Items 1 and 2).
WARNING
CAUTION
Operate wire rope hoists evenly to decrease chance of equipment failure. 7. 8. With assistance, use wire rope hoists (Figure 3, Item 10) to lift operator platform assembly (Figure 2, Item 1) until operator platform mount clears bolt path in frame assembly. Install two screws (Figure 3, Item 7), washers (Figure 3, Item 6), and new locknuts (Figure 3, Item 3) in platform locking hole frame assembly (Figure 3, Item 4) and operator platform assembly (Figure 2, Item 1). Tighten locknuts to 48-55 lb-ft (65-75 Nm).
0235-4
TM 5-3895-379-23-2
0235
RAISE PLATFORM - Continued
2 1 3 4 5 6 10 7
8
M0744SWR
0235-5
TM 5-3895-379-23-2
0235
LOWER PLATFORM 1. Remove two locknuts (Figure 4, Item 4), washers (Figure 4, Item 6), and screws (Figure 4, Item 7) from frame assembly (Figure 4, Item 5) and operator platform assembly (Figure 4, Item 3).
WARNING
CAUTION
Operate wire rope hoists evenly to decrease chance of equipment failure. 2. 3. 4. 5. With assistance, use wire rope hoists (Figure 4, Item 8) to lower operator platform assembly (Figure 4, Item 3) until platform rests on frame assembly (Figure 4, Item 5). Remove wire rope hoists (Figure 4, Item 8) from each chain and eyelets in handrail assemblies (Figure 4, Items 1 and 2). Remove short section of chain (Figure 4, Item 10) from cutout in each front side of yoke assembly (Figure 4, Item 9). Install two screws (Figure 4, Item 7), washers (Figure 4, Item 6), and locknuts (Figure 4, Item 4) in storage locations in frame assembly (Figure 4, Item 5). Tighten locknuts to 48-55 lb-ft (65-75 Nm).
2 1
3 4 3 5 6 7
8 10 9
M0745SWR
Figure 4. Lower Operator Platform Assembly.
0235-6
TM 5-3895-379-23-2
0235
LOWER PLATFORM - Continued 6. Install four washers (Figure 5, Item 3), screws (Figure 5, Item 2), washers (Figure 5, Item 4), and nuts (Figure 5, Item 5) in operator platform assembly (Figure 5, Item 1). Tighten nuts to 60-90 lb-ft (81-122 Nm).
2 1 3 1 2 3
4 5
4 5
M1158SWR
Figure 5. 7.
Lower Operator Platform Assembly.
Pull pin assembly (Figure 6, Item 3) up and rotate operator station (Figure 6, Item 4) completely clockwise or counterclockwise forward position. Release pin assembly ensuring that pin is securely seated in hole (Figure 6, Item 5) in operator platform.
1 2
4
M1157SWR
Lower Operator Platform Assembly.
0235-7
TM 5-3895-379-23-2
0235
FOLLOW-ON MAINTENANCE 1. 2. 3. Close right and left-side door assemblies. (TM 5-3895-379-10) Place handrail assemblies in operation position. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0235-8
TM 5-3895-379-23-2
0236
FIELD MAINTENANCE OPERATOR PLATFORM AND OPERATOR STATION REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Lifting Device, Minimum Capacity 1,250 lb (567 kg) Link (WP 0289, Table 1, Item 22) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0288, Table 1, Item 12) Tag, Marker (WP 0288, Table 1, Item 70) Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figures 101, 102, and 103 Equipment Condition Rollover protection structure (ROPS) removed. (WP 0234) Operator platform assembly raised. (WP 0235) Left- and right-side door assemblies opened. (TM 5-3895-379-10)
0236-1
TM 5-3895-379-23-2
0236
REMOVAL
WARNING
Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.
CAUTION
Cap and plug all lines and fittings immediately to prevent any contaminants from entering the system. Tag all hydraulic lines and electrical wires as they are removed or disconnected.
NOTE
Tag and mark all hydraulic lines as they are removed for installation purposes. Cap and plug all lines and fittings to prevent any contaminants from entering the system. 1. 2. 3. Release pressure in hydraulic system by slowly loosening the fill cap on the top of the hydraulic oil tank. Disconnect wiring harnesses (Figure 1, Items 3 and 4). Remove two nuts (Figure 1, Item 1) and clamp (Figure 1, Item 2).
1 2 3 4
M0746SWR
Figure 1.
Operator Platform and Operator Station Removal.
0236-2
TM 5-3895-379-23-2
0236
REMOVAL - Continued 4. Disconnect hose assemblies (Figure 2, Items 1 and 2).

1
M0747SWR
Figure 2. 5. 6. 7.
Disconnect hose assemblies (Figure 3, Items 3, 6, and 7). Remove bolt (Figure 3, Item 1), hose assemblies (Figure 2, Items 1 and 2) and (Figure 3, Item 3) from clamp (Figure 3, Item 2). Remove bolt (Figure 3, Item 4) from clamp (Figure 3, Item 5) on hose assembly (Figure 3, Item 3).
3, 4, 5
6
M0748SWR
Figure 3.
0236-3
TM 5-3895-379-23-2
0236
REMOVAL - Continued 8. Disconnect hose assemblies (Figure 4, Item 1) underneath roller.

1
M0749SWR
Figure 4. 9. 10.
Disconnect hose assembly (Figure 5, Item 1). Remove bolt (Figure 5, Item 2) from clamp (Figure 5, Item 3) on hose assemblies (Figure 4, Item 1) and (Figure 5, Item 1) and the frame.
1, 2, 3
M0750SWR
Figure 5.
0236-4
TM 5-3895-379-23-2
0236
REMOVAL - Continued 11. 12. Lower operator platform (WP 0235). Remove bolts (Figure 6, Item 1) and locknuts (Figure 6, Item 2).
1, 2
M0751SWR
Figure 6. 13.
Remove bolt (Figure 7, Item 1) from each side of the front rail assembly.
1
M0752SWR
Figure 7.
0236-5
TM 5-3895-379-23-2
0236
REMOVAL - Continued
NOTE
The weight of the operator platform is 1,050 lb (476 kg). 14. 15. 16. Install lifting bracket to each corner of the operator platform (Figure 8, Item 1). Install lifting device and remove operator platform (Figure 8, Item 1) from roller. Position operator platform (Figure 8, Item 1) securely on wooden blocks.
M0753SWR
Figure 8.
NOTE
The weight of the console and seat assembly is 1,250 lb (567 kg). 17. Remove eight bolts (Figure 9, Item 1).
M0754SWR
Figure 9.
0236-6
TM 5-3895-379-23-2
0236
REMOVAL - Continued 18. Attach a lifting device and remove console and seat assembly (Figure 10, Item 1) from operator platform (Figure 10, Item 2).
M0755SWR
Figure 10. Operator Platform and Operator Station Removal.
0236-7
TM 5-3895-379-23-2
0236
REMOVAL - Continued 19. 20. 21. Remove two bolts (Figure 11, Item 6). Remove two bolts (Figure 11, Item 5), nuts (Figure 11, Item 4), and clamp (Figure 11, Item 2) from hose assemblies (Figure 11, Item 3). Clean and inspect bearing assembly on operator platform (Figure 10, Item 2). If bearing is warped or damaged, replace operator platform (Figure 10, Item 2).
4
M0756SWR
Figure 11. Operator Platform and Operator Station Removal. END OF TASK INSTALLATION 1. 2. Install two bolts (Figure 12, Item 5), nuts (Figure 12, Item 4), and clamps (Figure 12, Item 2) to hose assemblies (Figure 12, Item 3). Install two bolts (Figure 12, Item 6).
0236-8
TM 5-3895-379-23-2
0236
4
M1163SWR
Figure 12. Operator Platform and Operator Station Installation.
NOTE
The weight of the console and seat assembly is 1,250 lb (567 kg). 3. 4. Install lifting device and install console and seat assembly (Figure 13, Item 1) to operator platform (Figure 13, Item 2). Install eight bolts (Figure 13, Item 3).
3
M0757SWR
0236-9
TM 5-3895-379-23-2
0236
NOTE
The weight of the operator platform is 1,050 lb (476 kg). 5. 6. Attach lifting device and install operator platform (Figure 14, Item 1) to roller. Remove lifting bracket from each corner of operator platform (Figure 14, Item 1).
M0758SWR
Figure 14. Operator Platform and Operator Station Installation. 7. Install bolt (Figure 15, Item 1) to each side of the front rail assembly.
1
M0759SWR
0236-10
TM 5-3895-379-23-2
0236
INSTALLATION - Continued 8. Install bolts (Figure 16, Item 1) and locknuts (Figure 16, Item 2).
1, 2
M0760SWR
Figure 16. Operator Platform and Operator Station Installation. 9. 10. 11. Raise operator platform (WP 0235). Install bolt (Figure 17, Item 2) to clamp (Figure 17, Item 3) on hose assemblies (Figure 18, Item 1) and (Figure 17, Item 1) and the frame. Connect hose assembly (Figure 17, Item 1).
1, 2, 3
M0761SWR
0236-11
TM 5-3895-379-23-2
0236
INSTALLATION - Continued 12. Connect hose assemblies (Figure 18, Item 1) underneath roller.
M0762SWR
Figure 18. Operator Platform and Operator Station Installation. 13. 14. 15. Install bolt (Figure 19, Item 4) to clamp (Figure 19, Item 5) on hose assembly (Figure 19, Item 3). Install bolt (Figure 19, Item 1), hose assemblies (Figure 20, Items 1 and 2) and (Figure 19, Item 3) to clamp (Figure 19, Item 2). Connect hose assemblies (Figure 19, Items 3, 6, and 7).
3, 4, 5
6
M0763SWR
0236-12
TM 5-3895-379-23-2
0236
INSTALLATION - Continued 16. Connect hose assemblies (Figure 20, Items 1 and 2).
1
M0764SWR
Figure 20. Operator Platform and Operator Station Installation. 17. 18. Connect wiring harnesses (Figure 21, Items 3 and 4). Install two nuts (Figure 21, Item 1) and clamp (Figure 21, Item 2).
1 2 3 4
M0765SWR
Figure 21. Operator Platform and Operator Station Installation. END OF TASK
0236-13
TM 5-3895-379-23-2
0236
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Lower operator platform assembly. (WP 0235) Tighten fill cap on top of hydraulic oil tank. (Volume 1, WP 0124) Install rollover protection structure (ROPS). (WP 0234) Close left- and right-side door assembly. (TM 5-3895-379-10)
0236-14
TM 5-3895-379-23-2
0237
FIELD MAINTENANCE ROTATE LOCK REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (WP 0289, Table 1, Item 42) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 104 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
REMOVAL 1. 2. 3. Remove four screws (Figure 1, Item 7), washers (Figure 1, Item 6), and rotate lock assembly (Figure 1, Item 5) from operator station (Figure 1, Item 1). Remove spring pin (Figure 1, Item 2), washer (Figure 1, Item 9), pin (Figure 1, Item 3), and spring (Figure 1, Item 8) from rotate lock assembly plate (Figure 1, Item 5). Remove two bearings (Figure 1, Item 4) from rotate lock assembly plate (Figure 1, Item 5).
2 3
8 9 10 4
6 7
M0766SWR
Rotate Lock Removal.
0237-1
TM 5-3895-379-23-2
0237
INSTALLATION 1. 2. 3. 4. 5. Install two bearings (Figure 2, Item 4) on rotate lock assembly plate (Figure 2, Item 5). Install spring (Figure 2, Item 8), washer (Figure 2, Item 9), and pin (Figure 2, Item 3) in rotate lock assembly plate (Figure 2, Item 5). Compress washer (Figure 2, Item 9) and spring (Figure 2, Item 8) and install spring pin (Figure 2, Item 2) in pin (Figure 2, Item 3). Install rotate lock assembly (Figure 2, Item 5) on operator station (Figure 2, Item 1) with four washers (Figure 2, Item 6) and screws (Figure 2, Item 7). Do not tighten screws. Align pin (Figure 2, Item 3) with hole in operator platform (Figure 2, Item 10) and tighten screws to 33-47 lb-ft (45-64 Nm).
1 2 3
8 9 10 4
6 7
M1258SWR
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE Remove chocks. (TM 5-3895-379-10) END OF TASK END OF WORK PACKAGE
Rotate Lock Installation.
0237-2
TM 5-3895-379-23-2
0238
FIELD MAINTENANCE OPERATOR PLATFORM MOUNT REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (WP 0289, Table 1, Item 42) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 101 Equipment Condition Operator platform assembly raised. (WP 0235)
REMOVAL
NOTE
Operator platform mounts are replaced the same way. One mount is shown. Remove two nuts (Figure 1, Item 4), washers (Figure 1, Item 2), mount (Figure 1, Item 3), two screws (Figure 1, Item 1), and washers (Figure 1, Item 2) from operator platform (Figure 1, Item 5).
1 2
3 2 4
M0767SWR
Operator Platform Mount Removal.
0238-1
TM 5-3895-379-23-2
0238
INSTALLATION Install mount (Figure 2, Item 3) on operator platform (Figure 2, Item 5) with two washers (Figure 2, Item 2), screws (Figure 2, Item 1), washers (Figure 2, Item 2), and nuts (Figure 2, Item 4). Tighten nuts to 30-35 lb-ft (41-47 Nm).
1 2
3 2 4
5
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE Lower operator platform assembly. (WP 0235) END OF TASK END OF WORK PACKAGE Operator Platform Mount Removal.
M1181SWR
0238-2
TM 5-3895-379-23-2
0239
FIELD MAINTENANCE VANDAL GUARD REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 103 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
REMOVAL Remove two shoulder screws (Figure 1, Item 1), washers (Figure 1, Item 2), and vandal guard (Figure 1, Item 3) from instrument box assembly (Figure 1, Item 4).
3 1 2
M0768SWR
Vandal Guard Removal.
0239-1
TM 5-3895-379-23-2
0239
INSTALLATION Install vandal guard (Figure 2, Item 3) on instrument box assembly (Figure 2, Item 4) with two washers (Figure 2, Item 2) and shoulder screws (Figure 2, Item 1).
3 1 2
M1278SWR
Vandal Guard Installation.
0239-2
TM 5-3895-379-23-2
0240
FIELD MAINTENANCE SEAT BELT AND LANYARD REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Remover Kit, Bolt (WP 0289, Table 1, Item 29) Wrench, Torque, 20-100 ft-lb (WP 0289, Table 1, Item 42) Materials/Parts Brush, Nylon (WP 0288, Table 1, Item 11) Sealing Compound, Loctite 271 (WP 0288, Table 1, Item 62) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 105 and 107 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0240-1
TM 5-3895-379-23-2
0240
REMOVAL
NOTE
Left and right seat belts must be replaced as a set. Seat belt fastener components must be replaced as a set each time seat belt is removed. Seat belt fastener contains all components required to attach seat belts to roller. 1. Remove locknut (Figure 1, Item 5), washer (Figure 1, Item 6), lanyard (Figure 1, Item 7), spacer (Figure 1, Item 2), and L-bracket (Figure 1, Item 8) from seat assembly (Figure 1, Item 4). Discard L-bracket, spacer, washer, and locknut. Remove left seat belt (Figure 1, Item 9), spacer (Figure 1, Item 3), spacer (Figure 1, Item 2), washer (Figure 1, Item 1), and screw (Figure 1, Item 10) from seat assembly (Figure 1, Item 4). Discard screw, washer, and spacers.
2.
4 10 9 REAR VIEW OF SEAT SHOWN FOR CLARITY

M0769SWR
Figure 1. 3. 4.
Seat Belt and Lanyard Removal.
Remove locknut (Figure 2, Item 7), washer (Figure 2, Item 1), lanyard (Figure 2, Item 2), and spacer (Figure 2, Item 6) from seat assembly (Figure 2, Item 3). Discard spacer, washer, and locknut. Remove right seat belt (Figure 2, Item 5), spacer (Figure 2, Item 6), and screw (Figure 2, Item 4) from seat assembly (Figure 2, Item 3). Discard screw and spacer.
0240-2
TM 5-3895-379-23-2
0240
REMOVAL - Continued
6 7 6
M0772SWR
Figure 2. 5.
If damaged, remove two locknuts (Figure 3, Item 5), washers (Figure 3, Item 4), lanyards (Figure 3, Item 3), and spacers (Figure 3, Item 2) from seat assembly (Figure 3, Item 1). Discard locknuts.
2
M0773SWR
0240-3
TM 5-3895-379-23-2
0240
CLEANING AND INSPECTION 1. 2. 3. 4. Clean seat belts with nylon brush. Check seat belts for loose threads and tears. Check buckle for proper operation. Check expiration date located on left seat belt. If date indicated on seat belts has passed, discard seat belt.
END OF TASK INSTALLATION 1. If installing new seat belts, punch out month and year boxes in which you are installing seat belts on punch card.
PUNCH CARD BOXES
M0770SWR
Figure 4.
Seat Belt and Lanyard Installation.
0240-4
TM 5-3895-379-23-2
0240
INSTALLATION - Continued 2. If removed, install two spacers (Figure 5, Item 2) and lanyards (Figure 5, Item 3) on seat assembly (Figure 5, Item 1) with two washers (Figure 5, Item 4) and new locknuts (Figure 5, Item 5).
2
M1165SWR
Figure 5. 3. 4.
Install spacer (Figure 6, Item 6) and right seat belt (Figure 6, Item 5) on seat assembly (Figure 6, Item 3) with screw (Figure 6, Item 4). Install spacer (Figure 6, Item 6) and lanyard (Figure 6, Item 2) on seat assembly (Figure 6, Item 3) with washer (Figure 6, Item 1) and new locknut (Figure 6, Item 7). Tighten locknut to 55 lb-ft (75 Nm).
6 7 6
M1164SWR
Figure 6.
0240-5
TM 5-3895-379-23-2
0240
INSTALLATION - Continued 5. 6. Install spacers (Figure 7, Items 2 and 3), washer (Figure 7, Item 1), and left seat belt (Figure 7, Item 9) with screw (Figure 7, Item 10). Install L-bracket (Figure 7, Item 8), spacer (Figure 7, Item 2), and lanyard (Figure 7, Item 7) on seat assembly (Figure 7, Item 4) with washer (Figure 7, Item 6) and new locknut (Figure 7, Item 5). Tighten locknut to 26-40 lb-ft (35-54 Nm).
4 10 9 REAR VIEW OF SEAT SHOWN FOR CLARITY

M0771SWR
0240-6
TM 5-3895-379-23-2
0241
FIELD MAINTENANCE SEAT ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Remover Kit, Bolt (WP 0289, Table 1, Item 29) Wrench, Torque, 20-100 ft-lb (WP 0289, Table 1, Item 42) Materials/Parts Locknut (WP 0290, Table 1, Item 117) Qty: Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 106 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
REMOVAL Remove four locknuts (Figure 1, Item 2) and seat assembly (Figure 1, Item 1) from seat suspension assembly (Figure 1, Item 3). Discard locknuts.
1 2 3
M0774SWR
Seat Assembly Removal.
0241-1
TM 5-3895-379-23-2
0241
INSTALLATION Install seat assembly (Figure 2, Item 1) on seat suspension assembly (Figure 2, Item 3) with four new locknuts (Figure 2, Item 2). Tighten locknuts to 15-25 lb-ft (20-34 Nm).
1 2 3
M1205SWR
Seat Assembly Installation.
0241-2
TM 5-3895-379-23-2
0242
FIELD MAINTENANCE SEAT ASSEMBLY REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Riveter, Blind, Hand (WP 0289, Table 1, Item 31) Screwdriver Attachment, Socket Wrench (WP 0289, Table 1, Item 32) Materials/Parts Locknut (WP 0290, Table 1, Item 117) Qty: 4 Rivet (WP 0290, Table 1, Item 119) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-370-23P, Figure 106 Equipment Condition Drums chocked. (TM 5-3895-379-10) Seat assembly removed (optional). (WP 0241)
DISASSEMBLY
NOTE
Seat assembly repair can be performed while seat assembly is either installed or removed from roller. This work package covers complete repair of seat assembly. Individual components can be replaced and/or repaired individually as needed. 1. 2. Drill out rivet (Figure 1, Item 5) and remove lanyard (Figure 1, Item 1) from seat shell (Figure 1, Item 4). Discard rivet. Remove six fasteners (Figure 1, Item 2) and literature holder (Figure 1, Item 3) from seat shell (Figure 1, Item 4).
2 1
M0775SWR
Figure 1.
Seat Assembly Disassembly.
0242-1
TM 5-3895-379-23-2
0242
DISASSEMBLY - Continued 3. 4. 5. 6. Remove three screws (Figure 2, Item 2) and left arm assembly (Figure 2, Item 4) from seat shell (Figure 2, Item 3). Remove three screws (Figure 2, Item 2) and right arm assembly (Figure 2, Item 1) from seat shell (Figure 2, Item 3). Remove clip (Figure 2, Item 6) and trim (Figure 2, Item 5) from seat shell (Figure 2, Item 3). Remove backrest cushion (Figure 2, Item 11) and seat cushion (Figure 2, Item 10) from seat shell (Figure 2, Item 3).
NOTE
Seat assembly must be moved to full forward or full rear position to remove screws and nuts holding seat supports to the adjuster assembly. 7. Remove four nuts (Figure 2, Item 7), screws (Figure 2, Item 8), and seat shell (Figure 2, Item 3) from seat adjuster (Figure 2, Item 9).
1 2
3 11 10 4 2
5 6 7 8 9
M0776SWR
Figure 2. Seat Assembly Disassembly. 8. 9. Remove four capscrews (Figure 3, Item 2), washers (Figure 3, Item 3), and two seat assembly bars (Figure 3, Item 4) from bottom of seat shell (Figure 3, Item 6). Remove four locknuts (Figure 3, Item 1) and seat adjuster (Figure 3, Item 5) from seat suspension (Figure 3, Item 7). Discard locknuts.
0242-2
TM 5-3895-379-23-2
0242
DISASSEMBLY - Continued
1 2 3 4
7 6
M0777SWR
Figure 3. END OF TASK ASSEMBLY 1. 2.
Seat Assembly Disassembly.
Install seat adjuster (Figure 4, Item 5) on seat suspension (Figure 4, Item 7) with four new locknuts (Figure 4, Item 1). Install two seat assembly bars (Figure 4, Item 4) on seat shell (Figure 4, Item 6) with four washers (Figure 4, Item 3) and capscrews (Figure 4, Item 2).
1 2 3 4
7 6
M1175SWR
Figure 4.
Seat Assembly Assembly.
0242-3
TM 5-3895-379-23-2
0242
NOTE
Seat assembly must be moved to full forward or full rear position to install screws and nuts holding seat supports to adjuster assembly. 3. 4. Install seat shell (Figure 5, Item 3) on seat adjuster (Figure 5, Item 9) with four screws (Figure 5, Item 8) and nuts (Figure 5, Item 7). Position seat cushion (Figure 5, Item 10) and backrest cushion (Figure 5, Item 11) in seat shell (Figure 5, Item 3).
NOTE
Seat cushion material must be wrapped around seat shell for proper installation. 5. 6. 7. Secure seat cushion (Figure 5, Item 10) and backrest cushion (Figure 5, Item 11) in seat shell (Figure 5, Item 3) using trim (Figure 5, Item 5) and clip (Figure 5, Item 6). Install right arm assembly (Figure 5, Item 1) on seat shell (Figure 5, Item 3) with three screws (Figure 5, Item 2). Install left arm assembly (Figure 5, Item 4) on seat shell (Figure 5, Item 3) with three screws (Figure 5, Item 2).
1 2
3 11 10 4 2
5 6 7 8 9
M1174SWR
Figure 5.
0242-4
TM 5-3895-379-23-2
0242
ASSEMBLY - Continued 8. 9. Install literature holder (Figure 6, Item 3) on seat shell (Figure 6, Item 4) with six fasteners (Figure 6, Item 2). Install lanyard (Figure 6, Item 1) on seat shell with new rivet (Figure 6, Item 5).
2 1
M0778SWR
Figure 6. END OF TASK FOLLOW-ON MAINTENANCE 1. 2.
If removed, install seat assembly. (WP 0241) Remove chocks. (TM 5-3895-379-10)
0242-5/6 blank
TM 5-3895-379-23-2
0243
FIELD MAINTENANCE SEAT SUSPENSION REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (WP 0289, Table 1, Item 42) Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figure 106 Equipment Condition Seat assembly removed. (WP 0241) Seat belt removed. (WP 0240)
REMOVAL
WARNING
NOTE
Seat suspension weighs 62 lb (28 kg). With assistance, remove four bolts (Figure 1, Item 1), washers (Figure 1, Item 2), and seat suspension assembly (Figure 1, Item 3) from operator platform assembly (Figure 1, Item 4).
1 2 3 4
M0779SWR
Seat Suspension Removal.
0243-1
TM 5-3895-379-23-2
0243
INSTALLATION With assistance, install seat suspension assembly (Figure 2, Item 3) on operator platform assembly (Figure 2, Item 4) with four washers (Figure 2, Item 2) and bolts (Figure 2, Item 1). Tighten bolts to 45-65 lb-ft (61-88 Nm).
1 2 3 4
M1131SWR
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install seat assembly. (WP 0241) Install seat belts. (WP 0240)
Seat Suspension Installation.
0243-2
TM 5-3895-379-23-2
0244
FIELD MAINTENANCE SEAT SUSPENSION REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Goggles (WP 0289, Table 1, Item 13) Screwdriver Attachment, Socket Wrench (WP 0289, Table 1, Item 32) Wrench, Torque, 0-300 in-lb (WP 0289, Table 1, Item 41) Wrench, Torque, 20-100 ft-lb (WP 0289, Table 1, Item 42) Materials/Parts Grease, Automotive and Artillery (WP 0288, Table 1, Item 24, 25, 26, 27) Sealing Compound, Loctite 271 (WP 0288, Table 1, Item 62) Locknut (WP 0290, Table 1, Item 38) Qty: 12 Push On Nut Materials/Parts (cont.) (WP 0290, Table 1, Item 131) Qty: 2 Locknut (WP 0290, Table 1, Item 36) Qty: 2 Locknut (WP 0290, Table 1, Item 98) Qty: 4 Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figure 107 Equipment Condition Seat suspension removed. (WP 0243)
DISASSEMBLY 1. 2. 3. Lift up on height adjustment lever (Figure 1, Item 1) to release spring tension. Turn knob (Figure 1, Item 4) counterclockwise to release spring tension. Remove spring pin (Figure 1, Item 3) and knob (Figure 1, Item 4) from bevel gear (Figure 1, Item 2).
LESS TENSION 3 4 MORE TENSION

Seat Suspension Disassembly.
M0780SWR
Figure 1.
0244-1
TM 5-3895-379-23-2
0244
DISASSEMBLY - Continued 4. 5. Remove four bolts (Figure 2, Item 6) and channel (Figure 2, Item 2) from left angle assembly (Figure 2, Item 3) and right angle assembly (Figure 2, Item 1). Remove four locknuts (Figure 2, Item 4), washers (Figure 2, Item 5), left angle assembly (Figure 2, Item 3), and right angle assembly (Figure 2, Item 1) from two links (Figure 2, Item 7). Discard locknuts.
5 6 7
Figure 2. Seat Suspension Disassembly. 6. 7. Remove two locknuts (Figure 3, Item 5), washers (Figure 3, Item 4), and link (Figure 3, Item 1) on left-side of seat suspension assembly (Figure 3, Item 3) from two links (Figure 3, Item 2). Discard locknuts. Remove two locknuts (Figure 3, Item 5) and washers (Figure 3, Item 4) on right-side of seat suspension assembly (Figure 3, Item 3) from two links (Figure 3, Item 2). Discard locknuts.
M0781SWR
WARNING
Height adjustment lever is under spring tension. Wear eye protection and use caution when removing height adjustment lever. Failure to follow this warning may cause injury. 8. While assistant lifts up on height adjustment lever (Figure 3, Item 6), remove link (Figure 3, Item 1) on right-side of seat suspension assembly (Figure 3, Item 3) from two links (Figure 3, Item 2).
0244-2
TM 5-3895-379-23-2
0244
2 5 4 1
M0782SWR
Figure 3. 9. 10.
Pry ends of two torsion springs (Figure 4, Item 3) on right-side of seat suspension assembly (Figure 4, Item 4) from two links (Figure 4, Item 1). Using a socket wrench screwdriver attachment, remove four bolts (Figure 4, Item 2), two links (Figure 4, Item 1), and two torsion springs (Figure 4, Item 3).
1 2
3
M0783SWR
Figure 4.
0244-3
TM 5-3895-379-23-2
0244
DISASSEMBLY - Continued 11. 12. 13. 14. Drive spring pin (Figure 5, Item 1) from latch assembly (Figure 5, Item 9). Remove height adjustment lever (Figure 5, Item 8), latch assembly (Figure 5, Item 9), and spring (Figure 5, Item 2) from upper housing assembly (Figure 5, Item 10). Remove cap (Figure 5, Item 7) from height adjustment lever (Figure 5, Item 8). Remove 24 fasteners (Figure 5, Item 5), plate (Figure 5, Item 6), and boot (Figure 5, Item 4) from seat suspension assembly (Figure 5, Item 3).
3 1 2 4
10 9 8
7 6 5
M0784SWR
Figure 5. Seat Suspension Disassembly.
WARNING
Upper housing assembly is under spring tension. Wear eye protection and use caution when removing upper housing assembly. Failure to follow this warning may cause injury. 15. 16. 17. While assistant compresses seat suspension (Figure 6, Item 4) remove drive shaft (Figure 6, Item 1) from push on nut (Figure 6, Item 3) and upper housing assembly (Figure 6, Item 5). Discard push on nut. Drive shaft (Figure 6, Item 1) from push on nut (Figure 6, Item 3) and lower housing assembly (Figure 6, Item 2). Discard push on nut. Remove gear assembly (Figure 6, Item 7) and flatwasher (Figure 6, Item 6) from upper housing assembly (Figure 6, Item 5).
0244-4
TM 5-3895-379-23-2
0244
2 3 1 1
4 5 6 3
M0785SWR
Figure 6. 18. 19.
Remove bevel gear (Figure 7, Item 1) from angle bracket (Figure 7, Item 5) and upper housing assembly (Figure 7, Item 3). Remove two locknuts (Figure 7, Item 4), square neck bolts (Figure 7, Item 2) and angle bracket (Figure 7, Item 5) from upper housing assembly (Figure 7, Item 3). Discard locknuts.
2 1
5 4
M0786SWR
Figure 7.
0244-5
TM 5-3895-379-23-2
0244
DISASSEMBLY - Continued 20. Remove upper housing assembly (Figure 8, Item 1) from arm (Figure 8, Item 2).
M0787SWR
Figure 8. Seat Suspension Disassembly.
0244-6
TM 5-3895-379-23-2
0244
DISASSEMBLY - Continued 21. 22. 23. Remove spring (Figure 9, Item 2) from lower housing assembly (Figure 9, Item 7) by turning spring to right until spring clears tabs (Figure 9, Item 1). Remove arm (Figure 9, Item 4) from lower housing assembly (Figure 9, Item 7) while sliding indicator (Figure 9, Item 10) from spring pin (Figure 9, Item 9). Remove four locknuts (Figure 9, Item 8), bolts (Figure 9, Item 6), left-hand angle (Figure 9, Item 5), and right-hand angle (Figure 9, Item 3) from lower housing assembly (Figure 9, Item 7). Discard locknuts.
1 3 10 4
9 8 7 6 5
M0788SWR
Figure 9.
0244-7
TM 5-3895-379-23-2
0244
DISASSEMBLY - Continued 24. Remove four roller guides (Figure 10, Item 3) from arm (Figure 10, Item 1).
NOTE
Note position of spacers prior to removal. 25. 26. 27. Remove spacer (Figure 10, Item 2), spacer (Figure 10, Item 6), and spacer (Figure 10, Item 5) from arm (Figure 10, Item 1). Remove four sleeve bearings (Figure 10, Item 4) from arm (Figure 10, Item 1). Remove indicator (Figure 10, Item 7) from arm (Figure 10, Item 1).
2 3 1 4
6 3 5 3 2
M0789SWR
Figure 10. Seat Suspension Disassembly. 28. 29. Remove two roller pads (Figure 11, Item 1) from upper housing assembly (Figure 11, Item 3). Remove two bumper assemblies (Figure 11, Item 2) from upper housing assembly (Figure 11, Item 3).
0244-8
TM 5-3895-379-23-2
0244
3
1
M0790SWR
Figure 11. 30. 31. 32. 33. 34.
Remove locknut (Figure 12, Item 7), bolt (Figure 12, Item 4), and shock absorber (Figure 12, Item 5) from lower housing assembly (Figure 12, Item 3). Discard locknut. Remove two sleeve bearings (Figure 12, Item 6) from shock absorber (Figure 12, Item 5). Remove two roller pads (Figure 12, Item 2) from lower housing assembly (Figure 12, Item 3). Remove two bumper assemblies (Figure 12, Item 1) from lower housing assembly (Figure 12, Item 3). Remove spring pin (Figure 12, Item 8) from lower housing assembly (Figure 12, Item 3).
2 3
4 2 6 5 7 6
M0791SWR
Figure 12.
0244-9
TM 5-3895-379-23-2
0244
DISASSEMBLY - Continued 35. Remove groove pin (Figure 13, Item 1), spacer (Figure 13, Item 2), and plate assembly (Figure 13, Item 3) from gear assembly (Figure 13, Item 4).
1 2
3 4
M1254SWR
Figure 13. Seat Suspension Disassembly. END OF TASK ASSEMBLY
NOTE
Plate assembly should be positioned at least halfway down threads of gear assembly. 1. Install plate assembly (Figure 14, Item 3) and spacer (Figure 14, Item 2) on gear assembly (Figure 14, Item 4) with groove pin (Figure 14, Item 1).
1 2
3 4
M0792SWR
Figure 14.
Seat Suspension Assembly.
0244-10
TM 5-3895-379-23-2
0244
ASSEMBLY - Continued 2. 3. 4. 5. 6. Install spring pin (Figure 15, Item 8) in lower housing assembly (Figure 15, Item 3) allowing pin to protrude from front of lower housing assembly. Install two bumper assemblies (Figure 15, Item 1) in lower housing assembly (Figure 15, Item 3). Install two roller pads (Figure 15, Item 2) in lower housing assembly (Figure 15, Item 3). Install two sleeve bearings (Figure 15, Item 6) in shock absorber (Figure 15, Item 5). Install shock absorber (Figure 15, Item 5) on lower housing assembly (Figure 15, Item 3) with bolt (Figure 15, Item 4) and new locknut (Figure 15, Item 7). Tighten locknut to 84-192 lb-in. (19-22 Nm).
2 0.60 TO 0.66 IN (15.2 TO 16.8 MM) 1 3
2 6 7 6 5
M0793SWR
Figure 15.
0244-11
TM 5-3895-379-23-2
0244
ASSEMBLY - Continued 7. 8. Install two bumper assemblies (Figure 16, Item 3) in upper housing assembly (Figure 16, Item 2). Install two roller pads (Figure 16, Item 1) in upper housing assembly (Figure 16, Item 2).
2
1
M0794SWR
Figure 16. 9. 10. 11. 12.
Install indicator (Figure 17, Item 7) on arm (Figure 17, Item 1). Install four sleeve bearings (Figure 17, Item 4) on arm (Figure 17, Item 1). Install spacers (Figure 17, Items 2, 5, and 6) on arm (Figure 17, Item 1). Install four roller guides (Figure 17, Item 3) on arm (Figure 17, Item 1).
2 3 4
6 3 5 3 2
M0795SWR
Figure 17.
0244-12
TM 5-3895-379-23-2
0244
ASSEMBLY - Continued 13. 14. 15. Slide indicator (Figure 18, Item 10) into spring pin (Figure 18, Item 9) while installing arm (Figure 18, Item 4) in lower housing assembly (Figure 18, Item 7). Apply sealing compound to threads of four bolts (Figure 18, Item 6). Install left-hand angle (Figure 18, Item 5) and right-hand angle (Figure 18, Item 3) on lower housing assembly (Figure 18, Item 7) with four bolts (Figure 18, Item 6) and new locknuts (Figure 18, Item 8). Tighten nuts to 84-192 lb-in. (9-22 Nm). Install shaft (Figure 21, Item 1) in lower housing assembly (Figure 18, Item 7) and arm (Figure 18, Item 4) with new push on nut (Figure 21, Item 3). Install spring (Figure 18, Item 2) in lower housing assembly (Figure 18, Item 7) by compressing and turning spring clockwise until spring is securely seated in three tabs (Figure 18, Item 1).
16. 17.
1 3 10 4
9 8 7 6 5
M0796SWR
Figure 18.
0244-13
TM 5-3895-379-23-2
0244
ASSEMBLY - Continued 18. Install upper housing assembly (Figure 19, Item 1) on arm (Figure 19, Item 2) by sliding arm and roller guides (Figure 17, Item 1) in channel of upper housing assembly.
M0797SWR
Figure 19.
NOTE
Ensure that arm is under shaft of bevel gear when bevel gear is installed. 19. 20. 21. Install angle bracket (Figure 20, Item 5) on upper housing assembly (Figure 20, Item 3) with two square neck bolts (Figure 20, Item 2) and new locknuts (Figure 20, Item 4). Do not tighten locknuts. Install bevel gear (Figure 20, Item 1) in angle bracket (Figure 20, Item 5) and upper housing assembly (Figure 20, Item 3). Apply grease to teeth of bevel gear (Figure 20, Item 1).
2 1
5 4
M0798SWR
Figure 20.
0244-14
TM 5-3895-379-23-2
0244
ASSEMBLY - Continued 22. Install flatwasher (Figure 21, Item 6) and gear assembly (Figure 21, Item 7) on upper housing assembly (Figure 21, Item 5).
WARNING
Upper housing assembly is under spring tension. Wear eye protection and use caution when removing upper housing assembly. Failure to follow this warning may cause injury.
NOTE
Rod of shock absorber must be fully extended to align hole for installation of rods. Ensure that square shoulder of drive shaft is fully seated in square hole of upper housing assembly before installing push-on nut. 23. While assistant compresses seat suspension assembly (Figure 21, Item 4), install drive shaft (Figure 21, Item 1) in upper housing assembly (Figure 21, Item 5), arm (Figure 18, Item 4), and shock absorber (Figure 15, Item 5) with new push on nut (Figure 21, Item 3).
2 3 1 1
4 5 6 3
M0799SWR
Figure 21.
0244-15
TM 5-3895-379-23-2
0244
ASSEMBLY - Continued 24. Install boot (Figure 22, Item 2) and plate (Figure 22, Item 5) on upper housing assembly (Figure 22, Item 1) and lower housing assembly (Figure 22, Item 3) with 24 fasteners (Figure 22, Item 4).
1 2
3 5 4
M0800SWR
Figure 22. 25. 26. 27. 28. 29. 30. 31.
Position torsion spring (Figure 23, Item 4) and one link (Figure 23, Item 1) on rear mounting bracket of upper housing assembly (Figure 23, Item 6). Install ends of torsion spring (Figure 23, Item 4) in right-side of upper housing assembly (Figure 23, Item 6) and link (Figure 23, Item 1). Apply sealing compound to threads of bolts (Figure 23, Item 3). Install torsion spring (Figure 23, Item 4) and link (Figure 23, Item 1) on upper housing assembly (Figure 22, Item 6) with two bolts (Figure 22, Item 3), using socket wrench screwdriver attachment. Position link (Figure 23, Item 2) on link (Figure 23, Item 1) on right-side of seat suspension assembly (Figure 23, Item 5) ensuring that hole is fully seated on shoulder of stud. Apply sealing compound to threads of locknut (Figure 23, Item 8). Install link (Figure 23, Item 2) on link (Figure 23, Item 1) with washer (Figure 23, Item 7) and new locknut (Figure 23, Item 8).
0244-16
TM 5-3895-379-23-2
0244
REAR 2 1 2 7 8 1 FRONT
2 6 5
4
M0801SWR
Figure 23.
0244-17
TM 5-3895-379-23-2
0244
ASSEMBLY - Continued 32. 33. 34. Install cap (Figure 24, Item 5) on height adjustment lever (Figure 24, Item 6). Install spring (Figure 24, Item 2), latch assembly (Figure 24, Item 3), and height adjustment lever (Figure 24, Item 6) in upper housing assembly (Figure 24, Item 4). Install spring pin (Figure 24, Item 1) in latch assembly (Figure 24, Item 3) and height adjustment lever (Figure 24, Item 6).
3 1 2 CROSS-SECTION VIEW 4
5 6
M0802SWR
Figure 24. 35. 36. 37. 38. 39. 40.
Position link (Figure 25, Item 1) on link (Figure 25, Item 3) on right-side of seat suspension assembly (Figure 25, Item 8) ensuring that hole is fully seated on shoulder of stud. Apply sealing compound to threads of locknut (Figure 25, Item 7). Install link (Figure 25, Item 1) on link (Figure 25, Item 3) with washer (Figure 25, Item 6) and new locknut (Figure 25, Item 7). Position link (Figure 25, Item 1) on fingers of latch assembly (Figure 25, Item 2). Position torsion spring (Figure 25, Item 4) and link (Figure 25, Item 3) on upper housing assembly (Figure 25, Item 9). Install ends of torsion spring (Figure 25, Item 4) in left-side of upper housing assembly (Figure 25, Item 9) and link (Figure 25, Item 3).
WARNING
Adhesives, solvents and sealing compounds can burn easily, can give off harmful vapors and are harmful to skin and clothing. To avoid injury or death, keep away from open fire and use in a well-ventilated area. If adhesive, solvent or retaining compound gets on skin or clothing, wash immediately with soap and water. 41. 42. Apply sealing compound to threads of bolts (Figure 25, Item 5). Install torsion spring (Figure 25, Item 4) and link (Figure 25, Item 3) on upper housing assembly (Figure 25, Item 9) with two bolts (Figure 25, Item 5), using socket wrench screwdriver attachment.
0244-18
TM 5-3895-379-23-2
0244
2 1 3 4
9 8 1 5 REAR
3 7 6 1 FRONT
M0803SWR
Figure 25. 43. 44. 45.
Position link (Figure 26, Item 1) on links (Figure 26, Item 2) on left-side of seat suspension assembly (Figure 26, Item 3) ensuring that holes are fully seated on shoulder of stud. Apply sealing compound to threads of locknuts (Figure 26, Item 5). Install link (Figure 26, Item 1) on links (Figure 26, Item 2) with two washers (Figure 26, Item 4) and new locknuts (Figure 26, Item 5). Tighten locknuts to 84-192 lb-in. (9-22 Nm).
2 5 4 1
M0804SWR
Figure 26.
0244-19
TM 5-3895-379-23-2
0244
ASSEMBLY - Continued 46. Install left angle assembly (Figure 27, Item 3) and right angle assembly (Figure 27, Item 1) on two links (Figure 27, Item 7) with four washers (Figure 27, Item 5) and new locknuts (Figure 27, Item 4). Tighten nuts to 84-192 lb-in. (9-22 Nm). Install channel (Figure 27, Item 2) from left angle assembly (Figure 27, Item 3) and right angle assembly (Figure 27, Item 1) with four bolts (Figure 27, Item 6). Tighten bolts to 84-192 lb-in. (9-22 Nm).
47.
5 6 7
Figure 27. 48. 49. 50. Seat Suspension Assembly.
M0805SWR
Install knob (Figure 28, Item 6) on bevel gear (Figure 28, Item 1) with spring pin (Figure 28, Item 5). Adjust angle bracket (Figure 28, Item 3) so that bevel gear (Figure 28, Item 1) fits snugly against gear assembly (Figure 28, Item 2) and knob (Figure 28, Item 6) feels firm. Tighten locknuts (Figure 28, Item 4).
M0806SWR
0244-20
TM 5-3895-379-23-2
0244
FOLLOW-ON MAINTENANCE Install seat suspension assembly. (WP 0243) END OF TASK END OF WORK PACKAGE
0244-21/22 blank
TM 5-3895-379-23-2
0245
FIELD MAINTENANCE TOOLBOX REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (WP 0289, Table 1, Item 42) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 108 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
REMOVAL 1. 2. Open lid (Figure 1, Item 1) of toolbox (Figure 1, Item 4). Remove two nuts (Figure 1, Item 6), screws (Figure 1, Item 2), washers (Figure 1, Item 3), and toolbox (Figure 1, Item 4) from operator platform (Figure 1, Item 5).
1 2 3 4
5
M0807SWR
Toolbox Removal.
0245-1
TM 5-3895-379-23-2
0245
INSTALLATION 1. 2. Install toolbox (Figure 2, Item 4) on operator platform (Figure 2, Item 5) with two screws (Figure 2, Item 2), washers (Figure 2, Item 3), and nuts (Figure 2, Item 6). Tighten nuts to 35 lb-ft (47 Nm). Close lid (Figure 2, Item 1) of toolbox (Figure 2, Item 4).
1 2 3 4
5
M0808SWR
Figure 2. Toolbox Installation. END OF TASK FOLLOW-ON MAINTENANCE Remove chocks. (TM 5-3895-379-10) END OF TASK END OF WORK PACKAGE
0245-2
TM 5-3895-379-23-2
0246
FIELD MAINTENANCE RIFLE MOUNTING BRACKET REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Wrench, Torque, 0-300 in-lb (WP 0289, Table 1, Item 41) Materials/Parts Locknut (WP 0290, Table 1, Item 69) Qty: Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 109 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) 4
REMOVAL 1. 2. Remove four locknuts (Figure 1, Item 2), screws (Figure 1, Item 6), washers (Figure 1, Item 5), and rifle mount bracket (Figure 1, Item 1) from four clamps (Figure 1, Item 3). Discard locknuts. Remove four clamps (Figure 1, Item 3) from hand rail assembly (Figure 1, Item 4).
5 2
3
M1045SWR
Rifle Mounting Bracket Removal.
0246-1
TM 5-3895-379-23-2
0246
INSTALLATION 1. 2. Position four clamps (Figure 2, Item 3) on hand rail assembly (Figure 2, Item 4). Install rifle mount bracket (Figure 2, Item 1) on four clamps (Figure 2, Item 3) with four screws (Figure 2, Item 6), washers (Figure 2, Item 5), and new locknuts (Figure 2, Item 2). Tighten locknuts to 168-264 in-lb (19-30 Nm).
5 2
3
M1232SWR
Rifle Mounting Bracket Installation.
0246-2
TM 5-3895-379-23-2
0247
FIELD MAINTENANCE ENGINE BLOCK HEATING ELEMENT REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Funnel, Flexible Spout (WP 0289, Table 1, Item 8) Pan, Drain, 5 Gal Cap. (WP 0289, Table 1, Item 23) Materials/Parts Tag, Marker (WP 0288, Table 1, Item 70) Locknut (WP 0290, Table 1, Item 123) Qty: Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 110 Equipment Condition Engine off. (TM 5-3895-379-10) Operator platform assembly raised. (WP 0235) Left-side door assembly opened. (TM 5-3895-379-10) Air cleaner cap removed. (Volume 1, WP 0117) 2
0247-1
TM 5-3895-379-23-2
0247
REMOVAL
WARNING
Ensure that external power cable is unplugged from receptacle before beginning replacement of engine block heating element. Working on the engine block heating element while external power cable is attached may cause injury or death. 1. Slide boot (Figure 1, Item 2) on cable (Figure 1, Item 1) back to expose two screws (Figure 1, Item 3) and screw (Figure 1, Item 6).
NOTE
Do not remove the screw holding the ground wire to the engine block heating element. The ground wire can be removed without removing the screw. Tag and mark all wires prior to removal. 2. 3. Remove two screws (Figure 1, Item 3) and wires (Figure 1, Item 4) from engine block heating element (Figure 1, Item 5). Loosen screw (Figure 1, Item 6) and remove wire (Figure 1, Item 7) from engine block heating element (Figure 1, Item 5).
5 4 3 1 2 6 7 4
M0809SWR
Figure 1.
Engine Block Heating Element Removal.
NOTE
Position funnel to allow controlled draining of the engine block into drain pan with a minimum 1 qt (0.9 Liter) capacity. 4. 5. Remove drain plug (Figure 2, Item 3) from engine block fitting (Figure 2, Item 1) and engine block (Figure 2, Item 2). Remove engine block heating element (Figure 1, Item 5) from engine block (Figure 2, Item 2).
0247-2
TM 5-3895-379-23-2
0247
REMOVAL - Continued 6. Remove engine block fitting (Figure 2, Item 1) from engine block (Figure 2, Item 2).
2 3
M0810SWR
Figure 2. 7. 8. 9.
Remove three nuts (Figure 3, Item 13), washers (Figure 3, Item 1), clips (Figure 3, Item 12), screws (Figure 3, Item 2), and washers (Figure 3, Item 1) from frame assembly (Figure 3, Item 3). Slide boot (Figure 3, Item 10) on cable (Figure 3, Item 11) back to expose two locknuts (Figure 3, Item 9). Remove two locknuts (Figure 3, Item 9), receptacle (Figure 3, Item 8), two screws (Figure 3, Item 4), receptacle cover (Figure 3, Item 5), and seal (Figure 3, Item 6) from bracket (Figure 3, Item 7). Discard locknuts.
3 2 1
1 13
12 11 10 9 8 7 6 5 4
M0811SWR
0247-3
TM 5-3895-379-23-2
0247
INSTALLATION 1. 2. 3. 4. Install seal (Figure 4, Item 6), receptacle cover (Figure 4, Item 5), two screws (Figure 4, Item 4), receptacle (Figure 4, Item 8), and two new locknuts (Figure 4, Item 9) on bracket (Figure 4, Item 7). Slide boot (Figure 4, Item 10) on cable (Figure 4, Item 11) to cover two locknuts (Figure 4, Item 9). Install cable (Figure 4, Item 11) into three clips (Figure 4, Item 12). Install three washers (Figure 4, Item 1), screws (Figure 4, Item 2), clips (Figure 4, Item 12), washers (Figure 4, Item 1), and nuts (Figure 4, Item 13) to frame assembly (Figure 4, Item 3).
3 2 1
1 13
12 11 10 9 8 7 6 5 4
M1136SWR
Figure 4. Engine Block Heating Element Installation. 5. 6. Install drain plug (Figure 5, Item 3) into engine block fitting (Figure 5, Item 1). If removed, install engine block fitting (Figure 5, Item 1) into engine block (Figure 5, Item 2).
2 3
M1135SWR
Figure 5. Engine Block Heating Element Installation.
0247-4
TM 5-3895-379-23-2
0247
INSTALLATION - Continued 7. 8. 9. 10. Install engine block heating element (Figure 6, Item 5) into engine block fitting (Figure 5, Item 1). Install wire (Figure 6, Item 7) to engine block heating element (Figure 6, Item 5) and tighten screw (Figure 6, Item 6). Install two wires (Figure 6, Item 4) and screws (Figure 6, Item 3) to engine block heating element (Figure 6, Item 5). Slide boot (Figure 6, Item 2) on cable (Figure 6, Item 1) to cover three screws (Figure 6, Items 3 and 6).
5 4 3 1 2 6 7 4
M1134SWR
Figure 6. Engine Block Heating Element Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Fill engine with coolant. (Volume 1, WP 0139) Install air cleaner cap. (Volume 1, WP 0117) Lower operator platform assembly. (WP 0235) Close left-side door assembly. (TM 5-3895-379-10) Start engine and check for leaks. (TM 5-3895-379-10)
0247-5/6 blank
TM 5-3895-379-23-2
0248
FIELD MAINTENANCE VEHICLE CLASSIFICATION SIGN KIT REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Wrench, Torque, 0-300 in-lb (WP 0289, Table 1, Item 41) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 111 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
REMOVAL Remove two screws (Figure 1, Item 2), washers (Figure 1, Item 3), and vehicle classification sign kit (Figure 1, Item 4) from front support (Figure 1, Item 1).
3 2
M0812SWR
Vehicle Classification Sign Kit Removal.
0248-1
TM 5-3895-379-23-2
0248
INSTALLATION
NOTE
Military Load Classification for the roller is 11. Install vehicle classification sign kit (Figure 2, Item 4) on front support (Figure 2, Item 1) with two washers (Figure 2, Item 3) and screws (Figure 2, Item 2). Tighten screws to 228 lb-in. (26 Nm).
3 2
M1285SWR
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE
Vehicle Classification Sign Kit Installation.
Remove chocks. (TM 5-3895-379-10) END OF TASK END OF WORK PACKAGE
0248-2
TM 5-3895-379-23-2
0249
FIELD MAINTENANCE DATA PLATE AND DECAL REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Drill Bit Set Standard (WP 0289, Table 1, Item 6) Drill, Hand (WP 0289, Table 1, Item 7) Gloves, Rubber (WP 0289, Table 1, Item 12) Goggles (WP 0289, Table 1, Item 13) Riveter, Blind, Hand (WP 0289, Table 1, Item 31) Materials/Parts Cleaning Compound, Solvent (WP 0288, Table 1, Item 13, 14, 15) Cloth, Cleaning (WP 0288, Table 1, Item 16) Rivet (WP 0290, Table 1, Item 43) Qty: 4 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 111 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Battery disconnect switch in OFF position. (TM 5-3895-379-10) Right-side door assembly opened. (TM 5-3895-379-10)
0249-1
TM 5-3895-379-23-2
0249
DATA PLATE REMOVAL
WARNING
Wear eye protection when drilling out rivets. Failure to do so could result in injury.
CAUTION
Avoid using a twist drill with an excessively large diameter when drilling out rivets. Failure to follow this caution could result in enlarged holes in roller, too large for rivet size needed. 1. 2. Drill out four rivets (Figure 1, Item 1) from data plate (Figure 1, Item 2). Discard rivets. Remove data plate (Figure 1, Item 2) from roller.
1
2
M0813SWR
Figure 1. Data Plate Removal. END OF TASK DATA PLATE INSTALLATION 1. 2. Position data plate (Figure 2, Item 2) to existing holes in roller. Install data plate (Figure 2, Item 2) with four new rivets (Figure 2, Item 1).
0249-2
TM 5-3895-379-23-2
0249
DATA PLATE INSTALLATION - Continued

1
2
M1167SWR
Figure 2. END OF TASK DECAL REMOVAL 1.
Data Plate Installation.
Remove decal (Figure 3, Item 1) from surface of roller.
1
M0814SWR
Figure 3.
Decal Removal.
WARNING
Cleaning compound, solvent MIL-PRF-680 Type III is an environmentally compliant and low toxic material. However, it may be irritating to the eyes and skin. The use of protective gloves and goggles is suggested. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. 2. If necessary, use cleaning compound, solvent to remove all traces of decal and adhesive.
END OF TASK
0249-3
TM 5-3895-379-23-2
0249
DECAL INSTALLATION 1. 2. Determine correct location for new decal (Figure 4, Item 1) (TM 5-3895-379-10). Ensure mounting surface on roller is clean and dry.
NOTE
Careful placement of decal is important. If wrinkles form in decal, instructions may not be legible. 3. Remove backing paper from decal (Figure 4, Item 1) and press decal into position. Ensure all corners of decal are firmly affixed.
1
M1168SWR
Decal Installation.
Close right-side door assembly. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0249-4
TM 5-3895-379-23-2
0250
FIELD MAINTENANCE HYDRAULIC VIBRATORY TESTS
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L (2) Equipment Condition Engine off. (TM 5-3895-379-10) Equipment Condition (cont.) Parking brake engaged. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
HIGH VIBRATORY FREQUENCY TEST
WARNING
At operating temperature, hydraulic oil is hot. Escaping hydraulicfluid under pressure can penetrate the skin, causing injury or death.
CAUTION
Hydraulic oil must be certified to have anti-rust, very high viscosity index, and antioxidation additive properties for heavy duty use. Oil temperature must be at 140F +/- 5F (60C +/- 21C).
NOTE
Vibratory frequency test must be conducted on uncompacted dirt or on tires. 1. 2. 3. 4. 5. 6. 7. 8. Place propel control lever in NEUTRAL (TM 5-3895-379-10). Start and run engine at HIGH idle, 2,325 +/- 25 rpm until oil temperature is at least 100F (38C) (TM 5-3895-379-10). Apply parking brake and place propel control lever in forward position (TM 5-3895-379-10). Place vibratory mode switch in dual drum position (TM 5-3895-379-10). Press button on top of propel control lever to start vibratory system (TM 5-3895-379-10). Record the reading from the Vibrations Per Minute (VPM) tachometer on steering console. Press button on top of propel control lever to stop vibratory system (TM 5-3895-379-10). Dual amplitude frequency must be 2,520 +/- 50 VPM in high.
END OF TASK
0250-1
TM 5-3895-379-23-2
0250
HIGH VIBRATORY FREQUENCY ADJUSTMENT 1. 2. 3. If frequency is not in range, vibratory pump must be adjusted. Adjust as follows: Loosen locknut (Figure 1, Item 1) on the adjustment screw (Figure 1, Item 2). To increase vibrations per minute, turn adjustment screw (Figure 1, Item 2) counterclockwise. To decrease, turn adjustment screw (Figure 1, Item 2) clockwise.
1, 2
M0815SWR
Figure 1. Hydraulic Vibratory Adjustment. END OF TASK LOW VIBRATORY FREQUENCY TEST 1. 2. 3. Place proper control lever in REVERSE (TM 5-3895-379-10). Place vibratory mode switch in low amplitude (TM 5-3895-379-10). Dual amplitude frequency must be 2,570 +/- 50 VPM in low.
END OF TASK
0250-2
TM 5-3895-379-23-2
0250
LOW VIBRATORY FREQUENCY ADJUSTMENT 1. 2. 3. If frequency is not in range, vibratory pump must be adjusted. Adjust as follows: Loosen locknut (Figure 2, Item 1) on the adjustment screw (Figure 2, Item 2). To increase vibrations per minute, turn adjustment screw (Figure 2, Item 2) counterclockwise. To decrease, turn adjustment screw (Figure 2, Item 2) clockwise.
1, 2
M1148SWR
Hydraulic Vibratory Adjustment.
0250-3
TM 5-3895-379-23-2
0250
INTER-CIRCUIT RELIEF VALVE TEST
WARNING
Use caution when using the propel control lever. Roller may move when switching from NEUTRAL to REVERSE. 1. 2. 3. 4. 5. 6. 7. Place proper control lever in NEUTRAL (TM 5-3895-379-10). Place vibratory mode switch in auto (TM 5-3895-379-10). Connect pressure gauge to tap (Figure 3, Item 3). Start and run engine at HIGH idle (TM 5-3895-379-10). Place vibratory mode switch in dual drum vibration position (TM 5-3895-379-10). Place propel control lever in REVERSE (TM 5-3895-379-10). Pressure reading should be 3,350 +/- 100 psi (23,100 kPa +/- 689 kPa). If pressure is not in range, inter circuit relief valve (Figure 3, Item 1) must be adjusted. To increase pressure, turn adjustment screw (Figure 3, Item 2) counterclockwise. To decrease, turn adjustment screw (Figure 3, Item 2) clockwise. Recheck pressure at tap (Figure 3, Item 3).
8.
M1149SWR
Figure 3. Hydraulic Vibratory Test. END OF TASK
0250-4
TM 5-3895-379-23-2
0250
FOLLOW-ON MAINTENANCE 1. 2. Turn engine off. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0250-5/6 blank
TM 5-3895-379-23-2
0251
FIELD MAINTENANCE VIBRATORY CONTROL SOLENOID REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 123 Equipment Condition Engine off. (TM 5-3895-379-10) Equipment Condition (cont.) Operator platform assembly raised. (WP 0235) Left-side door assembly opened. (TM 5-3895-379-10)
0251-1
TM 5-3895-379-23-2
0251
REMOVAL 1. 2. 3. 4. 5. Remove two screws (Figure 1, Item 1) that fasten two electrical connectors (Figure 1, Item 2) to two solenoids (Figure 1, Item 6). Remove two electrical connectors (Figure 1, Item 2) from two solenoids (Figure 1, Item 6). Remove four bolts (Figure 1, Item 4) and one bolt (Figure 1, Item 5) from vibratory control valve body (Figure 1, Item 3). Remove vibratory control valve body (Figure 1, Item 3) from roller. Remove two solenoids (Figure 1, Item 6) from vibratory control valve body (Figure 1, Item 3).
4
M0816SWR
Vibratory Control Solenoid Removal.
0251-2
TM 5-3895-379-23-2
0251
INSTALLATION 1. 2. 3. 4. 5. Install two solenoids (Figure 2, Item 6) to vibratory control valve body (Figure 2, Item 5). Install vibratory control valve body (Figure 2, Item 3) to roller. Install four bolts (Figure 2, Item 4) and one bolt (Figure 2, Item 5) to vibratory control valve body (Figure 2, Item 3). Install two electrical connectors (Figure 2, Item 2) to two solenoids (Figure 2, Item 6). Install two screws (Figure 2, Item 1) that fasten two electrical connectors (Figure 2, Item 2) to two solenoids (Figure 2, Item 6).
4
M0817SWR
Vibratory Control Solenoid Installation.
Lower operator platform assembly. (WP 0235) Close left-side door assembly. (TM 5-3895-379-10)
0251-3/4 blank
TM 5-3895-379-23-2
0252
FIELD MAINTENANCE VIBRATORY MOTOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (WP 0289, Table 1, Item 23) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0288, Table 1, Item 12) Rag, Wiping (WP 0288, Table 1, Item 60) Strap, Tiedown, Electrical (WP 0288, Table 1, Item 67, 68, 69) Tag, Marker (WP 0288, Table 1, Item 70) Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figure 121 Equipment Condition Engine off. (TM 5-3895-379-10) Hydraulic tank drained. (Volume 1, WP 0124) Left-side door assembly opened. (TM 5-3895-379-10)
0252-1
TM 5-3895-379-23-2
0252
REMOVAL 1. Remove electrical tiedown strap (Figure 1, Item 5) and disconnect electrical connector (Figure 1, Item 4).
CAUTION
Cap and plug all hoses, fittings, and openings immediately after removal. Contaminants entering the system may cause premature failure.
NOTE
Use drain pan to catch any hydraulic oil that may drain from system. Dispose of oil IAW local policy and ordinances. Ensure all spills are cleaned up. Tag and mark all hydraulic lines and hoses to ensure correct installation. 2. 3. 4. Disconnect two hose assemblies (Figure 1, Item 3) and two hose assemblies (Figure 1, Item 2) from vibratory motor (Figure 1, Item 8). Remove four nuts (Figure 1, Item 6) and washers (Figure 1, Item 7) from plate (Figure 1, Item 9). Pull vibratory motor (Figure 1, Item 8) from drum (Figure 1, Item 1).
1 2
4 4
3 6, 7 9
2 8
M0818SWR
Figure 1.
Vibratory Motor Removal.
0252-2
TM 5-3895-379-23-2
0252
REMOVAL - Continued 5. 6. Remove four bolts (Figure 2, Item 4) and washers (Figure 2, Item 3) from plate (Figure 2, Item 1), that fasten vibratory motor (Figure 2, Item 2) to driveshaft. With assistance, remove vibratory motor (Figure 2, Item 2) from roller.
3 4
M0819SWR
Figure 2. END OF TASK INSPECTION 1. 2.
Vibratory Motor Removal.
Inspect all parts and hoses for damage and wear. Replace worn or damaged parts. Ensure vibration motor and accessories are clean, dry, and free of all dirt and foreign material.
END OF TASK
0252-3
TM 5-3895-379-23-2
0252
INSTALLATION 1. With assistance, position vibratory motor (Figure 3, Item 8) to drum (Figure 3, Item 1) and install to driveshaft.
1 2
4 4
3 6, 7 9
2 8
M1259SWR
Figure 3.
Vibratory Motor Installation.
0252-4
TM 5-3895-379-23-2
0252
INSTALLATION - Continued 2. Install four washers (Figure 4, Item 3) and bolts (Figure 4, Item 4) through plate (Figure 4, Item 1) to fasten vibration motor (Figure 4, Item 2).
3 4
M1260SWR
Figure 4. 3.
Vibratory Motor Installation.
Install four washers (Figure 3, Item 7) and nuts (Figure 3, Item 6) on plate (Figure 3, Item 9).
NOTE
Remove all caps and plugs from hoses and openings prior to assembly. 4. 5. Connect two hose assemblies (Figure 3, Item 3) and two hose assemblies (Figure 3, Item 2) to vibratory motor (Figure 3, Item 8). Connect electrical connector (Figure 3, Item 4) and install new electrical tiedown strap (Figure 3, Item 5).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Fill hydraulic tank. (Volume 1, WP 0124) Close left-side door assembly. (TM 5-3895-379-10) Battery switch to ON position. (TM 5-3895-379-10) Operate roller and check for proper operation and leaks. (TM 5-3895-379-10)
0252-5/6 blank
TM 5-3895-379-23-2
0253
FIELD MAINTENANCE VIBRATORY COOLING/CONTROL VALVE REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Wrench, Torque, 0-300 in-lb (WP 0289, Table 1, Item 41) Wrench, Torque, 20-100 ft-lb (WP 0289, Table 1, Item 42) Materials/Parts Cleaning Compound, Solvent (WP 0288, Table 1, Item 13, 14, 15) Lubricating Oil, Gear (WP 0288, Table 1, Item 32, 33, 34) Materials/Parts (cont.) Rag, Wiping (WP 0288, Table 1, Item 60) O-Ring (WP 0290, Table 1, Item 72) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 123 WP 0251 Equipment Condition Vibratory cooling/control valve removed. (WP 0254)
0253-1
TM 5-3895-379-23-2
0253
DISASSEMBLY 1. 2. 3. 4. 5. Remove two nuts (Figure 1, Item 1) and coil assemblies (Figure 1, Item 12) from valve solenoids (Figure 1, Item 2). Remove two valve solenoids (Figure 1, Item 2) and O-rings (Figure 1, Item 3) from valve block (Figure 1, Item 11). Remove charge relief valve (Figure 1, Item 4) and O-ring (Figure 1, Item 5) from valve block (Figure 1, Item 11). Discard O-ring. Remove spike relief valve (Figure 1, Item 8), two back-up rings (Figure 1, Item 9), and O-rings (Figure 1, Item 10) from valve block (Figure 1, Item 11). Discard back-up rings and O-rings. Remove Pressure Override Relief (POR) valve (Figure 1, Item 6) and O-ring (Figure 1, Item 7) from valve block (Figure 1, Item 11). Discard O-ring.
2, 3
4, 5 6, 7 12 11 8, 9, 10
M0820SWR
Figure 1. 6. 7.
Vibratory Cooling/Control Valve Removal.
Remove shuttle valve (Figure 2, Item 1), two back-up rings (Figure 2, Item 2), and three O-rings (Figure 2, Item 3) from valve block (Figure 1, Item 11). Discard back-up rings and O-rings. Remove check valve (Figure 2, Item 4), back-up ring (Figure 2, Item 5), and two O-rings (Figure 2, Item 6) from valve block (Figure 1, Item 11). Discard back-up ring and O-rings.
0253-2
TM 5-3895-379-23-2
0253
1, 2, 3
4, 5, 6
M0821SWR
Figure 2. Vibratory Cooling/Control Valve Removal. END OF TASK CLEANING AND INSPECTION 1. 2. 3. Before the vibratory cooling/control valve is assembled, make sure all valve parts are clean, dry, and free of all dirt and foreign material. Inspect all parts for damage or wear and replace worn or damaged parts if found. Lubricate all back-up rings and O-rings with clean lubricating oil prior to assembly.
END OF TASK ASSEMBLY 1. 2. Install two new O-rings (Figure 3, Item 6), one new back-up ring (Figure 3, Item 5), and check valve (Figure 3, Item 4) in valve block (Figure 4, Item 11). Tighten relief valve to 180 lb-in. (20 Nm). Install three new O-rings (Figure 3, Item 3), two new back-up rings (Figure 3, Item 2), and shuttle valve (Figure 3, Item 1) to valve block (Figure 4, Item 11). Tighten shuttle valve to 65 lb-ft (88 Nm).
1, 2, 3
4, 5, 6
M1215SWR
Figure 3. Vibratory Cooling/Control Valve Assembly.
0253-3
TM 5-3895-379-23-2
0253
ASSEMBLY - Continued 3. 4. 5. 6. 7. Install new O-ring (Figure 4, Item 7) and POR valve (Figure 4, Item 6) into valve block (Figure 4, Item 11). Tighten POR valve to 25 lb-ft (34 Nm). Install two new O-rings (Figure 4, Item 10), back-up rings (Figure 4, Item 9), and spike relief valve (Figure 4, Item 8) into valve block (Figure 4, Item 11). Tighten spike relief valve to 35 lb-ft (47 Nm). Install new O-ring (Figure 4, Item 5) and charge relief valve (Figure 4, Item 4) into valve block (Figure 4, Item 11). Tighten charge relief valve to 45 lb-ft (61 Nm). Install two new O-rings (Figure 4, Item 3) and valve solenoid (Figure 4, Item 2) into valve block (Figure 4, Item 11). Install two coil assemblies (Figure 4, Item 12) and two nuts (Figure 4, Item 1) into valve solenoids (Figure 4, Item 2). Tighten charge relief valve to 60 lb-ft (81 Nm).
2, 3
4, 5 6, 7 12 11 8, 9, 10
M1214SWR
Figure 4. Vibratory Cooling/Control Valve Assembly. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install vibratory cooling control valve. (WP 0254) Operate roller and check for proper operation and leaks. (TM 5-3895-379-10)
0253-4
TM 5-3895-379-23-2
0254
FIELD MAINTENANCE VIBRATORY COOLING/CONTROL VALVE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (WP 0289, Table 1, Item 23) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0288, Table 1, Item 12) Cleaning Compound, Solvent (WP 0288, Table 1, Item 13, 14, 15) Lubricating Oil, Engine, 15W40 Grade (WP 0288, Table 1, Item 29, 30, 31) Rag, Wiping (WP 0288, Table 1, Item 60) Strap, Tiedown, Electrical (WP 0288, Table 1, Item 67, 68, 69) Materials/Parts (cont.) Tag, Marker (WP 0288, Table 1, Item 70) O-Ring (WP 0290, Table 1, Item 122) Qty: Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-10 TM 5-3895-379-23P, Figure 122 and 123 Equipment Condition Hydraulic system drained. (Volume 1, WP 0124)
0254-1
TM 5-3895-379-23-2
0254
REMOVAL
WARNING
NOTE
Use drain pan to catch any hydraulic oil that may drain from system. Dispose of oil IAW local policy and ordinances. Ensure all spills are cleaned up. Mark and tag two electrical connectors for installation purposes. 1. 2. Disconnect two electrical connectors (Figure 1, Item 3) from vibratory cooling/control valve (Figure 1, Item 6). Remove electrical tiedown strap (Figure 1, Item 1) that fastens electrical harness to bracket (Figure 1, Item 2).
NOTE
Cap and plug all lines and fittings to prevent any contaminants from entering the system. 3. 4. Disconnect seven hose assemblies (Figure 1, Item 4) from vibratory cooling/control valve (Figure 1, Item 6). Remove six bolts (Figure 1, Item 5) securing vibratory cooling/control valve (Figure 1, Item 6) to vibratory pump (Figure 1, Item 9).
WARNING
Use caution when handling heavy parts. Provide adequate support and use assistance during procedure. Failure to follow this warning may cause injury.
NOTE
Weight of vibration cooling/control valve is 62 lb (28 kg). 5. 6. With assistance, remove vibratory cooling/control valve and spacer (Figure 1, Item 7). Remove four O-rings (Figure 1, Item 8) from spacer (Figure 1, Item 7) and vibratory cooling/control valve (Figure 1, Item 6). Discard O-rings.
0254-2
TM 5-3895-379-23-2
0254
REMOVAL - Continued
1, 2 3
4 4
M0822SWR
7, 8
Figure 1. Vibratory Cooling/Control Valve Removal. END OF TASK
0254-3
TM 5-3895-379-23-2
0254
INSTALLATION
WARNING
Use caution when handling heavy parts. Provide adequate support and use assistance during procedure. Failure to follow this warning may cause injury.
NOTE
The weight of the vibration cooling/control valve is 62 lb (28 kg). Prior to installation, lubricate O-rings with a light coat of lubricating oil. 1. 2. Install four new O-rings (Figure 2, Item 8) on spacer (Figure 2, Item 7) and vibratory cooling/control valve (Figure 2, Item 6). With assistance, position vibratory cooling/control valve and spacer (Figure 2, Item 7) to vibratory pump (Figure 2, Item 9) and install six bolts (Figure 2, Item 5).
NOTE
Remove caps and plugs before connecting hose assemblies. 3. 4. 5. Connect seven hose assemblies (Figure 2, Item 4) to vibratory cooling/control valve (Figure 2, Item 6). Position electrical harness to bracket (Figure 2, Item 2) and fasten electrical tiedown straps (Figure 2, Item 1) to secure electrical harness. Connect two electrical connectors (Figure 2, Item 3) to vibratory cooling/control valve (Figure 2, Item 6).
1, 2 3
4 4
M1284SWR
7, 8
Vibratory Cooling/Control Valve Installation.
0254-4
TM 5-3895-379-23-2
0254
FOLLOW-ON MAINTENANCE 1. 2. Fill hydraulic oil tank with oil to correct level. (Volume 1, WP 0124) Operate roller and test for proper operation and leaks. (TM 5-3895-379-10)
0254-5/6 blank
TM 5-3895-379-23-2
0255
FIELD MAINTENANCE HYDRAULIC OIL SAMPLING VALVE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (WP 0289, Table 1, Item 23) Materials/Parts Rag, Wiping (WP 0288, Table 1, Item 60) Sealing Compound, Loctite 271 Materials/Parts (cont.) (WP 0288, Table 1, Item 62) O-Ring (WP 0290, Table 1, Item 120) Qty: Personnel Required Construction Equipment Repairer 91L Equipment Condition Drums chocked. (TM 5-3895-379-10) Hydraulic tank drained. (Volume 1, WP 0124) Left-side door assembly opened. (TM 5-3895-379-10)
0255-1
TM 5-3895-379-23-2
0255
REMOVAL
WARNING
Oil is very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury. 1. Remove hydraulic oil sampling valve drain cap (Figure 1, Item 4) from hydraulic oil sampling valve (Figure 1, Item 5).
NOTE
Use drain pan to catch any hydraulic oil that may drain from system. Dispose of oil IAW local policy and ordinances. Ensure all spills are cleaned up. 2. 3. 4. 5. Place drain pan with 1 qt (0.9 Liter) minimum capacity under hydraulic oil sampling valve (Figure 1, Item 5). Turn and hold knurled knob (Figure 1, Item 6) in direction of arrow and allow remainder of hydraulic oil to drain. Loosen locking nut (Figure 1, Item 3) on hydraulic oil sampling valve (Figure 1, Item 5) and remove hydraulic oil sampling valve from tee (Figure 1, Item 1). Remove O-ring (Figure 1, Item 2) from hydraulic oil sampling valve (Figure 1, Item 5). Discard O-ring.
1 2 3 6 5 4
M0823SWR
Figure 1. Hydraulic Oil Sampling Valve Removal. 6. 7. If damaged, remove tee (Figure 2, Item 4) from hydraulic oil pump (Figure 2, Item 1). Remove cap (Figure 2, Item 2), preformed packing (Figure 2, Item 3), boss reducer (Figure 2, Item 6), and two O-rings (Figure 2, Item 5) from tee (Figure 2, Item 4).
0255-2
TM 5-3895-379-23-2
0255
REMOVAL - Continued
5 2
3 4 6 5
M0824SWR
Figure 2. Hydraulic Oil Sampling Valve Removal. END OF TASK INSTALLATION 1. 2. 3. 4. Install new O-ring (Figure 3, Item 5) in tee (Figure 3, Item 4). Apply sealing compound to threads of tee (Figure 3, Item 4) and install new preformed packing (Figure 3, Item 3) and cap (Figure 3, Item 2) on tee. Apply sealing compound to threads of tee (Figure 3, Item 4) and install new O-ring (Figure 3, Item 5) and boss reducer (Figure 3, Item 6) on tee. If removed, apply sealing compound to threads of tee (Figure 3, Item 4) and install tee in hydraulic oil pump (Figure 3, Item 1).
5 2
3 4 6 5
M1133SWR
Figure 3. Hydraulic Oil Sampling Valve Installation.
0255-3
TM 5-3895-379-23-2
0255
INSTALLATION - Continued 5. Install new O-ring (Figure 4, Item 2) on hydraulic oil sampling valve (Figure 4, Item 5).
NOTE
When installing hydraulic oil sampling valve, position drain down for ease in sample collection. 6. 7. Apply sealing compound to threads of hydraulic oil sampling valve (Figure 4, Item 5) and position on tee (Figure 4, Item 1). Tighten locking nut (Figure 4, Item 3). Install hydraulic oil sampling valve drain cap (Figure 4, Item 4) on hydraulic oil sampling valve (Figure 4, Item 5).
1 2 3 6 5 4
M1132SWR
Figure 4. Hydraulic Oil Sampling Valve Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Close left-side door assembly. (TM 5-3895-379-10) Fill hydraulic tank. (Volume 1, WP 0124) Start engine and check for leaks. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0255-4
TM 5-3895-379-23-2
0256
FIELD MAINTENANCE HYDRAULIC OIL SAMPLING
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (WP 0289, Table 1, Item 23) Materials/Parts Rag, Wiping (WP 0288, Table 1, Item 60) Personnel Required Construction Equipment Repairer 91L References DA Pam 750-8 TM 5-3895-379-23P, Figure 122 Equipment Condition Engine on. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Left-side door assembly opened. (TM 5-3895-379-10)
0256-1
TM 5-3895-379-23-2
0256
SAMPLING
WARNING
Prolonged contact with lubricating oil, MIL-L-2105, may cause skin rash. Skin and clothing that come in contact with lubricating oil should be thoroughly washed immediately. Saturated clothing should be removed immediately. Areas in which lubricating oil is used should be well ventilated to keep fumes to a minimum. Oil is very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury. There is no clearance for personnel between frame and yoke when roller turns. Injury or death from crushing could occur. Steering frame must be locked before lifting, transporting, or servicing roller in articulation area with engine running. Failure to follow this warning may cause injury or death. Unlock steering frame before operation. Failure to follow this warning may cause injury or death. When working on a running engine, provide shielding for exposed rotating parts. Tools, clothing, or hands can get caught and cause injury.
CAUTION
Sample hydraulic oil with oil warm, not HOT, to allow for draining of waste particles that are suspended in oil. As oil cools, suspended particles settle on the bottom of the hydraulic reservoir and cannot be removed by draining oil. Failure to follow this recommendation procedure can result in disproportionate sample collection.
NOTE
Refer to DA Pam 750-8 for sampling requirements. Use drain pan to catch any hydraulic oil that may drain from system. Dispose of oil IAW local policy and ordinances. Ensure all spills are cleaned up. 1. 2. 3. 4. 5. Run engine until hydraulic oil is warm, not hot. Remove hydraulic oil sampling valve drain cap (Figure 1, Item 2) from hydraulic oil sampling valve (Figure 1, Item 1). Place container with 1 qt (0.9 Liter) minimum capacity under hydraulic oil sampling valve (Figure 1, Item 1). Turn and hold knurled knob (Figure 1, Item 3) in direction of arrow until hydraulic oil sample is collected. Release knob when sample has been collected. Install hydraulic oil sampling valve drain cap (Figure 1, Item 2) on hydraulic oil sampling valve (Figure 1, Item 1).
0256-2
TM 5-3895-379-23-2
0256
SAMPLING - Continued
OPEN
2
M0825SWR
Figure 1. 6. Turn engine off.
Hydraulic Oil Sampling.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Submit hydraulic oil sample to your Army Oil Analysis Program (AOAP) laboratory for analysis. Close left-side door assembly. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0256-3/4 blank
TM 5-3895-379-23-2
0257
FIELD MAINTENANCE HYDRAULIC OIL FILTER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (WP 0289, Table 1, Item 23) Materials/Parts Lubricating Oil, Engine, 15W40 Grade (WP 0288, Table 1, Item 29, 30, 31) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 129 Equipment Condition Hydraulic oil drained. (Volume 1, WP 0124) Right-side door assembly opened. (TM 5-3895-379-10)
0257-1
TM 5-3895-379-23-2
0257
REMOVAL
WARNING
NOTE
Use drain pan with 2 qt (1.9 Liters) minimum capacity to catch any hydraulic oil that may drain from system. Remove hydraulic oil filter (Figure 1, Item 2) from hydraulic oil filter assembly (Figure 1, Item 1) and allow remaining hydraulic oil to drain. Dispose of oil IAW local policy and ordinances. Ensure all spills are cleaned up.
INSTALL
REMOVE 2
M0826SWR
Figure 1. Hydraulic Oil Filter Removal. END OF TASK CLEANING AND INSPECTION 1. Clean filter assembly base (Figure 2, Item 1) and ensure that all old gasket material is removed.
0257-2
TM 5-3895-379-23-2
0257
CLEANING AND INSPECTION - Continued
NOTE
Excessive amounts of debris in filter can be an indication of internal wear and possible hydraulic system component failure. If large amounts of debris are found, notify Direct Support Maintenance. 2. Inspect element (Figure 2, Item 4) for metal or other debris. Report any excessive debris found in element to supervisor.
END OF TASK INSTALLATION
CAUTION
Do not overtighten filter on filter base. Failure to follow this caution may cause damage to filter. 1. 2. Apply a light coat of lubricating oil on filter gasket (Figure 2, Item 2). Install filter (Figure 2, Item 3) on filter base (Figure 2, Item 1). Tighten filter 3/4 of a turn after filter makes contact with filter base.
1
INSTALL 4 REMOVE 3 2
M0827SWR
Hydraulic Oil Filter Installation.
0257-3
TM 5-3895-379-23-2
0257
FOLLOW-ON MAINTENANCE 1. 2. 3. Close right-side door assembly. (TM 5-3895-379-10) Fill hydraulic oil system. (Volume 1, WP 0124) Start engine and check for leaks. (TM 5-3895-379-10)
0257-4
TM 5-3895-379-23-2
0258
FIELD MAINTENANCE HYDRAULIC FILTER ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (WP 0289, Table 1, Item 23) Materials/Parts Lubricating Oil MIL-L-2104 OE/,30 Grade (WP 0288, Table 1, Item 54, 55) Sealing Compound, Loctite 271 (WP 0288, Table 1, Item 62) O-Ring (WP 0290, Table 1, Item 68) Qty: O-Ring (WP 0290, Table 1, Item 24) Qty: Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 129 References (cont.) Volume 1, WP 0071 Volume 1, WP 0073 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Hydraulic oil drained. (Volume 1, WP 0124) Right-door assembly opened. (TM 5-3895-379-10)
3 1
0258-1
TM 5-3895-379-23-2
0258
REMOVAL
WARNING
NOTE
Use drain pan to catch any hydraulic oil that may drain from system. Dispose of oil IAW local policy and ordinances. Ensure all spills are cleaned up. 1. 2. Place drain pan with 2 qt (1.9 Liters) minimum capacity under hydraulic oil filter assembly (Figure 1, Item 1). Remove hydraulic oil filter (Figure 1, Item 2) from hydraulic oil filter assembly (Figure 1, Item 1) and allow remaining hydraulic oil to drain.
INSTALL
REMOVE 2
M0171SWR
Figure 1. Hydraulic Filter Assembly Removal. 3. Loosen nut (Figure 2, Item 2) and remove hose assembly (Figure 2, Item 1) and O-ring (Figure 2, Item 3) from hydraulic oil filter assembly (Figure 2, Item 4). Discard O-ring.
0258-2
TM 5-3895-379-23-2
0258
REMOVAL - Continued
2
M0172SWR
Figure 2. 4. 5. 6. 7.
Hydraulic Filter Assembly Removal.
Loosen nut (Figure 3, Item 8) and remove hose assembly (Figure 3, Item 7) and O-ring (Figure 3, Item 9) from hydraulic oil filter assembly (Figure 3, Item 10). Discard O-ring. Loosen nut (Figure 3, Item 2) and remove hose assembly (Figure 3, Item 3) and O-ring (Figure 3, Item 1) from elbow (Figure 3, Item 10). Discard O-ring. Remove elbow (Figure 3, Item 11) and O-ring (Figure 3, Item 9) from hydraulic oil filter assembly (Figure 3, Item 10). Discard O-ring. Remove four screws (Figure 3, Item 5), washers (Figure 3, Item 4), and hydraulic oil filter assembly (Figure 3, Item 10) from frame assembly (Figure 3, Item 6).
7 6 5 4 1 2 3
11
10
M0173SWR
Hydraulic Filter Assembly Removal.
0258-3
TM 5-3895-379-23-2
0258
INSTALLATION 1. 2. 3. 4. Install hydraulic oil filter assembly (Figure 4, Item 10) on frame assembly (Figure 4, Item 6) with four washers (Figure 4, Item 4) and screws (Figure 4, Item 5). Apply sealing compound to threads of elbow (Figure 4, Item 11) and install new O-ring (Figure 4, Item 9) and elbow on hydraulic oil filter assembly (Figure 4, Item 10). Apply sealing compound to threads of hose assembly (Figure 4, Item 3) and install new O-ring (Figure 4, Item 1) and hose assembly on elbow (Figure 4, Item 11). Tighten nut (Figure 4, Item 2). Apply sealing compound to threads of hose assembly (Figure 4, Item 7) and install new O-ring (Figure 4, Item 9) and hose assembly on hydraulic oil filter assembly (Figure 4, Item 10). Tighten nut (Figure 4, Item 8).
7 6 5 4 1 2 3
11
10
M1249SWR
Figure 4. Hydraulic Filter Assembly Installation. 5. Apply sealing compound to threads of hose assembly (Figure 5, Item 1) and install new O-ring (Figure 5, Item 3) and hose assembly on hydraulic oil filter assembly (Figure 5, Item 4). Tighten nut (Figure 5, Item 2).
0258-4
TM 5-3895-379-23-2
0258
2
M1084SWR
Figure 5. 6.
Hydraulic Filter Assembly Installation.
Apply a light coating of hydraulic oil on the filter gasket.
CAUTION
Do not overtighten filter on oil hydraulic oil filter assembly. Failure to follow this caution may cause damage to filter. 7. Install hydraulic oil filter (Figure 6, Item 2) on hydraulic oil filter assembly (Figure 6, Item 1). Tighten filter 3/4 of a turn after filter makes contact with filter base.
INSTALL
REMOVE 2
M1085SWR
Hydraulic Filter Assembly Installation.
0258-5
TM 5-3895-379-23-2
0258
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Close right-side door assembly. (TM 5-3895-379-10) Fill hydraulic oil system. (Volume 1, WP 0124) Start engine and check for leaks. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0258-6
TM 5-3895-379-23-2
0259
FIELD MAINTENANCE HYDRAULIC HOSES, LINES, AND FITTINGS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (WP 0289, Table 1, Item 23) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0288, Table 1, Item 12) Lubricating Oil, General Purpose (WP 0288, Table 1, Item 40, 41, 42, 43, 44, 45, 46, 47) Rag, Wiping (WP 0288, Table 1, Item 60) Tag, Marker (WP 0288, Table 1, Item 70) O-Ring (WP 0290, Table 1, Item 68) Qty: 1 Gasket (WP 0290, Table 1, Item 92) Qty: 1 Materials/Parts (cont.) O-Ring (WP 0290, Table 1, Item 104) Qty: 1 O-Ring (WP 0290, Table 1, Item 24) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 127 Volume 1, WP 0071 Volume 1, WP 0073 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Hydraulic system drained. (Volume 1, WP 0124) Operator platform assembly raised. (WP 0235)
0259-1
TM 5-3895-379-23-2
0259
REMOVAL
WARNING
CAUTION
Wipe area clean around all hydraulic connections to be opened during removal. Cap oil lines and plug openings after removing lines. Contamination of hydraulic system may cause premature failure.
NOTE
Use the same procedure as shown for all hydraulic lines, hoses, and fittings. Tag and mark all hydraulic lines to ensure correct installation. Use drain pan to catch any hydraulic oil that may drain from system. Dispose of oil IAW local policy and ordinances. Ensure all spills are cleaned up. 1. 2. 3. 4. 5. For lines held in position with clamps, remove nut (Figure 1, Item 7), washer (Figure 1, Item 6), bolt (Figure 1, Item 3), washer (Figure 1, Item 4), and clamp (Figure 1, Item 5) from lines. For hydraulic lines with elbow fittings, disconnect lines (Figure 1, Item 14) from fitting (Figure 1, Item 10). Remove two O-rings (Figure 1, Items 8 and 9) from fitting and discard O-rings. Remove fitting. For hydraulic lines with elbow bosses, disconnect line (Figure 1, Item 1) from elbow boss fitting (Figure 1, Item 2). Remove elbow boss fitting (Figure 1, Item 2) from valve check (Figure 1, Item 12). Remove check valve (Figure 1, Item 12), O-ring (Figure 1, Item 11), and gasket (Figure 1, Item 13). Discard O-ring and gasket.
0259-2
TM 5-3895-379-23-2
0259
REMOVAL - Continued
1 2
14 12 11 10 9 8 13 5 6 7
M0174SWR
Figure 1. Hydraulic Hoses, Lines, and Fittings Removal. END OF TASK
0259-3
TM 5-3895-379-23-2
0259
INSTALLATION
CAUTION
Wipe all ends, line fittings, and mounting surfaces clean and dry. Utilize line wrenches for installation to avoid damage to fittings and connectors.
NOTE
Apply a light film of clean lubricating oil to all new O-rings prior to installation. 1. 2. 3. 4. 5. 6. Install new gasket (Figure 2, Item 13) and new O-ring (Figure 2, Item 11) on check valve (Figure 2, Item 12). Install check valve. Install elbow boss fitting (Figure 2, Item 2) on check valve (Figure 2, Item 12). For hydraulic lines with elbow bosses, connect line (Figure 2, Item 1) to elbow boss fitting (Figure 2, Item 2). For hydraulic lines with elbow fittings, install two new O-rings (Figure 2, Items 8 and 9) on elbow fitting (Figure 2, Item 10). Install elbow fitting. Install end of line (Figure 2, Item 14) on elbow fitting (Figure 2, Item 10). For lines held in position with clamp, install clamp (Figure 2, Item 5), washer (Figure 2, Item 4), bolt (Figure 2, Item 3), washer (Figure 2, Item 6), and nut (Figure 2, Item 7) on line or lines.
0259-4
TM 5-3895-379-23-2
0259
1 2
14 12 11 10 9 8 13 5 6 7
M1273SWR
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3.
Hydraulic Hoses, Lines, and Fittings Installation.
Refill hydraulic tank. (Volume 1, WP 0124) Start engine and cycle cylinders. Check that oil is visible in sight gauge on hydraulic tank. Add oil if necessary. (Volume 1, WP 0073) Operate roller and check proper operation and leaks. (TM 5-3895-379-23)
0259-5/6 blank
TM 5-3895-379-23-2
0260
FIELD MAINTENANCE HYDRAULIC OIL COOLER AND FAN SHROUD REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (WP 0289, Table 1, Item 23) Materials/Parts Tag, Marker (WP 0288, Table 1, Item 70) Gasket (WP 0290, Table 1, Item 92) Qty: O-Ring (WP 0290, Table 1, Item 104) Qty: O-Ring (WP 0290, Table 1, Item 68) Qty: O-Ring (WP 0290, Table 1, Item 24) Qty: Locknut (WP 0290, Table 1, Item 74) Qty: Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figures 38 and 127 References (cont.) Volume 1, WP 0071 Volume 1, WP 0073 Equipment Condition Operator platform assembly raised. (WP 0235) Hydraulic oil tank drained. (Volume 1, WP 0124) Fan guard removed. (Volume 1, WP 0146) Radiator removed. (Volume 1, WP 0136)
3 1 3 1 1
0260-1
TM 5-3895-379-23-2
0260
REMOVAL 1. 2. 3. 4. 5. Loosen nut (Figure 1, Item 1) and remove elbow (Figure 1, Item 2) from connector (Figure 1, Item 9). Loosen nut (Figure 1, Item 1) and remove elbow (Figure 1, Item 2) from connector (Figure 1, Item 4). If damaged, remove hose assembly (Figure 1, Item 3) from two elbows (Figure 1, Item 2). Remove connector (Figure 1, Item 4), gasket (Figure 1, Item 5), and O-ring (Figure 1, Item 6) from hydraulic oil cooler (Figure 1, Item 7). Discard gasket and O-ring. Remove connector (Figure 1, Item 9), gasket (Figure 1, Item 8), and O-ring (Figure 1, Item 6) from hydraulic oil cooler (Figure 1, Item 7). Discard gasket and O-ring.
9 8 7 6
2 1 4 5
M0175SWR
Figure 1. Hydraulic Oil Cooler and Fan Shroud Removal.
NOTE
Tag and mark all hoses prior to removal. 6. 7. Loosen nut (Figure 2, Item 2) and remove hose (Figure 2, Item 3) from elbow (Figure 2, Item 1). Loosen nut (Figure 2, Item 5) and remove hose (Figure 2, Item 4) from elbow (Figure 2, Item 6).
0260-2
TM 5-3895-379-23-2
0260
REMOVAL - Continued
3 4 5 6
M0176SWR
Figure 2. Hydraulic Oil Cooler and Fan Shroud Removal. 8. 9. Remove elbow (Figure 3, Item 2) and gasket (Figure 3, Item 1) and O-ring (Figure 3, Item 7) from hydraulic oil cooler (Figure 3, Item 6). Discard gasket and O-ring. Remove elbow (Figure 3, Item 3) and O-rings (Figure 3, Items 4 and 5) from hydraulic oil cooler (Figure 3, Item 6). Discard O-rings.
2 3
1 4 7 5 6
M0177SWR
0260-3
TM 5-3895-379-23-2
0260
REMOVAL - Continued 10. Remove locknut (Figure 4, Item 8), washer (Figure 4, Item 5), washer (Figure 4, Item 6), washer (Figure 4, Item 5), and screw (Figure 4, Item 4) from bracket (Figure 4, Item 10) and engine lifting bracket (Figure 4, Item 9). Discard locknut. Remove two screws (Figure 4, Item 3), washers (Figure 4, Item 2), and bracket (Figure 4, Item 10) from hydraulic oil cooler (Figure 4, Item 1). If damaged, remove mounting (Figure 4, Item 7) from bracket (Figure 4, Item 10).
3 2 4 1 10 7 9 5 8 5 6
11. 12.
M0178SWR
0260-4
TM 5-3895-379-23-2
0260
REMOVAL - Continued
WARNING
CAUTION
Hydraulic oil cooler is filled with hydraulic oil. Care should be taken not to spill oil during removal.
NOTE
Hydraulic oil cooler weighs 90 lb (41 kg). 13. With assistance, remove two locknuts (Figure 5, Item 6), washers (Figure 5, Item 2), washers (Figure 5, Item 7), rubber mountings (Figure 5, Item 8), rubber mountings (Figure 5, Item 4), hydraulic oil cooler (Figure 5, Item 3), two washers (Figure 5, Item 2), and screws (Figure 5, Item 1) from frame assembly (Figure 5, Item 5). Discard locknuts.
1 2
3 4 8 5
7 2 6
M0179SWR
0260-5
TM 5-3895-379-23-2
0260
REMOVAL - Continued
NOTE
Use drain pan to catch any hydraulic oil that may drain from system. Dispose of oil IAW local policy and ordinances. Ensure all spills are cleaned up. 14. 15. Turn hydraulic oil cooler over and drain fluid into 5 gal (19 Liters) drain pan. Remove eight screws (Figure 6, Item 4), washers (Figure 6, Item 3), and fan shroud (Figure 6, Item 2) from hydraulic oil cooler (Figure 6, Item 1).
1 2
3 4
M0180SWR
Figure 6. Hydraulic Oil Cooler and Fan Shroud Removal. END OF TASK INSTALLATION 1. Install fan shroud (Figure 7, Item 2) on hydraulic oil cooler (Figure 7, Item 1) with eight washers (Figure 7, Item 3) and screws (Figure 7, Item 4).
1 2
3 4
M1267SWR
Figure 7.
Hydraulic Oil Cooler and Fan Shroud Installation.
0260-6
TM 5-3895-379-23-2
0260
WARNING
NOTE
Hydraulic oil cooler weighs 90 lb (41 kg). 2. With assistance, install hydraulic oil cooler (Figure 8, Item 3) on frame assembly (Figure 8, Item 5) with two screws (Figure 8, Item 1), washers (Figure 8, Item 2), rubber mountings (Figure 8, Item 4), rubber mountings (Figure 8, Item 8), washers (Figure 8, Item 7), washers (Figure 8, Item 2), and new locknuts (Figure 8, Item 6).
1 2
3 4 8 5
7 2 6
M1266SWR
Figure 8.
0260-7
TM 5-3895-379-23-2
0260
INSTALLATION - Continued 3. 4. 5. If removed, install mounting (Figure 9, Item 7) on bracket (Figure 9, Item 10). Install bracket (Figure 9, Item 10) on hydraulic oil cooler (Figure 9, Item 1) with two washers (Figure 9, Item 2) and screws (Figure 9, Item 3). Install screw (Figure 9, Item 4), washer (Figure 9, Item 5), washer (Figure 9, Item 6), washer (Figure 9, Item 5), and new locknut (Figure 9, Item 8) on bracket (Figure 9, Item 10) and engine lifting bracket (Figure 9, Item 9).
3 2 4 1 10 7 9 5 8 5 6
M0181SWR
Figure 9. 6. 7.
Install two O-rings (Figure 10, Items 4 and 5) and elbow (Figure 10, Item 3) on hydraulic oil cooler (Figure 10, Item 6). Install O-ring (Figure 10, Item 7) and gasket (Figure 10, Item 1) and elbow (Figure 10, Item 2) on hydraulic oil cooler (Figure 10, Item 6).
2 3
1 4 7 5 6
M0182SWR
Figure 10.
0260-8
TM 5-3895-379-23-2
0260
INSTALLATION - Continued 8. 9. Install hose (Figure 11, Item 4) on elbow (Figure 11, Item 6) and tighten nut (Figure 11, Item 5). Install hose (Figure 11, Item 3) on elbow (Figure 11, Item 1) and tighten nut (Figure 11, Item 2).
3 4 5 6
M0183SWR
Figure 11.
0260-9
TM 5-3895-379-23-2
0260
INSTALLATION - Continued 10. 11. 12. 13. 14. Install new gasket (Figure 12, Item 8), new O-ring (Figure 12, Item 6), and connector (Figure 12, Item 9) on hydraulic oil cooler (Figure 12, Item 7). Install new gasket (Figure 12, Item 5), new O-ring (Figure 12, Item 6), and connector (Figure 12, Item 4) on hydraulic oil cooler (Figure 12, Item 7). Install hose assembly (Figure 12, Item 3) on two elbows (Figure 12, Item 2). Install elbow (Figure 12, Item 2) on connector (Figure 12, Item 4) and tighten nut (Figure 12, Item 1). Install elbow (Figure 12, Item 2) on connector (Figure 12, Item 9) and tighten nut (Figure 12, Item 1).
9 8 7 6
2 1 4 5
6
Figure 12. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Install fan guard. (Volume 1, WP 0146) Install radiator. (Volume 1, WP 0136) Lower operator platform. (WP 0235) Fill hydraulic oil tank. (Volume 1, WP 0124) Start engine and check for leaks. (TM 5-3895-379-10)
M0184SWR
0260-10
TM 5-3895-379-23-2
0261
FIELD MAINTENANCE HYDRAULIC OIL CAP ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Drill, Hand (WP 0289, Table 1, Item 7) Gloves, Rubber (WP 0289, Table 1, Item 12) Goggles (WP 0289, Table 1, Item 13) Materials/Parts Cleaning Compound, Solvent (WP 0288, Table 1, Item 13, 14, 15) Cloth, Cleaning (WP 0288, Table 1, Item 16) Gasket (WP 0290, Table 1, Item 116) Qty: 1 Gasket (WP 0290, Table 1, Item 71) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 31 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
REMOVAL 1. 2. 3. 4. Remove lock (Figure 1, Item 1) from cap assembly (Figure 1, Item 3). Lift lever (Figure 1, Item 2) and turn cap assembly (Figure 1, Item 3) counterclockwise until cap can be removed from hydraulic tank (Figure 1, Item 4). Remove strainer (Figure 1, Item 6) from hydraulic tank (Figure 1, Item 4). Remove gasket (Figure 1, Item 5) from strainer (Figure 1, Item 6). Discard gasket.
1 6 5
2 3 4
M0186SWR
Figure 1. Hydraulic Oil Cap Assembly Removal. END OF TASK
0261-1
TM 5-3895-379-23-2
0261
DISASSEMBLY 1. Remove gasket (Figure 2, Item 5) and pressure plate (Figure 2, Item 6) from cover (Figure 2, Item 8). Discard gasket.
WARNING
Retaining ring is under spring tension to avoid injury, wear eye protection and use caution when installing. 2. 3. Remove retaining ring (Figure 2, Item 4), cap (Figure 2, Item 7), and ball (Figure 2, Item 3) from cover (Figure 2, Item 8). If damaged, drill pin (Figure 2, Item 1) out and remove lever (Figure 2, Item 2) from cover (Figure 2, Item 8).
2 8
7 3 6 5 4
M0187SWR
Figure 2. Hydraulic Oil Cap Disassembly. END OF TASK
0261-2
TM 5-3895-379-23-2
0261
CLEANING 1. Remove debris from strainer (Figure 3, Item 1).
M0188SWR
Figure 3.
Hydraulic Oil Cap Assembly Cleaning and Inspection.
WARNING
Cleaning compound, solvent MIL-PRF-680 Type III is an environmentally compliant and low toxic material. However, it may be irritating to the eyes and skin. The use of protective gloves and goggles is suggested. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. 2. 3. Clean all metal parts with cleaning compound, solvent. Use cleaning cloth or compressed air to dry all metal parts.
END OF TASK
0261-3
TM 5-3895-379-23-2
0261
INSPECTION Check cap (Figure 4, Item 7) and cover (Figure 4, Item 8) for nicks, cracks, dents, and stripped threads. Replace all damaged parts.
7 6 5 4
M1146SWR
Figure 4. END OF TASK INSTALLATION 1.
Hydraulic Oil Cap Assembly Cleaning and Inspection.
Install lever (Figure 5, Item 2) on cover (Figure 5, Item 8) with pin (Figure 5, Item 1).
WARNING
Retaining ring is under spring tension to avoid injury, wear eye protection and use caution when installing. 2. 3. Install ball (Figure 5, Item 3), cap (Figure 5, Item 7), and retaining ring (Figure 5, Item 4) in cover (Figure 5, Item 8). Install pressure plate (Figure 5, Item 6) and new gasket (Figure 5, Item 5) in cover (Figure 5, Item 8).
0261-4
TM 5-3895-379-23-2
0261
7 6 5 4
M1147SWR
Figure 5. Hydraulic Oil Cap Assembly Installation. END OF TASK ASSEMBLY 1. 2. 3. 4. Install new gasket (Figure 6, Item 5) on strainer (Figure 6, Item 6). Install strainer (Figure 6, Item 6) in hydraulic tank (Figure 6, Item 4). Lift lever (Figure 6, Item 2) and turn cap assembly (Figure 6, Item 3) clockwise until cap assembly is secure on hydraulic tank (Figure 6, Item 4). Install lock (Figure 6, Item 1) on cap assembly (Figure 6, Item 3).
1 6 5
2 3 4
M0189SWR
Hydraulic Oil Cap Assembly.
0261-5
TM 5-3895-379-23-2
0261
FOLLOW-ON MAINTENANCE Remove chocks. (TM 5-3895-379-10) END OF TASK END OF WORK PACKAGE
0261-6
TM 5-3895-379-23-2
0262
FIELD MAINTENANCE VIBRATORY BEARING RESERVOIR SERVICE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (WP 0289, Table 1, Item 23) Materials/Parts Lubricating Oil, Gear (WP 0288, Table 1, Item 32, 33, 34) Rag, Wiping (WP 0288, Table 1, Item 60) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 131 References (cont.) Volume 1, WP 0071 Volume 1, WP 0073 Equipment Condition Engine on. (TM 5-3895-379-10)
DRAIN
NOTE
Front and rear vibratory bearing reservoir is serviced the same way. Front vibratory bearing reservoir is shown. 1. Move roller (Figure 1, Item 1) until bar (Figure 1, Item 5) is at top of drum (Figure 1, Item 4).
2
M0190SWR
5
Figure 1. 2. Turn engine off (TM 5-3895-379-10).
4
Vibratory Bearing Reservoir Drain.
0262-1
TM 5-3895-379-23-2
0262
DRAIN - Continued 3. Chock drums (TM 5-3895-379-10).
WARNING
Oil is very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury. 4. 5. 6. Place drain pan with 3 gal (11.31 Liters) minimum capacity under plug (Figure 2, Item 2). Remove plug (Figure 2, Item 2) from vibratory reservoir (Figure 2, Item 3). Allow oil to drain completely from vibratory reservoir (Figure 2, Item 3).
2
M0191SWR
4
Figure 2. Vibratory Bearing Reservoir Drain.
END OF TASK CLEANING AND INSPECTION 1. 2. 3. 4. Clean plug. Clean area around plug openings. Inspect threads for crossed or peeled condition. Replace damaged plug.
END OF TASK
0262-2
TM 5-3895-379-23-2
0262
FILL 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Install plug (Figure 3, Item 2) in vibratory reservoir (Figure 3, Item 3). Remove chocks from drums (TM 5-3895-379-10). Start engine (TM 5-3895-379-10). Move roller (Figure 3, Item 1) until bar (Figure 3, Item 5) is at bottom of drum (Figure 3, Item 4). Turn off engine (TM 5-3895-379-10). Chock drums (TM 5-3895-379-10). Place drain pan with of 3.1 gal (12 Liters) minimum capacity under fill hole. Remove plug (Figure 3, Item 2) from vibratory reservoir (Figure 3, Item 3). Add oil (Volume 1, WP 0071) and (Volume 1, WP 0073). Install plug (Figure 3, Item 2) in vibratory reservoir (Figure 3, Item 3). Check oil level gage (Figure 3, Item 6) on roller drum (Figure 3, Item 5). Oil level is correct when oil fills half of oil level gage viewing window.
3 6
2
M0192SWR
4
Figure 3. Vibratory Bearing Reservoir Fill.
END OF TASK FOLLOW-ON MAINTENANCE Remove chocks. (TM 5-3895-379-10) END OF TASK END OF WORK PACKAGE
0262-3/4 blank
TM 5-3895-379-23-2
0263
FIELD MAINTENANCE DRUM SCRAPER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (WP 0289, Table 1, Item 42) Materials/Parts Rag, Wiping (WP 0288, Table 1, Item 60) Locknut (WP 0290, Table 1, Item 10) Qty: Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figure 132 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
56
0263-1
TM 5-3895-379-23-2
0263
REMOVAL
WARNING
NOTE
Front and rear drum scraper are replaced the same way. Front drum scraper is shown. Drum scraper replacement is the same for CB534B and CB534C Rollers, except where noted. CB534B Roller is shown. Scraper and plates weigh 31 lb (14 kg). 1. With assistance, remove four locknuts (Figure 1, Item 4), washers (Figure 1, Item 5), bolts (Figure 1, Item 2), and scraper (Figure 1, Item 3) from plate (Figure 1, Item 1). Discard locknuts.
1 2
5 4 3
M0193SWR
Figure 1. 2.
Drum Scraper Removal.
Remove three locknuts (Figure 2, Item 5), washers (Figure 2, Item 6), bolts (Figure 2, Item 1), plate (Figure 2, Item 2), and plate (Figure 2, Item 4) from scraper (Figure 2, Item 3). Discard locknuts.
0263-2
TM 5-3895-379-23-2
0263
REMOVAL - Continued
1 2
6 5
Figure 2.
4
3
M0194SWR
NOTE
Perform Step (3) if removing plate from bumper assembly or yoke assembly. Plates (Figure 3, Item 1) apply to CB534C Roller. 3. If damaged, remove eight bolts (Figure 3, Item 4), washers (Figure 3, Item 5), four plates (Figure 3, Item 6), and plates (Figure 3, Item 1) from bumper assembly (Figure 3, Item 3) or yoke assembly (Figure 3, Item 2).
1 6
3 5 4 2
M0195SWR
Figure 3.
0263-3
TM 5-3895-379-23-2
0263
REMOVAL - Continued
NOTE
Perform Step (4) only if removing from frame assembly. Plates (Figure 4, Item 7) apply to CB534C Roller. 4. If damaged, remove eight nuts (Figure 4, Item 8), bolts (Figure 4, Item 4), washers (Figure 4, Item 5), four plates (Figure 4, Item 7), and plates (Figure 4, Item 1) from frame assembly (Figure 4, Item 6).
1 4 11 1 2 10 9 3 8 7 6 5
M0196SWR
Figure 4. END OF TASK INSTALLATION
NOTE
Plates (Figure 5, Item 11) apply to CB534C Roller. 1. If removed, install four plates (Figure 5, Item 1) and plates (Figure 5, Item 11) on bumper assembly (Figure 5, Item 2) or yoke assembly (Figure 5, Item 3) with eight washers (Figure 5, Item 10) and bolts (Figure 5, Item 9).
0263-4
TM 5-3895-379-23-2
0263
1 4 11 1 2 10 9 3 8 7 6 5
M1208SWR
Figure 5.
Drum Scraper Installation.
CAUTION
Adjust spring and drum clearance to 1/2 in. (12 mm). Failure to do so can cause damage to drum or scraper, see Figure 6. 2. Adjust spring and drum clearance by positioning spring 1/2 in. (12 mm) from surface of drum and tighten bolts (Figure 7, Item 9).
1/2 IN. (12 MM) SPRING CLEARANCE
M0198SWR
Figure 6.
0263-5
TM 5-3895-379-23-2
0263
NOTE
Plates (Figure 7, Item 11) apply to CB534C Roller. 3. If removed, install four plates (Figure 7, Item 1) and plates (Figure 7, Item 7) on frame assembly (Figure 7, Item 6) with eight washers (Figure 7, Item 5), bolts (Figure 7, Item 4), and nuts (Figure 7, Item 8).
1 4 11 1 2 10 9 3 8 7 6 5
M0199SWR
Figure 7. 4.
Adjust spring and drum clearance to 1/2 in. (12 mm).
NOTE
Do not tighten nuts until final adjustment of scraper to drum. Refer to ADJUSTMENT for proper scraper position. 5. Install plate (Figure 8, Item 4) and plate (Figure 8, Item 2) on scraper (Figure 8, Item 3) with three bolts (Figure 8, Item 1), washers (Figure 8, Item 6), and new locknuts (Figure 8, Item 5).
1 2
6 5
Figure 8.
4
3
M0200SWR
0263-6
TM 5-3895-379-23-2
0263
WARNING
NOTE
Scraper and plates weight 31 lb (14 kg). 6. With assistance, install scraper (Figure 9, Item 3) on plates (Figure 9, Item 1) with four bolts (Figure 9, Item 2), washers (Figure 9, Item 5), and new locknuts (Figure 9, Item 4). Do not tighten nuts.
1 2
5 4
3
M0201SWR
0263-7
TM 5-3895-379-23-2
0263
ADJUSTMENT
NOTE
A small amount of preload on the scraper may be necessary to increase effectiveness. 1. 2. Install scraper (Figure 10, Item 3) so that scraper contains drum surface firmly and evenly from end-to-end without bending. Tighten locknuts (Figure 10, Item 2) to 60 lb-ft (81 Nm) from center of scraper outward while applying pressure on plate (Figure 10, Item 1) to ensure a small amount of preload on the scraper.
1 2 3
M0202SWR
Drum Scraper Adjustment.
0263-8
TM 5-3895-379-23-2
0264
FIELD MAINTENANCE DRUM ASSEMBLY REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Bolt (M12 x 1.75 x 40 mm) Bolt (M12 x 1.75 x 88 mm) Bolt (M16 x 2.0 x 85 mm) Inserter, Seal (WP 0289, Table 1, Item 19) Lifting Device, Minimum Capacity 4,500 lb (2,041 kg) Link (3) (WP 0289, Table 1, Item 22) Torque, Wrench, 0-300 in-lb (WP 0289, Table 1, Item 41) Materials/Parts Sealing Compound, Loctite 271 (WP 0288, Table 1, Item 62) Tag, Marker (WP 0288, Table 1, Item 70) Locknut (WP 0290, Table 1, Item 102) Qty: Materials/Parts (cont.) O-Ring (WP 0290, Table 1, Item 22) Qty: O-Ring (WP 0290, Table 1, Item 34) Qty: Personnel Required Construction Equipment Repairer 91L (2) References WP 0262 TM 5-3895-379-23P, Figures 97, 131, 132, and 133 Equipment Condition Drums chocked. (TM 5-3895-379-10) Drum assembly removed. (WP 0265) Propel motor removed. (Volume 1, WP 0205) Vibratory motor removed. (WP 0252) 1 4
90
0264-1
TM 5-3895-379-23-2
0264
DRUM DISASSEMBLY
WARNING
NOTE
The disassembly and assembly procedure is the same for front drum assembly and rear drum assembly. Drain lubricant from vibratory bearing lube reservoir (WP 0262). Weight of drum assembly is approximately 4,500 lb (2,041 kg). Weight of plate and support as a unit is 310 lb (141 kg). Weight of support is 75 lb (34 kg). Weight of eccentric assembly is 460 lb (209 kg). Weight of each housing is approximately 135 lb (61 kg). 1. Attach lifting device straps to plate (Figure 1, Item 2) and support (Figure 1, Item 11). Remove 24 bolts (Figure 1, Item 12) and washers (Figure 1, Item 13) that fasten plate (Figure 1, Item 2) to mounts (Figure 1, Item 1) and remove plate (Figure 1, Item 2) and support (Figure 1, Item 11), as a unit, from drum assembly (Figure 1, Item 14). Position plate (Figure 1, Item 2) and support (Figure 1, Item 11), as a unit, on transmission repair stand. Remove 25 locknuts (Figure 1, Item 3), washers (Figure 1, Item 5), and bolts (Figure 1, Item 6). Discard locknuts. With assistance, remove supports (Figure 1, Items 4 and 11) from plate (Figure 1, Item 2). Remove two fittings (Figure 1, Item 8), 24 bolts (Figure 1, Item 7), washers (Figure 1, Item 5), and nuts (Figure 1, Item 9) and bearing assembly (Figure 1, Item 10) from plate (Figure 1, Item 2).
2. 3. 4. 5.
0264-2
TM 5-3895-379-23-2
0264
DRUM DISASSEMBLY - Continued

5 6 4 2 3 8 1 7
9 10
14
1 2 13 12
11
Figure 1.
Drum Disassembly.
0264-3
TM 5-3895-379-23-2
0264
DRUM DISASSEMBLY - Continued 6. 7. 8. 9. 10. Remove nine nuts (Figure 2, Item 8), washers (Figure 2, Item 7), and plate (Figure 2, Item 6) from drum assembly (Figure 1, Item 14). Remove four bolts (Figure 2, Item 10), washers (Figure 2, Item 9), and driveshaft (Figure 2, Item 11). Remove nut (Figure 2, Item 3) and washer (Figure 2, Item 4) from wheel clamp (Figure 2, Item 5). Use puller to remove wheel clamp (Figure 2, Item 5) and key (Figure 2, Item 1) from eccentric assembly (Figure 2, Item 2). Remove six bolts (Figure 2, Item 17) and plate (Figure 2, Item 18) from eccentric assembly (Figure 2, Item 2).
NOTE
DO NOT remove two locknuts at location (X) at this time. Two nuts must remain to hold eccentric assembly in place. 11. Bend tabs (Figure 2, Item 12) down on eight locks (Figure 2, Item 13) and remove 14 of 16 locknuts (Figure 2, Item 14) and eight locks (Figure 2, Item 15) from housing (Figure 2, Item 16). Discard locknuts.
0264-4
TM 5-3895-379-23-2
0264
DRUM DISASSEMBLY - Continued
3, 4
5 1, 2 7 6 8 11 9 10
18
17 2 12, 13 14, 15
16 X
M0204SWR
Figure 2.
Drum Disassembly.
0264-5
TM 5-3895-379-23-2
0264
DRUM DISASSEMBLY - Continued 12. 13. 14. Remove 24 bolts (Figure 3, Item 6), washers (Figure 3, Item 5), and nuts (Figure 3, Item 1) that fasten six mounts (Figure 3, Item 8) on both ends of drum assembly (Figure 3, Item 2). Install lifting link brackets to drum assembly (Figure 3, Item 2). Attach a lifting device and stand drum assembly (Figure 3, Item 2) on end. Remove remaining two locknuts (Figure 3, Item 4) that hold eccentric assembly (Figure 3, Item 3) to drum assembly (Figure 3, Item 2).
1 8 7
X 5 6 4
M0205SWR
Drum Disassembly.
0264-6
TM 5-3895-379-23-2
0264
ECCENTRIC DISASSEMBLY 1. Install link bracket on eccentric assembly (Figure 4, Item 3). Attach a lifting strap and lifting device to link bracket and remove housing (Figure 4, Item 2), with eccentric assembly (Figure 4, Item 3), from drum assembly (Figure 3, Item 2). Position eccentric assembly (Figure 4, Item 3) on transmission stand. Remove three bolts (Figure 4, Item 6) and washers (Figure 4, Item 7) that hold housings (Figure 4, Items 2 and 5) together. Remove link bracket from eccentric assembly (Figure 4, Item 3). Use three M16 forcing screws to separate housings (Figure 4, Items 2 and 5). Install suitable link brackets on housing (Figure 4, Item 2). Attach a lifting device and remove housing (Figure 4, Item 2) from housing (Figure 4, Item 5).
2
2. 3. 4.
7 6
M0206SWR
Figure 4.
Drum Eccentric Disassembly.
0264-7
TM 5-3895-379-23-2
0264
ECCENTRIC DISASSEMBLY - Continued 5. 6. 7. 8. 9. 10. 11. 12. Remove O-ring (Figure 5, Item 1) from housing (Figure 5, Item 13). Discard O-ring. Remove four bolts (Figure 5, Item 2), washer (Figure 5, Item 3), cover (Figure 5, Item 4), and tapered bearing (Figure 5, Item 5) from housing (Figure 5, Item 6). Bend tabs on locks (Figure 5, Item 8) downward and remove jam nuts (Figure 5, Item 9), locks (Figure 5, Item 10), and nuts (Figure 5, Item 11) that hold eight bolts (Figure 5, Item 12). Install positioning bolts to weight assembly (Figure 5, Item 22) and use lifting device to position weight assembly (Figure 5, Item 22) on transmission stand. Remove six bolts (Figure 5, Item 15), washers (Figure 5, Item 16), and two pipes (Figure 5, Item 18) from housing (Figure 5, Item 13). Remove two O-rings (Figure 5, Item 19) from two pipes. Discard O-ring. Remove oil seal (Figure 5, Item 14) and sleeve (Figure 5, Item 17) from housing (Figure 5, Item 13). Install lifting brackets on housing (Figure 5, Item 13). Attach a lifting device to lifting brackets and remove housing (Figure 5, Item 13) from transmission stand. Remove four bolts (Figure 5, Item 2), washers (Figure 5, Item 3), cover (Figure 5, Item 4), and tapered bearing (Figure 5, Item 5) from housing (Figure 5, Item 13).
0264-8
TM 5-3895-379-23-2
0264
ECCENTRIC DISASSEMBLY - Continued

6
5 1 3 2 4
22
3 4 21 20 19 18 5
8, 9, 10 11, 12
17 15 14 16 13
M0207SWR
Figure 5.
0264-9
TM 5-3895-379-23-2
0264
NOTE
Place alignment marks on weight assembly components for assembly. 13. Remove lifting brackets from weight assembly (Figure 6, Item 1) and remove four bolts (Figure 6, Item 2), eight nuts (Figure 6, Item 18), four tabs (Figure 6, Item 19), and shaft (Figure 6, Item 3) from counter weight (Figure 6, Item 4). Remove weight (Figure 6, Item 5) from counter weight (Figure 6, Item 4). Remove counter weight (Figure 6, Item 4) from shaft (Figure 6, Item 11). Remove six bolts (Figure 6, Item 6) and washers (Figure 6, Item 7) that fasten thrust block (Figure 6, Item 8) to shaft (Figure 6, Item 11). Use three forcing screws to remove thrust block (Figure 6, Item 8) from shaft (Figure 6, Item 11). Remove, as a unit, spur (Figure 6, Item 9), spring (Figure 6, Item 10), shaft (Figure 6, Item 13), drive key (Figure 6, Item 16), and pin (Figure 6, Item 17) from shaft (Figure 6, Item 11). Remove spring (Figure 6, Item 10) from shaft (Figure 6, Item 13). Remove oil ring (Figure 6, Item 14), ring (Figure 6, Item 15), and sleeve (Figure 6, Item 12) from shaft (Figure 6, Item 11). Remove pin (Figure 6, Item 17) and drive key (Figure 6, Item 16) from shaft (Figure 6, Item 11).
14. 15. 16. 17. 18. 19. 20.
0264-10
TM 5-3895-379-23-2
0264
14, 15
17 16
18 19
18 8
4 3 2
13 12 11 10 9
M0208SWR
0264-11
TM 5-3895-379-23-2
0264
ECCENTRIC ASSEMBLY
WARNING
NOTE
The disassembly and assembly procedure is the same for front drum assembly and rear drum assembly. Drain lubricant from vibratory bearing lube reservoir. Weight of drum assembly is approximately 4,500 lb (2,041 kg). Weight of plate and support as a unit is 310 lb (141 kg). Weight of support is 75 lb (34 kg). Weight of eccentric assembly is 460 lb (209 kg). Weight of each housing is approximately 135 lb (61 kg). 1. 2. 3. 4. 5. 6. Install pin (Figure 7, Item 17) and drive key (Figure 7, Item 16) to shaft (Figure 7, Item 11). Install oil ring (Figure 7, Item 14), ring (Figure 7, Item 15), and sleeve (Figure 7, Item 12) to shaft (Figure 7, Item 11). Install spring (Figure 7, Item 10) to shaft (Figure 7, Item 13). Install, as a unit, spur (Figure 7, Item 9), spring (Figure 7, Item 10), shaft (Figure 7, Item 13), drive key (Figure 7, Item 16), and pin (Figure 7, Item 17) to shaft (Figure 7, Item 11). Install thrust block (Figure 7, Item 8) to shaft (Figure 7, Item 11). Install counter weight (Figure 7, Item 4) to shaft (Figure 7, Item 11). Install six bolts (Figure 7, Item 6) and washers (Figure 7, Item 7) that fasten thrust block (Figure 7, Item 8) to shaft (Figure 7, Item 11).
NOTE
Notice alignment marks on weight assembly components for assembly. 7. 8. Install weight (Figure 7, Item 5) to counter weight (Figure 7, Item 4). Install weight assembly (Figure 7, Item 1) and install four bolts (Figure 7, Item 2), eight nuts (Figure 7, Item 18), four tabs (Figure 7, Item 19), and shaft (Figure 7, Item 3) to counter weight (Figure 7, Item 4).
0264-12
TM 5-3895-379-23-2
0264
ECCENTRIC ASSEMBLY - Continued
14, 15
17 16
18 19
18 8
4 3 2
13 12 11 10 9
M1137SWR
Figure 7.
Drum Eccentric Assembly.
0264-13
TM 5-3895-379-23-2
0264
ECCENTRIC ASSEMBLY - Continued 9. 10. 11. 12. Install four bolts (Figure 8, Item 2), washers (Figure 8, Item 3), cover (Figure 8, Item 4), and tapered bearing (Figure 8, Item 5) to housing (Figure 8, Item 13). Install lifting brackets on housing (Figure 8, Item 13). Attach a lifting device to lifting brackets and move housing (Figure 8, Item 13) to transmission stand. Install oil seal (Figure 8, Item 14) and sleeve (Figure 8, Item 17) to housing (Figure 8, Item 13). Install six bolts (Figure 8, Item 15), washers (Figure 8, Item 16), two new O-rings (Figure 8, Item 19), and two pipes (Figure 8, Item 18) to housing (Figure 8, Item 13). Tighten bolts to a torque of 15 + 4 lb-ft (20 + 5 Nm).
NOTE
Apply retaining compound to six bolts. 13. 14. Use lifting device to position weight assembly (Figure 8, Item 22) on housing (Figure 8, Item 13). Install jam nuts (Figure 8, Item 10), locks (Figure 8, Item 11), and nuts (Figure 8, Item 12) to eight bolts (Figure 8, Item 8) and bend tabs on locks (Figure 8, Item 9) into position.
NOTE
Apply retaining compound to four bolts. 15. 16. 17. 18. 19. 20. Install four bolts (Figure 8, Item 2), washers (Figure 8, Item 3), cover (Figure 8, Item 4), and tapered bearing (Figure 8, Item 5) to housing (Figure 8, Item 6). Tighten bolts to a torque of 15 + 4 lb-ft (20 + 5 Nm). Install new O-ring (Figure 8, Item 1) to housing (Figure 8, Item 13). Install suitable link brackets on housing (Figure 8, Item 6). Attach a lifting device and install housing (Figure 8, Item 6) to housing (Figure 8, Item 13). Remove link bracket from eccentric assembly (Figure 8, Item 7). Install three bolts (Figure 8, Item 20) and washers (Figure 8, Item 21) to housing (Figure 8, Items 6 and 13). Tighten bolts to a torque of 15 + 4 lb-ft (20 + 5 Nm). Install link bracket on eccentric assembly (Figure 8, Item 7). Attach a lifting strap and lifting device to link bracket and install housing (Figure 8, Item 6), with eccentric assembly (Figure 8, Item 7), to drum assembly (Figure 9, Item 4).
0264-14
TM 5-3895-379-23-2
0264
ECCENTRIC ASSEMBLY - Continued

6
5 1 3 2 4
22
3 4 21 20 19 18 5
8, 9, 10 11, 12
17 15 14 16 13
M0209SWR
Drum Eccentric Assembly.
0264-15
TM 5-3895-379-23-2
0264
DRUM ASSEMBLY
NOTE
Apply sealing compound to sixteen nuts. 1. 2. 3. Install two new locknuts (Figure 9, Item 5) at (Figure 9, Item 3) to hold eccentric assembly (Figure 9, Item 4) to drum assembly (Figure 9, Item 2). Tighten nuts to 276 27 lb-ft (374 37 Nm). Install lifting link brackets to drum assembly (Figure 9, Item 2). Attach a lifting device and lay drum assembly (Figure 9, Item 2) on floor. Weight of drum assembly (Figure 9, Item 2) is approximately 4,500 lb (2,041 kg). Install 24 bolts (Figure 9, Item 7), washers (Figure 9, Item 6), and nuts (Figure 9, Item 1) that fasten six mounts (Figure 9, Item 9) on both ends of drum assembly (Figure 9, Item 2).
0264-16
TM 5-3895-379-23-2
0264
DRUM ASSEMBLY - Continued
1 9 8
3 6 7 5
M0210SWR
Figure 9.
Drum Assembly.
0264-17
TM 5-3895-379-23-2
0264
DRUM ASSEMBLY - Continued 4. Install remaining 14 of 16 new locknuts (Figure 10, Item 14) and eight locks (Figure 10, Item 15) to housing (Figure 10, Item 16). Bend tabs (Figure 10, Item 12) into position on eight locks (Figure 10, Item 13). Tighten nuts to 276 27 lb-ft (374 37 Nm). Install six bolts (Figure 10, Item 17) and plate (Figure 10, Item 18) to eccentric assembly (Figure 10, Item 2). Install wheel clamp (Figure 10, Item 5) and key (Figure 10, Item 1) to eccentric assembly (Figure 10, Item 2). Install nut (Figure 10, Item 3) and washer (Figure 10, Item 4) to wheel clamp (Figure 10, Item 5).
5. 6. 7.
NOTE
Apply sealing compound to four bolts and nine nuts. 8. 9. Install four bolts (Figure 10, Item 10), washers (Figure 10, Item 9), and drive shaft (Figure 10, Item 11). Install nine nuts (Figure 10, Item 8), washers (Figure 10, Item 7), and plate (Figure 10, Item 6) to drum assembly (Figure 11, Item 14).
0264-18
TM 5-3895-379-23-2
0264
DRUM ASSEMBLY - Continued
3, 4
5 1, 2 7 6 8 11 9 10
18
17 2 12, 13 14, 15
16 X
M0211SWR
Figure 10.
Drum Assembly.
0264-19
TM 5-3895-379-23-2
0264
DRUM ASSEMBLY - Continued 10. 11. 12. 13. Install two fittings (Figure 11, Item 8), 24 bolts (Figure 11, Item 7), washers (Figure 11, Item 5), nuts (Figure 11, Item 9), and bearing assembly (Figure 11, Item 10) to plate (Figure 11, Item 2). Use two persons to install supports (Figure 11, Item 11) and (Figure 11, Item 4) to plate (Figure 11, Item 2). Install 25 new locknuts (Figure 11, Item 3), washers (Figure 11, Item 5), and bolts (Figure 11, Item 6). Attach lifting device straps to plate (Figure 11, Item 2) and support (Figure 11, Item 11). Remove 24 bolts (Figure 11, Item 12) and washers (Figure 11, Item 13) that fasten plate (Figure 11, Item 2) to mounts (Figure 11, Item 1) and remove plate (Figure 11, Item 2) and support (Figure 11, Item 11), as a unit, to drum assembly (Figure 11, Item 14).
5 4 2 3 8 1
9 10
14
1 2 13 12
11
4
M0212SWR
Drum Assembly.
0264-20
TM 5-3895-379-23-2
0264
FOLLOW-ON MAINTENANCE 1. 2. 3. Install propel motor. (Volume 1, WP 0205) Install vibratory motor. (WP 0252) Install drum assembly. (WP 0265)
0264-21/22 blank
TM 5-3895-379-23-2
0265
FIELD MAINTENANCE DRUM ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Lifting Device, Minimum Capacity 4,750 lb (2,155 kg) Pan, Drain, 5 Gal. Cap. (WP 0289, Table 1, Item 23) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0288, Table 1, Item 12) Strap, Tiedown, Electrical (WP 0288, Table 1, Item 67, 68, 69) Tag, Marker (WP 0288, Table 1, Item 70) Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-10 TM 5-3895-379-23P, Figure 133 Equipment Condition Engine off. (TM 5-3895-379-10) Chock drum not being replaced. (TM 5-3895-379-10) Hydraulic side of oil tank drained. (Volume 1, WP 0124) Supports (bumpers) removed. (WP 0229)
0265-1
TM 5-3895-379-23-2
0265
REMOVAL
NOTE
Front and rear drum procedures are the same, except where noted. CB534B and CB534C Roller procedures are the same, except where noted. 1. Disconnect electrical connector (Figure 1, Item 2). Remove all electrical tiedown straps that fasten wiring harness (Figure 1, Item 3) to drum support (Figure 1, Item 1). Move the wiring harness out of the way. Discard ties.
3
M0213SWR
Figure 1. Drum Assembly Removal.
0265-2
TM 5-3895-379-23-2
0265
REMOVAL - Continued 2. Remove two bolts (Figure 2, Item 3), washers (Figure 2, Item 4), and clamp (Figure 2, Item 2) from drum support (Figure 2, Item 1).
2 3, 4
M0214SWR
Figure 2. 3.
Drum Assembly Removal.
Remove bolt (Figure 3, Item 3), washer (Figure 3, Item 4), and clamp (Figure 3, Item 2) that fasten hose assemblies (Figure 3, Item 1) to yoke (Figure 3, Item 5).
3 1 2 4 5
M0215SWR
Figure 3.
0265-3
TM 5-3895-379-23-2
0265
REMOVAL - Continued
WARNING
CAUTION
Cap and plug all lines and fittings to prevent any contaminants from entering the system. Tag and mark all hydraulic lines and electrical wires as they are removed or disconnected. Use container to capture any hydraulic oil which may drain from lines. Dispose of hydraulic oil IAW local policy and ordinances. 4. Disconnect four hose assemblies (Figure 4, Item 2) from vibratory motor (Figure 4, Item 1). Cap and plug hoses and ports immediately. Move hose assemblies aside.
2
1 2
M0216SWR
Figure 4. Drum Assembly Removal. 5. 6. 7. Remove bolt (Figure 5, Item 5), washer (Figure 5, Item 4), and clamp (Figure 5, Item 3) that fasten hose assemblies (Figure 5, Item 9) to drum support (Figure 1, Item 1). Remove bolt (Figure 5, Item 12) and clamp (Figure 5, Item 1) that fasten hose assemblies (Figure 5, Item 9) to yoke (Figure 5, Item 2). Remove all ties, bolt (Figure 5, Item 11), two washers (Figure 5, Item 8), nut (Figure 5, Item 7), and clamp (Figure 5, Item 6) from frame (Figure 5, Item 10). Discard ties.
0265-4
TM 5-3895-379-23-2
0265
REMOVAL - Continued
1 2 4
7 8
3 6
9 8 9 12 11
M0217SWR
10
Figure 5.
0265-5
TM 5-3895-379-23-2
0265
REMOVAL - Continued
NOTE
The front drum does not have a harness. 8. For the front drum assembly (Figure 6, Item 3), disconnect five hose assemblies (Figure 6, Item 1) from propel motor (Figure 6, Item 2). Cap and plug hoses and ports immediately. Move hose assemblies aside.
1 2
3
M0218SWR
Figure 6. Drum Assembly Removal.
0265-6
TM 5-3895-379-23-2
0265
REMOVAL - Continued 9. 10. For the rear drum assembly (Figure 7, Item 4), disconnect six hose assemblies (Figure 7, Item 1) from propel motor (Figure 7, Item 2). Cap and plug hoses and ports immediately. Move hose assemblies aside. Attach a lifting device to drum assembly (Figure 7, Item 4). Position jackstand under both sides of yoke (Figure 8, Item 3).
2 1 3
4
M0219SWR
Figure 7.
0265-7
TM 5-3895-379-23-2
0265
REMOVAL - Continued 11. On propel side of drum assembly (Figure 8, Item 6), remove eight bolts (Figure 8, Item 7) and washers (Figure 8, Item 8) that fasten drum support (Figure 8, Item 1) to yoke (Figure 8, Item 3).
NOTE
The CB534B Roller model has shims between drum support (Figure 8, Item 1) and yoke (Figure 8, Item 3) on vibratory side of drum assembly. Note the number of shims when removing six bolts. 12. On vibratory side of drum assembly (Figure 8, Item 6), remove six bolts (Figure 8, Item 5) and washers (Figure 8, Item 4) that fasten drum support (Figure 8, Item 1) to yoke (Figure 8, Item 3). For the CB534B Roller, remove shims (Figure 8, Item 2).
WARNING
NOTE
Weight of drum assembly is 4,750 lb (2,155 kg). 13. Raise drum assembly (Figure 8, Item 6) until it is just off floor. Move drum assembly away from roller until it is clear of yoke or frame. Place drum assembly on floor and chock drum.
0265-8
TM 5-3895-379-23-2
0265
REMOVAL - Continued
3 4 5 2 1
1 7 8
M0220SWR
0265-9
TM 5-3895-379-23-2
0265
INSTALLATION
WARNING
NOTE
Weight of drum assembly is 4,750 lb (2,155 kg). 1. 2. Remove chocks (TM 5-3895-379-10). Place drum assembly (Figure 9, Item 4) into lifting device. Raise drum assembly (Figure 9, Item 4) until it is just off floor. Move drum assembly into roller yoke or frame.
NOTE
The CB534B Roller model has shims between drum support (Figure 10, Item 1) and yoke (Figure 10, Item 3) on vibratory side of drum assembly. Note the number of shims when replacing six bolts. 3. On vibratory side of drum assembly (Figure 9, Item 4), install six bolts (Figure 10, Item 5) and washers (Figure 10, Item 4) that fasten drum support (Figure 10, Item 1) to yoke (Figure 10, Item 3). For the CB534B Roller, install shims (Figure 10, Item 2). On propel side of drum assembly (Figure 9, Item 4), install eight bolts (Figure 10, Item 7) and washers (Figure 10, Item 8) that fasten drum support (Figure 10, Item 1) to yoke (Figure 10, Item 3). Remove the lifting device from drum assembly (Figure 9, Item 4). Remove jackstands from both sides of yoke (Figure 10, Item 3). For the rear drum assembly (Figure 9, Item 4), connect six hose assemblies (Figure 9, Item 1) to propel motor (Figure 9, Item 2).
4. 5. 6.
0265-10
TM 5-3895-379-23-2
0265
2 1 3
4
M0221SWR
Figure 9.
Drum Assembly Installation.

3 4 5 2 1
1 7 8
M1288SWR
Figure 10.
0265-11
TM 5-3895-379-23-2
0265
INSTALLATION - Continued 7. For the front drum assembly (Figure 11, Item 3), connect five hose assemblies (Figure 11, Item 1) to propel motor (Figure 11, Item 2).
1 2
3
M0222SWR
Figure 11.
0265-12
TM 5-3895-379-23-2
0265
INSTALLATION - Continued 8. 9. 10. Install new electrical tiedown straps, bolt (Figure 12, Item 11), two washers (Figure 12, Item 8), nut (Figure 12, Item 7), and clamp (Figure 12, Item 6) to frame (Figure 12, Item 10). Install bolt (Figure 12, Item 12) and clamp (Figure 12, Item 1) that fasten hose assemblies (Figure 12, Item 9) to yoke (Figure 12, Item 2). Install bolt (Figure 12, Item 5), washer (Figure 12, Item 4), and clamp (Figure 12, Item 3) that fasten hose assemblies (Figure 12, Item 9) to drum support (Figure 12, Item 2).
1 2 4 3
7 8 6
9 8 9 12 11 10
M0223SWR
Figure 12.
0265-13
TM 5-3895-379-23-2
0265
INSTALLATION - Continued 11. Connect four hose assemblies (Figure 13, Item 2) to vibratory motor (Figure 13, Item 1).
2
1 2
M0224SWR
Figure 13. 12.
Install bolt (Figure 14, Item 3), washer (Figure 14, Item 4), and clamp (Figure 14, Item 2) that fasten hose assemblies (Figure 14, Item 1) to yoke (Figure 14, Item 5).
3 1 2 4 5
M0225SWR
Figure 14.
0265-14
TM 5-3895-379-23-2
0265
INSTALLATION - Continued 13. Install two bolts (Figure 15, Item 3), washers (Figure 15, Item 4), and clamp (Figure 15, Item 2) to drum support (Figure 15, Item 1).
2 3, 4
M0226SWR
Figure 15.
0265-15
TM 5-3895-379-23-2
0265
INSTALLATION - Continued 14. Connect electrical connector (Figure 16, Item 2). Install new electrical tiedown straps that fasten wiring harness (Figure 16, Item 3) to drum support (Figure 16, Item 1).
3
M0227SWR
Figure 16. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Install supports (bumpers). (WP 0229)
Fill hydraulic side of tank. (Volume 1, WP 0124) Remove chocks from drum not being replaced. (TM 5-3895-379-10)
0265-16
TM 5-3895-379-23-2
0266
FIELD MAINTENANCE RESILIENT DRUM MOUNTS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Lifting Device, Minimum Capacity 310 lb (141 kg) Link (WP 0289, Table 1, Item 22) Materials/Parts Tag, Marker (WP 0288, Table 1, Item 70) Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figure 133 Equipment Condition Drums chocked. (TM 5-3895-379-10) Supports (bumpers) removed. (WP 0229) Propel motor removed. (Volume 1, WP 0204) Vibratory motor removed. (WP 0252)
0266-1
TM 5-3895-379-23-2
0266
REMOVAL
WARNING
NOTE
Weight of plate and support is 310 lb (141 kg). 1. 2. 3. 4. Attach lifting device straps with link bracket to plate (Figure 1, Item 9) and support (Figure 1, Item 6). Remove 24 bolts (Figure 1, Item 7) and washers (Figure 1, Item 8) that fasten plate (Figure 1, Item 9) to mounts (Figure 1, Item 1). With assistance, remove plate (Figure 1, Item 9) and support (Figure 1, Item 6) as a unit from drum assembly (Figure 1, Item 2). Remove 24 bolts (Figure 1, Item 5), washers (Figure 1, Item 4), and nuts (Figure 1, Item 3) that fasten six mounts (Figure 1, Item 1) to drum assembly (Figure 1, Item 2).
1 9 8
5 6
4 3
M0228SWR
Figure 1. Resilient Drum Mounts Removal. END OF TASK
0266-2
TM 5-3895-379-23-2
0266
INSTALLATION 1. 2. Install 24 bolts (Figure 2, Item 5), washers (Figure 2, Item 4), and nuts (Figure 2, Item 3) that fasten six mounts (Figure 2, Item 1) to drum assembly (Figure 2, Item 2). Attach lifting device straps with link bracket to plate (Figure 2, Item 9) and support (Figure 2, Item 6). Install 24 bolts (Figure 2, Item 7) and washers (Figure 2, Item 8) that fasten plate (Figure 2, Item 9) to mounts (Figure 2, Item 1) and install plate (Figure 2, Item 9) and support (Figure 2, Item 6), as a unit, to drum assembly (Figure 2, Item 2).
1 9 8
5 6
4 3
M1209SWR
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4.
Resilient Drum Mounts Installation.
Install propel motor. (Volume 1, WP 0204) Install vibratory motor. (WP 0252) Install supports (bumpers). (WP 0229) Remove chocks. (TM 5-3895-379-10)
0266-3/4 blank
TM 5-3895-379-23-2
0267
FIELD MAINTENANCE WATER SPRAY PIPE ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Goggles (WP 0289, Table 1, Item 13) Materials/Parts Brush, Cleaning, Tool and Parts (WP 0288, Table 1, Item 10) Cloth, Cleaning (WP 0288, Table 1, Item 16) Detergent, GP Liquid (WP 0288, Table 1, Item 17) Materials/Parts (cont.) Sealing Compound (WP 0288, Table 1, Item 62) Wood Block, Approximately 6 in. (152 mm) tall, 6 in. (152 mm) wide, and 12 in. (305 mm) long Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-10 TM 5-3895-379-23P, Figures 136 and 137 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Water spray system drained. (TM 5-3895-379-10)
0267-1
TM 5-3895-379-23-2
0267
REMOVAL
NOTE
Front and rear water spray pipe assembly are maintained the same way. Front water spray pipe assembly is shown. 1. 2. Remove two nuts (Figure 1, Item 6), washers (Figure 1, Item 7), and straps (Figure 1, Item 1) from bumper assembly (Figure 1, Item 5). Lift water spray tank (Figure 1, Item 2) and place wood block (Figure 1, Item 3) between tank and drum (Figure 1, Item 4).
3 1
7 6 5 4
M0229SWR
Figure 1. 3.
Water Spray Pipe Assembly Removal.
Loosen two fittings (Figure 2, Item 3) and remove two tubes (Figure 2, Items 2 and 4) from two elbows (Figure 2, Item 1).
0267-2
TM 5-3895-379-23-2
0267
REMOVAL - Continued
M0230SWR
Figure 2. Water Spray Pipe Assembly Removal. 4. Remove eight screws (Figure 3, Item 6), washers (Figure 3, Item 5), clamp halves (Figure 3, Item 1), four inserts (Figure 3, Item 4), and water spray pipe assemblies (Figure 3, Item 3) from water spray tank (Figure 3, Item 2).
5 6
M0231SWR
Figure 3. Water Spray Pipe Assembly Removal. END OF TASK
0267-3
TM 5-3895-379-23-2
0267
DISASSEMBLY 1. 2. 3. 4. 5. Remove cap (Figure 4, Item 7) from clamp (Figure 4, Item 1) by turning counterclockwise. Remove screen (Figure 4, Item 5), seal (Figure 4, Item 8), and nozzle (Figure 4, Item 6) from cap (Figure 4, Item 7). Remove two screws (Figure 4, Item 2) and clamp (Figure 4, Item 1) from water spray pipe assembly (Figure 4, Item 4). Repeat Steps (1) through (3) for remaining clamps as required. Remove two elbows (Figure 4, Item 3) from water spray pipe assembly (Figure 4, Item 4).
2 1
8 7 5 6
M0232SWR
Figure 4. END OF TASK CLEANING AND INSPECTION 1.
Water Spray Pipe Disassembly.
Clean screen, seal, nozzle, and clamp with detergent and water. Remove difficult deposits with a stiff bristle brush.
WARNING
Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT direct compressed air against human skin. Failure to follow this warning may cause injury or death. Make sure air stream is directed away from user and other personnel in the area. To prevent injury, user must wear protective goggles or face shield. 2. Use a cleaning cloth or compressed air to dry metal parts.
0267-4
TM 5-3895-379-23-2
0267
CLEANING AND INSPECTION - Continued 3. 4. 5. 6. 7. Check cap and clamp for cracks and wear on locking parts. Check screen for crushing, corrosion, or tears. Check seal for cracks, tears, or other signs of deterioration. Check nozzle for clogging, corrosion, or excessive wear. Replace all damaged parts.
END OF TASK ASSEMBLY 1. 2. 3. Apply sealing compound to threads and install two elbows (Figure 5, Item 3) in water spray pipe assembly (Figure 5, Item 4). Install clamp (Figure 5, Item 1) in water spray pipe assembly (Figure 5, Item 4) with two screws (Figure 5, Item 2). Install nozzle (Figure 5, Item 6), seal (Figure 5, Item 8), and screen (Figure 5, Item 5) in cap (Figure 5, Item 7).
CAUTION
Failure to ensure that cap is securely snapped into locked position will result in possible loss of nozzle components when water spray system is operated. 4. Install cap (Figure 5, Item 7) on clamp (Figure 5, Item 1) and turn clamp clockwise until clamp snaps into locked position.
2 1
8 7 5 6
M0233SWR
Figure 5. 5.
Water Spray Pipe Assembly.
Repeat Steps (2) through (4) for remaining clamps as required.
END OF TASK
0267-5
TM 5-3895-379-23-2
0267
INSTALLATION 1. Install water spray pipe assemblies (Figure 6, Item 3), four inserts (Figure 6, Item 4), and eight clamp halves (Figure 6, Item 1) on water spray tank (Figure 6, Item 2) with eight washers (Figure 6, Item 5) and screws (Figure 6, Item 6). Snug, but do not tighten, screws.
4 5 6
M0234SWR
Figure 6. Water Spray Pipe Assembly Installation. 2. Position two tubes (Figure 7, Items 2 and 4) on elbows (Figure 7, Item 1) and tighten fittings (Figure 7, Item 3).
1
M0235SWR
Figure 7. Water Spray Pipe Assembly Installation.
0267-6
TM 5-3895-379-23-2
0267
INSTALLATION - Continued 3. 4. 5. Lift water spray tank (Figure 8, Item 2) and remove wood block (Figure 8, Item 3). Lower water spray tank (Figure 8, Item 2) on bumper assembly (Figure 8, Item 5). Install two straps (Figure 8, Item 1) in bumper assembly (Figure 8, Item 5) with two washers (Figure 8, Item 7) and nuts (Figure 8, Item 6). Tighten nuts until strap tension is snug.
3 1
7 6 5 4
M0236SWR
Figure 8. Water Spray Pipe Assembly Installation. 6. Fill water spray system and check for leaks (TM 5-3895-379-10).
END OF TASK
0267-7
TM 5-3895-379-23-2
0267
ADJUSTMENT
NOTE
Water Spray pipes (Figure 9, Item 1) are correctly adjusted when water spray covers 100% of width of drum surface (Figure 9, Item 4). There are two methods of adjustment. 1. Method A (perform every time spray pipe is removed). a. b. c. d. Start engine and operate water spray system (TM 5-3895-379-10). While screws (Figure 9, Item 2) are not tightened, turn spray pipe assembly (Figure 9, Item 3) until spray makes best contact with drum surface (Figure 9, Item 4). Tighten screw (Figure 9, Item 2). Turn off water spray system and engine (TM 5-3895-379-10).
2 4 3
M0237SWR
Figure 9. Water Spray Pipe Adjustment.
0267-8
TM 5-3895-379-23-2
0267
ADJUSTMENT - Continued 2. Method B (perform anytime). a. b. c. Start engine and operate water spray system (TM 5-3895-379-10). Turn slot in nozzle (Figure 10, Item 1) until water spray fan pattern (Figure 10, Item 3) makes full and equal contact with drum surface (Figure 10, Item 2). Turn off water spray system and engine (TM 5-3895-379-10).
3 2 1
M0238SWR
Water Spray Pipe Adjustment.
0267-9/10 blank
TM 5-3895-379-23-2
0268
FIELD MAINTENANCE WATER LEVEL GAUGE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 134 Equipment Condition Engine off. (TM 5-3895-379-10) Equipment Condition (cont.) Drums chocked. (TM 5-3895-379-10) Water tank drained. (TM 5-3895-379-10)
0268-1
TM 5-3895-379-23-2
0268
REMOVAL
NOTE
Front and rear water level gauges are replaced the same way. Rear water level gauge is shown. Note position of gauge face to aid in installation. Remove four screws (Figure 1, Item 1), water level gauge (Figure 1, Item 2), and gasket (Figure 1, Item 3) from water tank (Figure 1, Item 4). Discard gasket if damaged.
M0239SWR
Figure 1. Water Level Gauge Removal. END OF TASK
0268-2
TM 5-3895-379-23-2
0268
INSTALLATION Install gasket (Figure 2, Item 3) and water level gauge (Figure 2, Item 2) on water tank (Figure 2, Item 4) with four screws (Figure 2, Item 1).
M1145SWR
Water Level Gauge Installation.
0268-3/4 blank
TM 5-3895-379-23-2
0269
FIELD MAINTENANCE WATER TANK REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Wrench, Torque, 0-300 in-lb (WP 0289, Table 1, Item 41) Wrench, Torque, 20-100 ft-lb (WP 0289, Table 1, Item 42) Materials/Parts Sealing Compound, Pipe Thread (WP 0288, Table 1, Item 63) Locknut (WP 0290, Table 1, Item 114) Qty: Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figure 134 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Water tank drained. (TM 5-3895-379-10) Water level gauge removed. (WP 0268) Water tank strainer assembly removed. (WP 0276) Water spray pipe assembly removed. (WP 0267) Water spray check valve removed. (WP 0274)
0269-1
TM 5-3895-379-23-2
0269
REMOVAL
WARNING
Use caution when removing cover from bumper assembly. Failure to follow this warning may cause injury.
NOTE
Cover weighs 12 lb (5.44 kg). Front and rear water tanks are replaced the same way. Front water tank is shown. If removing water tank for wiring harness or front or rear support replacement, perform only Steps (1) and (2) and Steps (5) and (6). 1. Remove four screws (Figure 1, Item 2), washers (Figure 1, Item 1), and cover (Figure 1, Item 3) from bumper assembly (Figure 1, Item 4).
4 3 1 2
M0240SWR
Figure 1. Water Tank Removal.
0269-2
TM 5-3895-379-23-2
0269
REMOVAL - Continued 2. 3. 4. Loosen fitting (Figure 2, Item 2) and remove tube (Figure 2, Item 1) from elbow (Figure 2, Item 3). Remove locknut (Figure 2, Item 5), washer (Figure 2, Item 6), cap assembly (Figure 2, Item 7), washer (Figure 2, Item 6), and bolt (Figure 2, Item 8) from bumper bracket (Figure 2, Item 4). Discard locknut. Remove cap assembly (Figure 2, Item 7) and nipple (Figure 2, Item 9) from water tank (Figure 2, Item 10).
10 9
4 7
6 8 6
5
M0241SWR
Figure 2.
Water Tank Removal.
0269-3
TM 5-3895-379-23-2
0269
REMOVAL - Continued 5. Position straps (Figure 3, Item 2) in front of bumper assembly (Figure 3, Item 3).
WARNING
NOTE
Water tank weighs 91 lb (41 kg). 6. With assistance, remove water tank (Figure 3, Item 1) from bumper assembly (Figure 3, Item 3).
2
Figure 3. Water Tank Removal.
M0242SWR
0269-4
TM 5-3895-379-23-2
0269
REMOVAL - Continued 7. Remove elbow (Figure 4, Item 3) from water tank (Figure 4, Item 2).
NOTE
Nut and fitting have left-hand thread. 8. If damaged, remove nut (Figure 4, Item 4), seal (Figure 4, Item 5), and fitting (Figure 4, Item 1) from water tank (Figure 4, Item 2).
1 5 4 3
M0243SWR
Figure 4. 9.
Water Tank Removal.
If damaged, remove two bolts (Figure 5, Item 1), washers (Figure 5, Item 2), and straps (Figure 5, Item 3) from bumper assembly (Figure 5, Item 4).
1 2
3 4
M0244SWR
Water Tank Removal.
0269-5
TM 5-3895-379-23-2
0269
INSTALLATION
NOTE
If installing water tank for wiring harness or front or rear support replacement, perform only Steps (4) and (5) and Steps (9) and (10). 1. If removed, install straps (Figure 6, Item 3) on bumper assembly (Figure 6, Item 4) with two washers (Figure 6, Item 2) and bolts (Figure 6, Item 1). Tighten bolts to 22-30 lb-ft (30-41 Nm).
1 2
3 4
M1144SWR
Figure 6. Water Tank Installation.
NOTE
Nut and fitting have left-hand thread. 2. 3. Install fitting (Figure 7, Item 1), seal (Figure 7, Item 5), and nut (Figure 7, Item 4) in water tank (Figure 7, Item 2). Tighten nut securely. Install elbow (Figure 7, Item 3) on water tank (Figure 7, Item 2).
1 5 4 3
M1143SWR
0269-6
TM 5-3895-379-23-2
0269
INSTALLATION - Continued 4. Position straps (Figure 8, Item 2) in front of bumper assembly (Figure 8, Item 3).
WARNING
NOTE
Water tank weighs 91 lb (41 kg). 5. With assistance, install water tank (Figure 8, Item 1) on bumper assembly (Figure 8, Item 3).
2
M0245SWR
0269-7
TM 5-3895-379-23-2
0269
INSTALLATION - Continued 6. 7. 8. 9. Apply sealing compound to threads of nipple (Figure 9, Item 9) and install nipple in water tank (Figure 9, Item 10). Install cap assembly (Figure 9, Item 7) on bumper bracket (Figure 9, Item 4) with bolt (Figure 9, Item 8), two washers (Figure 9, Item 6), and new locknut (Figure 9, Item 5). Tighten locknut to 84-132 lb-in. (9-15 Nm). Install cap assembly (Figure 9, Item 7) on nipple (Figure 9, Item 9) by turning tee-handle fully right until cap assembly is snug in nipple. Position tube (Figure 9, Item 1) on elbow (Figure 9, Item 3) and tighten fitting (Figure 9, Item 2).
10 9
4 7
6 8 6
5
M0246SWR
0269-8
TM 5-3895-379-23-2
0269
WARNING
Use caution when installing cover on bumper assembly. Failure to follow this warning may cause injury. 10. Install cover (Figure 10, Item 3) on bumper assembly (Figure 10, Item 4) with four washers (Figure 10, Item 1) and bolts (Figure 10, Item 2). Tighten bolts to 180-300 lb-in. (20-34 Nm).
4 3
1 2
M0247SWR
Figure 10. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. Install water level gauge. (WP 0268) Install water strainer assembly. (WP 0276) Install water spray check valve. (WP 0274)
Water Tank Installation.
Install and adjust water spray pipe. (WP 0267) Fill water spray system. (TM 5-3895-379-10) Start engine, operate water spray system, and check for leaks. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0269-9/10 blank
TM 5-3895-379-23-2
0270
FIELD MAINTENANCE WATER SPRAY PUMP REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Wrench, Torque, 0-300 in-lb (WP 0289, Table 1, Item 41) Wrench, Torque, 20-100 ft-lb (WP 0289, Table 1, Item 42) Materials/Parts Strap, Tiedown, Electrical (WP 0288, Table 1, Item 67, 68, 69) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 135 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0270-1
TM 5-3895-379-23-2
0270
REMOVAL
WARNING
NOTE
Water spray pump for CB534B and CB534C Rollers are serviced the same way except where noted. The CB534B Roller is shown. Front and rear water spray pump are replaced the same way. The rear water spray pump is shown. 1. Remove four bolts (Figure 1, Item 2), washers (Figure 1, Item 1), and cover (Figure 1, Item 3) from bumper assembly (Figure 1, Item 4).
4 3 1 2
M0248SWR
Figure 1.
Water Spray Pump Removal.
0270-2
TM 5-3895-379-23-2
0270
REMOVAL - Continued
NOTE
Remove electrical tiedown straps as required. 2. 3. Turn valve handle (Figure 2, Item 7) to closed position (CB534B Roller). Disconnect water pump connector (Figure 2, Item 5) from connector (Figure 2, Item 6).
NOTE
Note position of elbows to aid in installation. 4. Remove two elbows (Figure 2, Item 2) and hose assemblies (Figure 2, Item 4) from water spray pump (Figure 2, Item 8).
CAUTION
Elbows are plastic. Use care when removing hose. Use of excessive force will cause elbows to break. 5. 6. Loosen two clamps (Figure 2, Item 3) and remove two hose assemblies (Figure 2, Item 4) from elbows (Figure 2, Item 2). Remove two screws (Figure 2, Item 11), plate (Figure 2, Item 10), two clamp halves (Figure 2, Item 1), and water spray pump (Figure 2, Item 8) from bumper assembly (Figure 2, Item 9).
1 2 3 1 4 5 6 CLOSED
OPEN 11 7
10
8
M0249SWR
Water Spray Pump Removal.
0270-3
TM 5-3895-379-23-2
0270
INSTALLATION 1. Install clamp half (Figure 3, Item 1), water spray pump (Figure 3, Item 8), clamp half (Figure 3, Item 1), plate (Figure 3, Item 10), and two screws (Figure 3, Item 11) on bumper assembly (Figure 3, Item 9). Tighten screws securely. Position two hose assemblies (Figure 3, Item 4) on elbows (Figure 3, Item 2) and tighten two clamps (Figure 3, Item 3). Install two elbows (Figure 3, Item 2) and hose assemblies (Figure 3, Item 3) on water spray pump (Figure 3, Item 8).
2. 3.
NOTE
Add electrical tiedown straps as required. 4. 5. Connect water spray pump connector (Figure 3, Item 5) to connector (Figure 3, Item 6). Turn valve handle (Figure 3, Item 7) to open position and check for leaks.
1 2 3 1 4 5 6 CLOSED
OPEN 11 7
10
8
M1138SWR
Figure 3. Water Spray Pump Installation.
0270-4
TM 5-3895-379-23-2
0270
WARNING
Use caution when installing cover on bumper assembly. Failure to follow this warning may cause injury. 6. Install cover (Figure 4, Item 3) on bumper assembly (Figure 4, Item 4) with four washers (Figure 4, Item 1) and bolts (Figure 4, Item 2). Tighten screws to 180-300 lb-in. (20-34 Nm).
4 3
1 2
M0250SWR
Water Spray Pump Installation.
Start engine, operate water spray system, and check for leaks. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0270-5/6 blank
TM 5-3895-379-23-2
0271
FIELD MAINTENANCE WATER SPRAY STRAINER ASSEMBLY REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Goggles (WP 0289, Table 1, Item 13) Materials/Parts Brush, Cleaning, Tool and Parts (WP 0288, Table 1, Item 10) Cloth, Cleaning (WP 0288, Table 1, Item 16) Detergent, GP Liquid (WP 0288, Table 1, Item 17) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 138 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0271-1
TM 5-3895-379-23-2
0271
DISASSEMBLY
NOTE
Water spray strainer assembly for CB534B and CB534C Rollers are serviced the same way except where noted. The CB534B Roller is shown. Front and rear water spray strainer assemblies are serviced the same way. The front water spray strainer assembly is shown. CB534C Roller does not have valve handle. 1. 2. 3. Turn valve handle (Figure 1, Item 1) to closed position. Remove strainer assembly bowl (Figure 1, Item 5) from strainer assembly (Figure 1, Item 2). Remove screen (Figure 1, Item 3) and seal (Figure 1, Item 4) from strainer assembly bowl (Figure 1, Item 2). Discard seal if damaged.
VIEW LOOKING UP 1 CLOSE
OPEN 2
CLOSE OPEN 5 4 3
M0251SWR
Figure 1. Water Spray Strainer Removal. END OF TASK
0271-2
TM 5-3895-379-23-2
0271
CLEANING AND INSPECTION 1. Clean strainer assembly bowl and screen with non-sudsing detergent and water. Remove difficult deposits with a cleaning brush.
WARNING
Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT direct compressed air against human skin. Failure to follow this warning may cause injury or death. Make sure air stream is directed away from user and other personnel in the area. To prevent injury, user must wear protective goggles or face shield. 2. 3. 4. 5. 6. Use cleaning cloth or compressed air to dry metal parts. Check bowl for cracking, corrosion or excessive wear. Check screen for clogging, corrosion, excessive wear and obvious signs of damage. Check all parts for stripped or damaged threads. Replace all damaged threads.
END OF TASK
0271-3
TM 5-3895-379-23-2
0271
ASSEMBLY 1. 2. 3. Install screen (Figure 2, Item 3) and seal (Figure 2, Item 4) on strainer assembly bowl (Figure 2, Item 5). Install strainer assembly bowl (Figure 2, Item 5) in strainer assembly (Figure 2, Item 2). Turn valve handle (Figure 2, Item 1) to the open position (CB534B Roller).
VIEW LOOKING UP 1 CLOSE
OPEN 2
CLOSE OPEN 5 4 3
M1289SWR
Figure 2. Water Spray Strainer Assembly. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Start engine, operate water spray system and check for leaks. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0271-4
TM 5-3895-379-23-2
0272
FIELD MAINTENANCE WATER SPRAY STRAINER ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Goggles (WP 0289, Table 1, Item 13) Wrench, Torque, 0-300 in-lb (WP 0289, Table 1, Item 41) Materials/Parts Brush, Cleaning, Tool and Parts (WP 0288, Table 1, Item 10) Cloth, Cleaning (WP 0288, Table 1, Item 16) Detergent, GP Liquid (WP 0288, Table 1, Item 17) Sealing Compound, Pipe Thread (WP 0288, Table 1, Item 63) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 138 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Water spray system drained. (TM 5-3895-379-10)
0272-1
TM 5-3895-379-23-2
0272
REMOVAL
NOTE
Water spray strainer assembly for CB534B and CB534C Rollers are serviced the same way except where noted. The CB534B Roller is shown. Front and rear water spray strainer assemblies are serviced the same way. 1. Remove four bolts (Figure 1, Item 2), washers (Figure 1, Item 1), and cover (Figure 1, Item 3) from bumper assembly (Figure 1, Item 4).
4 3 1 2
M0252SWR
Figure 1. Water Spray Strainer Removal.
0272-2
TM 5-3895-379-23-2
0272
REMOVAL - Continued 2. 3. Loosen two fittings (Figure 2, Item 2) and remove two tubes (Figure 2, Items 3 and 7) from adapters (Figure 2, Item 1). Loosen hose clamp (Figure 2, Item 5) and remove stainer assembly (Figure 2, Item 6) from bumper assembly (Figure 2, Item 4).
NOTE
On CB534C Roller, two bolts fasten the strainer base to the bumper instead of clamp. 4. If damaged, remove hose clamp (Figure 2, Item 5) from bumper assembly (Figure 2, Item 4).
2 7 1
1 5 4
M0253SWR
Water Spray Strainer Removal.
0272-3
TM 5-3895-379-23-2
0272
DISASSEMBLY
NOTE
CB534C Roller does not have valve or adapters. Remove two adapters (Figure 3, Item 1), valve (Figure 3, Item 4), and two bushings (Figure 3, Item 3) from strainer assembly (Figure 3, Item 2).
2 1 3 3
1 4
M0254SWR
Figure 3. END OF TASK CLEANING/INSPECTION 1.
Water Spray Strainer Disassembly.
Clean fittings, bushings, valve, and strainer assembly with detergent and water. Remove difficult deposits with cleaning brush.
WARNING
Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT direct compressed air against human skin. Failure to follow this warning may cause injury or death. Make sure air stream is directed away from user and other personnel in the area. To prevent injury, user must wear protective goggles or face shield. 2. 3. 4. 5. Use a cleaning cloth or compressed air to dry metal parts. Check fittings, bushings, and valve for clogging, corrosion, or excessive wear. Check strainer assembly for clogging, corrosion, excessive wear, and obvious signs of damage. Check all parts for stripped or damaged threads.
0272-4
TM 5-3895-379-23-2
0272
CLEANING/INSPECTION - Continued 6. Replace all damaged parts.
END OF TASK ASSEMBLY
NOTE
CB534C Roller does not have valve or adapters. Apply sealing compound to threads of two bushings (Figure 4, Item 3) and install two bushings (Figure 4, Item 3), valve (Figure 4, Item 4) (CB534B Roller), and two adapters (Figure 4, Item 1) in strainer assembly (Figure 4, Item 2).
2 1 3 3
1 4
M1142SWR
Water Spray Strainer Assembly.
0272-5
TM 5-3895-379-23-2
0272
INSTALLATION 1. 2. If removed, install hose clamp (Figure 5, Item 5) on bumper assembly (Figure 5, Item 4). Install strainer assembly (Figure 5, Item 6) in hose clamp (Figure 5, Item 5). Tighten clamp.
CAUTION
Directional arrows on strainer assembly must point left when strainer assembly is installed. Arrows indicate direction of water flow through strainer assembly. Failure to position strainer assembly arrow pointing left will result in poor equipment performance and possible equipment damage. 3. Position two tubes (Figure 5, Items 3 and 7) on adapters (Figure 5, Item 1) and tighten two fittings (Figure 5, Item 2).
2 7 1
1 5 4
M1141SWR
Figure 5.
Water Spray Strainer Installation.
0272-6
TM 5-3895-379-23-2
0272
INSTALLATION - Continued 4. Install cover (Figure 6, Item 3) on bumper assembly (Figure 6, Item 4) with four washers (Figure 6, Item 1) and bolts (Figure 6, Item 2). Tighten screws to 180-300 lb-in. (20-34 Nm).
4 3
1 2
M0255SWR
Water Spray Strainer Installation.
Fill water spray system. (TM 5-3895-379-10) Start engine, operate water spray system, and check for leaks. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0272-7/8 blank
TM 5-3895-379-23-2
0273
FIELD MAINTENANCE WATER SPRAY TUBES AND FITTINGS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Materials/Parts Strap, Tiedown, Electrical (WP 0288, Table 1, Item 67, 68, 69) Tag, Marker (WP 0288, Table 1, Item 70) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 136 and 137 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Water spray system drained. (TM 5-3895-379-10)
0273-1
TM 5-3895-379-23-2
0273
TYPE 1 FITTING REPLACEMENT
NOTE
Type 1 fitting replacement is the same on angle fitting and straight fitting. Angle fitting shown. Tag and mark each end of water line before removal. Remove clamps and support brackets as required. Remove electrical tiedown straps as required. 1. 2. Remove nut (Figure 1, Item 1) from fitting (Figure 1, Item 3). Pull water line (Figure 1, Item 5) from fitting (Figure 1, Item 3).
NOTE
Tube may come off with line or stay with fitting. Perform Step (4) only if tube stayed with fitting. 3. 4. Cut water line (Figure 1, Item 5) directly behind bushing (Figure 1, Item 4) and discard water line end, nut (Figure 1, Item 1), bushing (Figure 1, Item 4), and tube (Figure 1, Item 2). Remove tube (Figure 1, Item 2) from fitting (Figure 1, Item 3).
1 5 3
4
M0256SWR
Figure 1. 5. 6. 7. 8. 9.
Water Spray Tubes and Fittings Replacement.
Install nut (Figure 2, Item 1) on water line (Figure 2, Item 5). Install bushing (Figure 2, Item 4) on water line (Figure 2, Item 5). Install tube (Figure 2, Item 2) in fitting (Figure 2, Item 3). Install water line (Figure 2, Item 5) on tube (Figure 2, Item 2) and in fitting (Figure 2, Item 3). Tighten nut (Figure 2, Item 1) to fitting (Figure 2, Item 3).
0273-2
TM 5-3895-379-23-2
0273
TYPE 1 FITTING REPLACEMENT - Continued
1 5 3
4
M0257SWR
Figure 2. END OF TASK TYPE 2 CLAMP REPLACEMENT 1. 2. 3. 4. Loosen clamp (Figure 3, Item 1).
Remove clamp (Figure 3, Item 1) and water line (Figure 3, Item 2) from fitting (Figure 3, Item 3). Discard clamp if damaged. Install clamp (Figure 3, Item 1) on water line (Figure 3, Item 2). Position water line (Figure 3, Item 2) on fitting (Figure 3, Item 3) and tighten clamp (Figure 3, Item 1).
2
M0258SWR
0273-3
TM 5-3895-379-23-2
0273
WATER LINES REPLACEMENT
NOTE
Use table below and Figure 4 to locate ends of all water lines on roller. Tag and mark each end of water line before removal. Cut electrical tiedown straps as necessary to remove water lines. When replacing water lines, remove tubing from roller, remove fittings, cut new tubing 1/4-1/2 in. (6-13 mm) longer than tubing being replaced, then install fittings. Table 1. Water Line Figure 4, Item 1 From Rear Tee (Figure 4, Item 4) Water Lines. To Rear Water Spray Pipe (Figure 4, Item 10) Rear Tee (Figure 4, Item 4)
Figure 4, Item 5
Rear Water Spray Pump (Figure 4, Item 6) Rear Water Spray Filter (Figure 4, Item 3) Rear Water Spray Tank (Figure 4, Item 26) Rear Check Valve (Figure 4, Item 9) Front Tee (Figure 4, Item 17)
Figure 4, Item 7
Rear Water Spray Pump (Figure 4, Item 6) Rear Water Spray Filter (Figure 4, Item 3) Rear Water Spray Pipe (Figure 4, Item 10) Side Tee and Drain Cock (Figure 4, Item 24) Front Water Spray Pipe (Figure 4, Item 22) Front Water Spray Filter (Figure 4, Item 16) Front Tee (Figure 4, Item 17)
Figure 4, Item 2
Figure 4, Item 11
Figure 4, Item 12
Figure 4, Item 13
Front Tee (Figure 4, Item 17)
Figure 4, Item 15
Front Water Spray Tank (Figure 4, Item 14) Front Water Spray Pump (Figure 4, Item 19) Front Water Spray Filter (Figure 4, Item 16) Front Check Valve (Figure 4, Item 21) Rear Tee (Figure 4, Item 4)
Figure 4, Item 18
Figure 4, Item 20
Front Water Spray Pump (Figure 4, Item 19) Front Water Spray Pipe (Figure 4, Item 22) Side Water Spray Valve (Figure 4, Item 25)
Figure 4, Item 23
Figure 4, Item 8
0273-4
TM 5-3895-379-23-2
0273
WATER LINES REPLACEMENT - Continued
2 1 26
7 8 1
9 10 8
11 25 24
12 23 22
13 21
12 20 14 13
19 18
17 16
15
M0259SWR
Water Lines Replacement. 0273-5

TM 5-3895-379-23-2
0273
FOLLOW-ON MAINTENANCE 1. 2. Fill water tanks and check for leaks. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0273-6
TM 5-3895-379-23-2
0274
FIELD MAINTENANCE WATER SPRAY CHECK VALVE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Goggles (WP 0289, Table 1, Item 13) Materials/Parts Brush, Cleaning, Tool and Parts (WP 0288, Table 1, Item 10) Cloth, Cleaning (WP 0288, Table 1, Item 16) Detergent, GP Liquid (WP 0288, Table 1, Item 17) Sealing Compound, Loctite 271 Materials/Parts (cont.) (WP 0288, Table 1, Item 62) Wood block, approximately 6 in. (152 mm) tall, 6 in. (152 mm) and 12 in. (305 mm) long. Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 134 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Water spray system drained (or low). (TM 5-3895-379-10)
0274-1
TM 5-3895-379-23-2
0274
NOTE
Front and rear front water spray check valves are replaced the same way. Front water spray check valve is shown. REMOVAL 1. 2. Remove two nuts (Figure 1, Item 5), washers (Figure 1, Item 6), and straps (Figure 1, Item 7) from bumper assembly (Figure 1, Item 4). Lift water tank (Figure 1, Item 1) and place wood block (Figure 1, Item 2) between tank and drum (Figure 1, Item 3).
2 7
6 5 4 3
Figure 1. 3. 4. 5. 6. Water Spray Check Valve Removal.
M0264SWR
Loosen fitting (Figure 2, Item 4) and remove tube (Figure 2, Item 3) from elbow (Figure 2, Item 5). Remove elbow (Figure 2, Item 5) from check valve body (Figure 2, Item 7). Remove check valve body (Figure 2, Item 7) and valve (Figure 2, Item 1) from check valve adapter (Figure 2, Item 2). Remove check valve adapter (Figure 2, Item 2) from water tank (Figure 1, Item 6).
0274-2
TM 5-3895-379-23-2
0274
REMOVAL - Continued
2 1
7 6
5 4
M0265SWR
Figure 2. END OF TASK CLEAN AND INSPECTION 1.
Water Spray Check Valve Removal.
Clean check valve, check valve body, and check valve adapter in non-sudsing detergent and water. Remove difficult deposits with a cleaning brush.
WARNING
Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT direct compressed air against human skin. Failure to follow this warning may cause injury or death. Make sure air stream is directed away from user and other personnel in the area. To prevent injury, user must wear protective goggles or face shield. 2. 3. 4. 5. Use cleaning cloth or compressed air to dry metal parts. Check check valve for corrosion or excessive wear. Check check valve body and check valve body adapter for nicks, cracks, crossed threads, or corrosion. Replace damaged parts.
END OF TASK
0274-3
TM 5-3895-379-23-2
0274
INSTALLATION 1. 2. 3. 4. Apply sealing coumpound to threads of check valve adapter (Figure 3, Item 2) and install check valve adapter in water spray tank (Figure 3, Item 6). Install valve (Figure 3, Item 1) and check valve body (Figure 3, Item 7) in check valve adapter (Figure 3, Item 2). Apply sealing compound to threads of elbow (Figure 3, Item 5) and install elbow in check valve body (Figure 3, Item 7). Install tube (Figure 3, Item 3) on elbow (Figure 3, Item 5) and tighten fitting (Figure 3, Item 4).
1 2
7 6
5 4
M1279SWR
Figure 3. Water Spray Check Valve Installation.
0274-4
TM 5-3895-379-23-2
0274
INSTALLATION - Continued 5. 6. 7. Lift water tank (Figure 4, Item 1) and remove wood block (Figure 4, Item 2) from between tank and drum (Figure 4, Item 3). Lower water tank (Figure 4, Item 1) on bumper assembly (Figure 4, Item 4). Install two straps (Figure 4, Item 7) on bumper assembly (Figure 4, Item 4) with two washers (Figure 4, Item 6) and nuts (Figure 4, Item 5). Tighten nuts until strap tension is snug.
1
2 7
6 5 4 3
M0266SWR
Figure 4. Water Spray Check Valve Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Fill water spray system. (TM 5-3895-379-10) Start engine, operate water spray system, and check for leaks. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0274-5/6 blank
TM 5-3895-379-23-2
0275
FIELD MAINTENANCE WATER SPRAY SCREEN ASSEMBLY MAINTENANCE (CB534C)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Goggles (WP 0289, Table 1, Item 13) Materials/Parts Brush, Cleaning, Tool and Parts (WP 0288, Table 1, Item 10) Cloth, Cleaning (WP 0288, Table 1, Item 16) Detergent, GP Liquid (WP 0288, Table 1, Item 17) Sealing Compound, Loctite 271 Materials/Parts (cont.) (WP 0288, Table 1, Item 62) O-Ring (WP 0290, Table 1, Item 39) Qty: Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 138 Equipment Condition Engine off. (TM 5-3895-379-10) Water spray system drained. (TM 5-3895-379-10)
REMOVAL
NOTE
Front and rear water tank screen assemblies are maintained the same way. Front water spray screen assembly is shown. 1. Remove four bolts (Figure 1, Item 2), washers (Figure 1, Item 1), and cover (Figure 1, Item 3) from bumper assembly (Figure 1, Item 4).
4 3 1 2
M0260SWR
Figure 1.
Water Spray Screen Assembly Removal.
0275-1
TM 5-3895-379-23-2
0275
REMOVAL - Continued 2. 3. 4. 5. Remove tube (Figure 2, Item 11) from connector (Figure 2, Item 10) and tube (Figure 2, Item 7) from elbow (Figure 2, Item 6). Remove fluid filter assembly (Figure 2, Item 9) from water filter (Figure 2, Item 3). Remove two bolts (Figure 2, Item 8), six washers (Figure 2, Item 2), two nuts (Figure 2, Item 1), and water filter (Figure 2, Item 3) from frame (Figure 2, Item 12). Remove connector (Figure 2, Item 10), elbow (Figure 2, Item 6), two bushings (Figure 2, Item 5), and two O-rings (Figure 2, Item 4) from fluid filter (Figure 2, Item 3). Discard O-rings.
7 1 6 2 5 2 3 12 4 5 10 11 9 2 8 4
M0261SWR
Figure 2. Water Spray Screen Assembly Removal. END OF TASK CLEANING AND INSPECTION 1. Clean connector, elbow, bushings, and strainer assembly with detergent and water. Remove difficult deposits with cleaning brush.
WARNING
Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT direct compressed air against human skin. Failure to follow this warning may cause injury or death. Make sure air stream is directed away from user and other personnel in the area. To prevent injury, user must wear protective goggles or face shield. 2. 3. 4. Use a cleaning cloth or compressed air to dry metal parts. Check connector, elbow, and bushings for clogging, corrosion, or excessive wear. Check fluid filter assembly for clogging, corrosion, excessive wear, and obvious signs of damage.
0275-2
TM 5-3895-379-23-2
0275
CLEANING AND INSPECTION - Continued 5. 6. Check all parts for stripped or damaged threads. Replace all damaged parts.
END OF TASK INSTALLATION 1. 2. 3. 4. 5. Install two new O-rings (Figure 3, Item 4) and bushings (Figure 3, Item 5) in fluid filter assembly (Figure 3, Item 9). Install fluid filter assembly (Figure 3, Item 9) in water filter (Figure 3, Item 3). Install fluid filter (Figure 3, Item 3) on frame (Figure 3, Item 12) with two bolts (Figure 3, Item 8), six washers (Figure 3, Item 2), and two nuts (Figure 3, Item 1). Install tube (Figure 3, Item 11) on connector (Figure 3, Item 10) and tube (Figure 3, Item 7) to elbow (Figure 3, Item 6). Apply sealing compound to elbow (Figure 3, Item 6) and connector (Figure 3, Item 10) and install in bushings (Figure 3, Item 5).
7 1 6 2 5 2 3 12 4 5 10 11 9 2 8 4
M1139SWR
Figure 3. Water Spray Screen Assembly Installation.
0275-3
TM 5-3895-379-23-2
0275
INSTALLATION - Continued 6. Install cover (Figure 4, Item 3), four washers (Figure 4, Item 1), and bolts (Figure 4, Item 2) to bumper assembly (Figure 4, Item 4).
4 3
1 2
M0262SWR
Figure 4. Water Spray Screen Assembly Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Fill water spray system. (TM 5-3895-379-10) Start engine. Operate water spray system and check for leaks. (TM 5-3895-379-10)
0275-4
TM 5-3895-379-23-2
0276
FIELD MAINTENANCE WATER TANK STRAINER ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Materials/Parts Locknut (WP 0290, Table 1, Item 114) Qty: Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 134 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0276-1
TM 5-3895-379-23-2
0276
REMOVAL
NOTE
Front and rear water tank strainer assemblies are replaced the same way. Front water tank strainer assembly is shown. 1. 2. 3. 4. Remove lid (Figure 1, Item 8) and strainer (Figure 1, Item 4) from water tank (Figure 1, Item 6). Remove locknut (Figure 1, Item 9), screw (Figure 1, Item 10), and lanyard (Figure 1, Item 1) from lid (Figure 1, Item 8). Discard locknut. Remove screw (Figure 1, Item 3), washer (Figure 1, Item 2), and lanyard (Figure 1, Item 1) from water tank (Figure 1, Item 6). Remove six screws (Figure 1, Item 7) and rim (Figure 1, Item 5) from water tank (Figure 1, Item 7).
1 3 2 10
5 8 9 6 7
M0263SWR
Water Tank Strainer Assembly Removal.
0276-2
TM 5-3895-379-23-2
0276
INSTALLATION 1. 2. 3. 4. Install rim (Figure 2, Item 5) on water tank (Figure 2, Item 6) with six screws (Figure 2, Item 7). Install lanyard (Figure 2, Item 1) on water tank (Figure 2, Item 6) with washer (Figure 2, Item 2) and screw (Figure 2, Item 3). Install lanyard (Figure 2, Item 1) on lid (Figure 2, Item 8) with screw (Figure 2, Item 10) and new locknut (Figure 2, Item 9). Install strainer (Figure 2, Item 4) and lid (Figure 2, Item 8) on water tank (Figure 2, Item 6).
4 1 3 2 10
5 8 9 6 7
M1140SWR
Water Tank Strainer Assembly Installation.
0276-3
TM 5-3895-379-23-2
0276
FOLLOW-ON MAINTENANCE Remove chocks. (TM 5-3895-379-10) END OF TASK END OF WORK PACKAGE
0276-4
TM 5-3895-379-23-2
0277
FIELD MAINTENANCE DRAIN COCK AND TEE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Goggles (WP 0289, Table 1, Item 13) Wrench, Torque, 0-300 in-lb (WP 0289, Table 1, Item 41) Wrench, Torque, 20-100 ft-lb (WP 0289, Table 1, Item 42) Materials/Parts Brush, Cleaning, Tool and Parts (WP 0288, Table 1, Item 10) Cloth, Cleaning (WP 0288, Table 1, Item 16) Detergent, GP Liquid (WP 0288, Table 1, Item 17) Sealing Compound, Loctite 271 (WP 0288, Table 1, Item 62) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 137 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Water spray system drained. (TM 5-3895-379-10)
0277-1
TM 5-3895-379-23-2
0277
REMOVAL
WARNING
NOTE
Front and rear drain cock and tee are replaced the same way. The front drain cock and tee are shown. 1. Remove four bolts (Figure 1, Item 2), washers (Figure 1, Item 1), and cover (Figure 1, Item 3) from bumper assembly (Figure 1, Item 4).
4 3 1 2
M0267SWR
Figure 1. Drain Cock and Tee Removal. 2. 3. Loosen nut (Figure 2, Item 9) and remove water line (Figure 2, Item 8) from adapter (Figure 2, Item 7). Loosen two nuts (Figure 2, Items 2 and 5) and remove water lines (Figure 2, Items 1 and 4) from elbows (Figure 2, Items 3 and 6).
0277-2
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0277
REMOVAL - Continued
3 1 2
6 9 8 7
M0268SWR
Figure 2. 4.
Drain Cock and Tee Removal.
Remove two screws (Figure 3, Item 5), washers (Figure 3, Item 4), plate (Figure 3, Item 3), and tee (Figure 3, Item 1) from bumper assembly (Figure 3, Item 2).
5 4 3 2
M0269SWR
Figure 3.
Drain Cock and Tee Removal.
0277-3
TM 5-3895-379-23-2
0277
REMOVAL - Continued
NOTE
Note location and position of each fitting to aid in installation. 5. Remove drain cock (Figure 4, Item 4), adapter (Figure 4, Item 5), and two elbows (Figure 4, Items 2 and 3) from tee (Figure 4, Item 1).
2 3
5 4
M0270SWR
Figure 4. Drain Cock and Tee Removal. END OF TASK CLEANING 1. Clean tee, fittings, and drain cock with detergent and water. Remove difficult deposits with cleaning brush.
WARNING
END OF TASK
0277-4
TM 5-3895-379-23-2
0277
INSPECTION 1. 2. 3. 4. Check tee for clogging, corrosion, or excessive wear. Check drain cock for clogging, corrosion, excessive wear, and obvious signs of damage. Check all parts for stripped or damaged threads. Replace all damaged parts.
END OF TASK INSTALLATION 1. Apply sealing compound to threads and install drain cock (Figure 5, Item 4), adapter (Figure 5, Item 5), and two elbows (Figure 5, Items 2 and 3) in tee (Figure 5, Item 1).
2 3
5 4
M1247SWR
Figure 5.
Drain Cock and Tee Installation.
0277-5
TM 5-3895-379-23-2
0277
INSTALLATION - Continued 2. Install tee (Figure 6, Item 1) and plate (Figure 6, Item 3) on bumper assembly (Figure 6, Item 2) with two screws (Figure 6, Item 5) and washers (Figure 6, Item 4). Tighten screws to 84-132 lb-in. (9-15 Nm).
5 4 3 2
M0271SWR
Figure 6. Drain Cock and Tee Installation. 3. 4. Install two water lines (Figure 7, Items 1 and 4) on elbows (Figure 7, Items 3 and 6) with two nuts (Figure 7, Items 2 and 5). Position water line (Figure 7, Item 8) on adapter (Figure 7, Item 7) and tighten nut (Figure 7, Item 9).
3 1 2
6 9 8 7
M0272SWR
Figure 7. Drain Cock and Tee Installation.
0277-6
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0277
WARNING
Use caution when installing cover on bumper assembly. Failure to follow this warning may cause injury. 5. Install cover (Figure 8, Item 3) on bumper assembly (Figure 8, Item 4) with four washers (Figure 8, Item 1) and bolts (Figure 8, Item 2). Tighten bolts to 15-25 lb-ft (20-34 Nm).
4 3
1 2
M0273SWR
Drain Cock and Tee Installation.
Fill water spray system. (TM 5-3895-379-10) Start engine, operate water spray system, and check for leaks. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0277-7/8 blank
TM 5-3895-379-23-2
0278
FIELD MAINTENANCE SIDE DRAIN COCK AND VALVE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Goggles (WP 0289, Table 1, Item 13) Wrench, Torque, 20-100 ft-lb (WP 0289, Table 1, Item 42) Materials/Parts Brush, Cleaning, Tool and Parts (WP 0288, Table 1, Item 10) Cloth, Cleaning (WP 0288, Table 1, Item 16) Detergent, GP Liquid (WP 0288, Table 1, Item 17) Sealing Compound, Loctite 271 (WP 0288, Table 1, Item 62) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 137 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Water spray system drained. (TM 5-3895-379-10) Right-side door assembly opened. (TM 5-3895-379-10)
0278-1
TM 5-3895-379-23-2
0278
REMOVAL
NOTE
The drain cock and valve are replaced the same way for the CB534B and CB534C Rollers. The CB534B Roller is shown. 1. 2. 3. 4. Open drain cock (Figure 1, Item 6) and drain any water that may still be in system. Close drain cock (Figure 1, Item 6). Loosen two nuts (Figure 1, Item 1) and remove two water lines (Figure 1, Item 2) from adapters (Figure 1, Item 3). Remove two bolts (Figure 1, Item 9), washers (Figure 1, Item 8), clips (Figure 1, Item 4), and tee (Figure 1, Item 7) from frame assembly (Figure 1, Item 5).
CLOSED OPEN 9 8 7 6 5
M0274SWR
Figure 1.
Side Drain Cock and Valve Removal.
0278-2
TM 5-3895-379-23-2
0278
REMOVAL - Continued 5. 6. Remove two adapters (Figure 2, Item 3) and tee (Figure 2, Item 2) from valve (Figure 2, Item 1). Remove drain cock (Figure 2, Item 4) from tee (Figure 2, Item 2).
NOTE
Note position of valve and tee prior to removal. 7. Remove valve (Figure 2, Item 1) from tee (Figure 2, Item 2) (CB534B Roller).
1 2 3
4
M0275SWR
Figure 2. Side Drain Cock and Valve Removal. END OF TASK CLEANING 1. Clean tee, fittings, and drain cock with detergent and water. Remove difficult deposits with a cleaning brush.
WARNING
END OF TASK
0278-3
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0278
INSPECTION 1. 2. 3. 4. Check tee for clogging, corrosion, or excessive wear. Check drain cock and valve for clogging, corrosion, excessive wear, and obvious signs of damage. Check all parts for stripped or damaged threads. Replace all damaged parts.
END OF TASK INSTALLATION 1. 2. Apply sealing compound to threads and install valve (Figure 3, Item 1) and drain cock (Figure 3, Item 4) in tee (Figure 3, Item 2). Install two adapters (Figure 3, Item 3) and tee (Figure 3, Item 2) on valve (Figure 3, Item 1) (CB534B Roller).
1 2 3
4
M1222SWR
Figure 3. 3. 4. 5.
Side Drain Cock and Valve Installation.
Install tee (Figure 4, Item 7) and two clips (Figure 4, Item 4) on frame assembly (Figure 4, Item 5) with two washers (Figure 4, Item 8) and bolts (Figure 4, Item 9). Tighten bolts to 33-47 lb-ft (45-64 Nm). Position two water lines (Figure 4, Item 2) on adapters (Figure 4, Item 3) and tighten nuts (Figure 4, Item 1). Ensure that drain cock (Figure 4, Item 6) is closed.
0278-4
TM 5-3895-379-23-2
0278
CLOSED OPEN 9 8 7 6 5
M0276SWR
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4.
Side Drain Cock and Valve Installation.
Close right-side door assembly. (TM 5-3895-379-10) Fill water spray system. (TM 5-3895-379-10) Start engine, operate water spray system, and check for leaks. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
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0279
FIELD MAINTENANCE GENERAL MAINTENANCE INSTRUCTIONS
INITIAL SETUP: Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0288, Table 1, Item 12) Cleaning Compound, Solvent (WP 0288, Table 1, Item 13, 14, 15) Detergent, GP Liquid (WP 0288, Table 1, Item 17) Lubricating Oil, Engine, 15W40 Grade (WP 0288, Table 1, Item 29, 30, 31) Rag, Wiping (WP 0288, Table 1, Item 60) Tag, Marker (WP 0288, Table 1, Item 70) Personnel Required Construction Equipment Repairer 91L References TB 43-0209 TM 9-233 TM 9-247 Volume 1, WP 0195
NOTE
Refer to (Volume 1, WP 0195) for General Wiring Repair instructions. SCOPE These general maintenance instructions contain general shop practices and specific methods you must be familiar with to properly maintain the CB534B and CB534C Rollers, Motorized, Vibrating Tandem Steel Drums. You should read and understand these practices and methods before starting maintenance tasks on the roller. END OF TASK WORK SAFETY 1. 2. 3. 4. 5. Before starting a task, think about the risks and hazards to your safety as well as others. Wear protective gear such as safety goggles or lenses, safety shoes, rubber apron or gloves. Protect yourself against injury. Observe all WARNINGs and CAUTIONs. When lifting heavy parts, have someone help you. Make sure that lifting equipment is working properly, that it is suitable for the task assigned, of sufficient load capacity, and is secured against slipping. Always use power tools carefully. Before beginning a procedure, ensure that the following conditions have been observed, unless otherwise specified: a. b. c. d. e. Roller must be parked on level ground with drums chocked. Engine must be off. Components which are hot at operating temperatures (i.e., cooling, exhaust, and hydraulic systems) must cool down before they are removed. Components must, however, be at operating temperature to be tested. Battery disconnect switch must be in OFF position or batteries disconnected when performing electrical system maintenance.
0279-1
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0279
WORK SAFETY - Continued f. Hydraulic system pressure must be relieved before disconnecting any hydraulic system line or fitting.
END OF TASK GENERAL INFORMATION 1. Before beginning a task, find out how much repair, modification or replacement is needed to fix the roller as described in this manual. Sometimes the reason for roller failure can be seen right away and complete teardown is not necessary. Disassemble the roller only as far as necessary to repair or replace damaged or broken parts. All tags and forms attached to the roller must be checked to learn the reason for removal from service. Check all Modification Work Orders (MWOs) and Technical Bulletins (TBs) for equipment changes and updates. In some cases a part may be damaged by removal. If the part appears to be good, and other parts behind it are not defective, leave it on and continue the procedure. Here are a few simple rules: a. b. c. Do not remove dowel pins or studs unless loose, bent, broken, or otherwise damaged. Do not pull bearings or bushings unless damaged. If you must get at parts behind them, pull out bearings or bushings carefully. Replace all gaskets, seals, O-rings, performed packings, cotter pins, spring pins, locknuts, and lockwashers.
2. 3.
END OF TASK CLEANING INSTRUCTIONS
WARNING
Cleaning compound, solvent MIL-PRF-680 Type III is an environmentally compliant and low toxic material. However, It may be irritating to the eyes and skin. The use of protective gloves and goggles is suggested. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Improper cleaning methods and use of unauthorized cleaning solvents may injure personnel and damage equipment. Refer to TM 9-247 for correct information. Improper cleaning methods and use of unauthorized cleaning solvents may injure personnel and damage equipment. Refer to TM 9-247 for correct information. Fire extinguishers should be placed nearby when using cleaning compound, solvent. Cloths or rags saturated with cleaning compound, solvent must be disposed of IAW authorized facilities procedures. Eye shields must be worn when cleaning with a wire brush. Flying rust and metal particles may cause injury. Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT direct compressed air against human skin. Failure to follow this warning may cause injury or death. Make sure air stream is directed away from user and other personnel in the area. To prevent injury, user must wear protective goggles or face shield.
0279-2
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0279
CLEANING INSTRUCTIONS - Continued 1. General. a. b. Cleaning instructions will be the same for the majority of parts and components that make up the rollers. The importance of cleaning must be thoroughly understood by maintenance personnel. Great care and effort are required in cleaning. Dirt and foreign material are a constant threat to satisfactory maintenance. The following should apply to all cleaning, inspection, repair, and assembly operations. (1) (2) (3) 2. Clean all parts before inspection, after repair, and before assembly. Hands should be kept free of accumulation of grease, which can collect dust, dirt, or grit. After cleaning, all parts should be covered or wrapped to protect them from dust and dirt. Parts that are subject to rust should be lightly oiled.
External Engine Cleaning. a. b. c. d. Protect all electrical equipment that could be damaged by the steam or moisture before steam cleaning. Cover all openings before steam cleaning. After cleaning, dry and apply a light coat of oil to all parts subject to rust. Clear out all tapped (threaded) holes with compressed air to remove dirt and cleaning fluid.
3.
Cleaning Disassembled Parts. a. b. c. d. e. Place all disassembled parts in wire baskets for cleaning. Dry and cover all cleaned parts. Place parts on or in "racks" and hold for inspection or repair. All parts subject to rusting must be lightly oiled and wrapped. Keep all related parts and components together. Do not mix parts.
4.
Castings. a. b. c. Clean inner and outer surfaces of castings and all areas subject to grease and oil with cleaning compound, solvent. Use a stiff brush to remove sludge and gum deposits. Clear out all tapped (threaded) holes with compressed air to remove dirt and cleaning solvent.
5.
Oil Passages. Particular attention must be given to all oil passages in castings and machined parts. Oil passages must be clean and free of any obstructions. a. b. c. Clean passages with wire probes to break up any sludge or gum deposits. Wash passages by flushing with cleaning compound, solvent. Dry passages with compressed air.
6.
Oil Seals, Electrical Cables, and Flexible Hoses.
CAUTION
Washing oil seals, electrical cables, and flexible hoses with dry cleaning solvents or mineral spirits will cause damage or destroy the material. a. b. Wash electrical cables and flexible hoses with a mild solution of detergent and water and wipe dry. Oil seals are generally damaged during removal; cleaning will not be necessary since new seals will be used in assembly.
0279-3
TM 5-3895-379-23-2
0279
CLEANING INSTRUCTIONS - Continued 7. Machined Surfaces. a. b. 8. Clean machine surfaces with cleaning compound, solvent. Dry surfaces with compressed air.
Mated Surfaces. a. b. Remove old gasket and/or sealing compound using a wire brush and cleaning compound, solvent. Lightly coat with oil and wrap all parts subject to rust before storing.
9. 10. 11. 12.
Rusted Surfaces. Clean all rusted surfaces using wire brush and crocus cloth. Oil-Bathed Internal Parts. Wipe oil-bathed internal parts clean with a cleaning cloth. Air-Actuated Internal Parts. Wash air-actuated internal parts clean with a cleaning cloth. Externally Exposed Parts. Wash externally exposed parts with detergent and water. Rinse thoroughly and air dry.
END OF TASK INSPECTION INSTRUCTIONS 1. 2. General. All components and parts must be carefully checked to determine if they are serviceable for reuse, if they can be repaired or if they must be scrapped. Drilled and Tapped (Threaded) Holes. a. b. c. 3. Inspect for wear, distortion (stretching), cracks, or any other damage in or around holes. Inspect threaded areas for wear, distortion, or evidence of cross-threading. Mark all damaged areas for repair or replacement.
Metal Lines, Flexible Lines (Hoses), and Fittings. a. b. c. d. Inspect lines for sharp kinks, cracks, bends, or dents. Inspect flexible lines for fraying, evidence of leakage, or loose fittings or connectors. Check all fittings and connectors for thread damage. Check for hex heads that are worn or rounded by poorly fitting wrenches. Mark all damaged material for repair or replacement.
4.
Castings. a. b. c. d. e. Inspect all ferrous and nonferrous castings for cracks using a magnifying glass and strong light. Particularly check areas around studs, pipe plugs, threaded inserts, and sharp corners. Replace all cracked castings. Inspect machined surfaces for nicks, burrs, or raised metal. Mark damaged areas for repair or replacement. Inspect all pipe plugs, pipe plug openings, screws, and screw openings for damaged or stripped threads. Check all gasket mating surfaces, flanges on housings, and supports for warpage with a straightedge or surface plate. Inspect mating flanges for discoloration that may indicate persistent oil leakage.
5.
Studs, Bolts, and Screws. Replace if threads are damaged, bent, loose, or stretched.
0279-4
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0279
INSPECTION INSTRUCTIONS - Continued 6. Gears.
NOTE
When gear teeth wear limits are not established, good judgement is required to determine if gear replacement is necessary. a. b. c. 7. Inspect all gears for cracks using a magnifying glass and strong light. No cracks are permissible. Inspect gear teeth for wear, sharp fins, burrs, and galled or pitted surfaces. Check keyway slots for wear or damage. If keyways are worn, damaged, or elongated, replace gear.
Bushing and Bushing Type Bearings. a. b. Check all bushings and bushing type bearings for secure fit, evidence of overheating, wear, burrs, nicks, and out-of-round condition. Replace as necessary. Check for dirt in lubrication holes or grooves. Holes and grooves must be clean and free from damage.
8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Oil Seals. Oil seals are mandatory replacement items. Core Hole Expansion Plugs. Inspect for leakage. Replace plugs when leakage is present. Machine Tooled Parts. Inspect for cracks, breaks, elongated holes, wear, and chips. Replace any damaged parts. Machined Surfaces. Inspect for cracks, evidence of wear, galled or pitted surface, burrs, nicks, and scratches. Mated Surfaces. Inspect for remains of old gasket, seal, secure fit, pitting, and evidence of leakage. Rusted Surfaces. Inspect for pitting, holes, and severe damage. Oil-Bathed Internal Parts. Inspect for cracks, nicks, burrs, evidence of overheating, and wear. Air-Actuated Internal Parts. Inspect for cracks, nicks, burrs, evidence of overheating, and wear. Externally Exposed Parts. Inspect for breaks, cracks, rust damage, and wear. Springs. Inspect for broken, collapsed, and twisted coils.
END OF TASK REPAIR INSTRUCTIONS 1. General. a. Any repair procedure peculiar to a specific part or component is covered in the work package relating to that item.
CAUTION
Repaired items must be thoroughly cleaned to remove metal chips and abrasives, to prevent these from entering working parts of the roller. b. After repair, clean all parts thoroughly to prevent dirt, metal chips, or other foreign material from entering any working parts.
0279-5
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0279
REPAIR INSTRUCTIONS - Continued 2. Castings. a. Only minor repairs to machined surfaces, flanges, and gasket mating surfaces are permitted. Remove minor nicks, burrs, and scratches with: (1) (2) (3) b. c. 3. Fine mill file. Crocus cloth dipped in cleaning solvent. Lapping across a surface plate.
Remachining of machined surfaces to repair damage, warpage, or uneven surfaces is not permitted. Replace castings. Repair damaged threaded pipe plug or screw threads with a tap. Repair oversize holes with threaded inserts.
Studs. a. b. Repair minor thread damage with a thread die. Replace studs having stripped or damaged threads as outlined below: (1) Remove using a stud remover. Back studs out slowly to avoid heat buildup and seizure that can cause stud to break off.
CAUTION
Refer to TM 9-233 to avoid damage to castings if welding method is used. (2) (3) 4. Gears. a. b. Remove gears using pullers. Only minor repairs to gears are permitted. Remove minor nicks, burrs, or scratches on gear teeth with: (1) (2) 5. 6. Fine mill file. Crocus cloth dipped in cleaning compound, solvent. If studs break off too short to use a stud remover, use a stud extractor to remove or use "welding method": weld bar stock or a nut to stud and remove with a wrench. Install replacement stud slowly to prevent heat buildup and snapping off.
Bushings and Bushing Type Bearings. When bushings and bushing type bearings seize to a shaft and spin in the bore, associated parts must also be replaced. Oil Seals. a. b. Remove oil seals by pressing or prying out, being careful not to damage casting or adapter bore. Always install new seal in bore using proper seal installation tool.
7.
Painting. Upon installation, restored parts must be painted IAW TB 43-0209.
END OF TASK
0279-6
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0279
LUBRICATION INSTRUCTIONS
NOTE
Refer to TM 5-3895-379-10 for detailed, illustrated instructions on proper lubrication. The following are some general practices to remember. 1. 2. 3. 4. Use the correct lubricant. Keep lubricants clean. Clean all fittings prior to lubrication. Lubricate clean, disassembled, and new parts to prevent rust.
END OF TASK STANDARD TOOL REQUIREMENTS 1. The following are general practices regarding the use of tools: a. b. c. d. e. f. 2. Always use the proper tool kit and tools for the procedure being performed. Ensure that tools are clean and lubricated to reduce wear and prevent rust. Keep track of tools. Do not be careless with them. Return tools to toolbox when finished with repair or maintenance. Return toolboxes and tools to tool storage when not in use. Inventory tools before and after each use.
Some maintenance tasks may require special or fabricated tools. The "Initial Setup" of the procedure will specify any special or fabricated tools needed to perform that procedure. Use these special tools only for the maintenance procedures for which they are designed or called out. If you are unfamiliar with a required tool, see your supervisor.
END OF TASK TAGGING WIRES AND HOSES 1. Use marker tags to identify all electrical wires, fuel, oil, coolant, and hydraulic lines, and any other parts which may be hard to identify or replace later. Fasten tags to parts during removal by wrapping wire fasteners around or through parts and twisting ends together. Position tags to be out of the way during cleaning, inspection, and repair. Mark tags with a pencil, pen, or marker. Whenever possible, identify electrical wires with the number of the terminal or wire to which it connects. If no markings can be found, tag both wires or wire and terminal, and use the same identifying mark for both. If you cannot tag a wire because it must fit through a small hole or you cannot reach it, write down the description of the wire and the point to which it connects or draw a simple diagram on paper. Be sure to write down enough information so you will be able to properly connect the wires during assembly. If you need to identify a loose wire, look for identifying number near end of the wire, stamped on a permanent metal tag. Compare the number to wire numbers on the appropriate electrical schematic. Identify fuel, oil, coolant, and hydraulic lines when you are taking off more than one line at the same time. Mark tags to point to which lines and hoses must be connected. If it is not obvious which end of a line goes where, tag each end of the line. Identify and tag other parts as required by name and installed location.
2.
3.
4.
END OF TASK
0279-7
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0279
LINES AND PORTS To keep dirt from contaminating fluid system when removing and installing fuel, oil, coolant, and hydraulic lines, perform the following steps: a. b. Clean fittings and surrounding area before disconnecting lines. Cover cap, plug, or tape lines and ports after disconnecting lines. When these are not available, use plastic bags and rubber bands, clean rags, duct tape or other similar materials to prevent dirt from entering system. Ensure that new and used parts are clean before installing. Replace all clamps and tiedown straps. Wait to remove cover, cap, plug, or tape from lines and ports until just before installing lines.
c. d. e.
END OF TASK FLUID DISPOSAL
NOTE
When servicing this vehicle, performing maintenance, or disposing of materials such as engine coolant, hydraulic fluid, lubricants, battery acids, or batteries consult your unit/local hazardous waste disposal center or safety office for local regulatory guidance. If further information is needed, please contact The Army Environmental Hotline at 1-800-872-3845. Dispose of contaminated drained fluids IAW Standard Operating Procedures (SOP) of your unit. END OF TASK END OF WORK PACKAGE
0279-8
TM 5-3895-379-23-2
0280
FIELD MAINTENANCE ELECTRICAL GENERAL MAINTENANCE INSTRUCTIONS
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-10
MULTIMETER USAGE 1. General. A multimeter is used to troubleshoot the electrical system of the roller. The multimeter ohms scale is used to test for continuity, shorts, and resistance. The multimeter voltmeter scale is used to test voltage levels at any point in the electrical system. Continuity Tests. Continuity tests are performed to check for breaks in a circuit (such as a fuse, switch, light bulb connector, or electrical wiring).
2.
NOTE
If readout will not zero properly, replace batteries and repeat zeroing procedure. If readout will not zero after batteries have been replaced, notify your supervisor. a. Zero Multimeter. (1) (2) (3) (4) Set multimeter to ON. Select OHMS. Select LOWEST VOLTAGE/OHMS scale. Touch black and red probes together and check for a zero indication on digital readout.
CAUTION
Before performing a continuity test, always place battery disconnect switch in OFF position (TM 5-3895-379-10) and disconnect circuit to be tested. Failure to follow this caution may damage multimeter. b. Testing for Continuity. (1) (2) (3) Zero multimeter. Connect black and red probes to both terminals of circuit being tested. Observe readout and interpret results as follows: (a) (b) If readout indicates any numeric value, circuit has continuity. If readout does not indicate any numeric value, or value is over the limits of the meter, circuit is open.
0280-1
TM 5-3895-379-23-2
0280
MULTIMETER USAGE - Continued
CAUTION
Before performing a continuity test, always place battery disconnect switch in OFF position (TM 5-3895-379-10) and disconnect circuit to be tested. Failure to follow this caution may damage multimeter. c. Testing for Shorts. A short (or short circuit) occurs when two circuits that should not be connected have continuity with each other. A short also occurs when a circuit that should not touch ground has continuity with ground. (1) (2) (3) Zero multimeter. Connect black probe to one pin and red probe to either ground or another pin. Observe readout and interpret results as follows: (a) (b) (c) If readout indicates any numeric value above 0 (zero) but less than the meter's limits, circuits are shorted or circuit is grounded, if testing to ground. If readout does not indicate a numeric value or value does not change when connected to circuit(s) in question, circuits are not shorted. If readout jumps or flickers, circuits are shorted or grounded intermittently.
CAUTION
Before performing a continuity test, always place battery disconnect switch in OFF position (TM 5-3895-379-10) and disconnect circuit to be tested. Failure to follow this caution may damage multimeter. d. Testing for Resistance. Allowable resistance readings depend on circuit being tested. Refer to the particular section dealing with that circuit or component for allowable readings. (1) (2) (3) (4) (5) 3. Zero multimeter. Select OHMS. Select lowest VOLTAGE/OHMS range. If test specifies ohms range, select required range. Connect black and red probes across circuit to be tested. Observe readout and interpret results as circuit resistance.
Voltage Tests. a. Measuring DC Voltage. (1) (2) (3) (4) b. Set multimeter to ON. Select lowest possible DC VOLTAGE range that is still higher than voltage to be measured. Connect red probe to positive (+) pin and black probe to negative (-) pin. Observe readout and interpret results as DC voltage in circuit being tested.
Measuring DC Voltage Drop.
NOTE
Voltage drop is defined as the amount of voltage loss that occurs through all or part of a circuit due to resistance. (1) (2) Set multimeter to ON. Select lowest possible DC VOLTAGE range that is still higher than voltage to be measured.
0280-2
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0280
MULTIMETER USAGE - Continued (3) (4) c. Connect red probe to test location closest to positive (+) side. Connect probe to test location closest to ground. Observe readout and interpret results as DC voltage in circuit being tested.
DC Voltage Drop Examples. (1) Good Voltage Drop. (a) Multimeter "A" is used to measure voltage drop across a good splice connection. Voltage reading at multimeter "A" should be low (about 0.1 volt). This means that resistance across this splice is low, resulting in low voltage drop.
24 - VOLT BATTERY PACK
GOOD SPLICE CONNECTION
M0277SWR
LAMP
SWITCH (CLOSED)
Figure 1. Electrical General Maintenance Instructions.
0280-3
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0280
MULTIMETER USAGE - Continued (b) Multimeter "B" is used to measure voltage drop across a closed switch. Voltage reading at multimeter "B" also should be low (about 0.1 volt). This means that resistance across this switch is low, resulting in low voltage drop.
LAMP
SWITCH (CLOSED)
M0278SWR
0280-4
TM 5-3895-379-23-2
0280
MULTIMETER USAGE - Continued (c) Multimeter "C" is used to measure voltage drop across a load, in this case a lamp. If voltages at multimeters "A" and "B" are 0.1 volt each, voltage reading at multimeter "C" will equal 23.8 volts. This is because the sum of all voltage drops in a circuit is equal to the source voltage.
LAMP
SWITCH (CLOSED)
M0279SWR
C
0280-5
TM 5-3895-379-23-2
0280
MULTIMETER USAGE - Continued (2) Bad Voltage Drop. (a) Multimeter "D" is used to measure voltage drop across a bad splice connection. The voltage reading at multimeter "D" is high (for example 7 volts). This means the resistance across this splice is high, resulting in high voltage drop. This would cause the lamp to be dimly lit when switch is closed.
BAD SPLICE CONNECTION
M0280SWR
LAMP
SWITCH (CLOSED)
Figure 4. Electrical General Maintenance Instructions. (b) Multimeter "E" is used to measure voltage drop across an open circuit, in this case an open switch. This could also be used to demonstrate the reading in a circuit with a broken wire. The voltage reading at multimeter "E" will be approximately 24 volts. This means that an open circuit or an open switch has infinite resistance, causing all voltage to be lost.
0280-6
TM 5-3895-379-23-2
0280
MULTIMETER USAGE - Continued
LAMP
SWITCH (OPEN)
M0281SWR
Figure 5. Electrical General Maintenance Instructions. END OF TASK RELAY INSPECTION AND TEST 1. Inspecting Relays. a. b. 2. Check for bent or damaged pins. Check for burned or damaged relay case.
Testing Relays.
NOTE
When testing relays, always refer to circuit diagram printed or stamped on relay case. a. b. Using a multimeter, check for continuity across relay coil. Using a multimeter, check open or closed contacts within relay.
0280-7/8 blank
TM 5-3895-379-23-2
0281
FIELD MAINTENANCE PREPARATION FOR STORAGE AND SHIPMENT
INITIAL SETUP: Materials/Parts Barrier Mat (WP 0288, Table 1, Item 9) Diesel Fuel (WP 0288, Table 1, Item 21, 22, 23) Lubricating Oil MIL-L-460002, 1 Grade (WP 0288, Table 1, Item 56, 57, 58) Sealing Compound (WP 0288, Table 1, Item 61) Tape PSA-Clear-Backing (WP 0288, Table 1, Item 71) Personnel Required Construction Equipment Repairer 91L References AR 190-13 TM 43-0139 TM 43-0209 References (cont.) TM 5-3895-379-10 Volume 1, WP 0004 Volume 1, WP 0005 Volume 1, WP 0071 Volume 1, WP 0100 Volume 1, WP 0118 Volume 1, WP 0121 Volume 1, WP 0124 Volume 1, WP 0127 Volume 1, WP 0129 Volume 1, WP 0134 Volume 1, WP 0151 Volume 1, WP 0191 WP 0270 WP 0271
SECURITY PROCEDURES For security procedures involved in storage and shipment of the roller, refer to AR 190-13. END OF TASK STORAGE INSTRUCTIONS 1. Short Term Storage (90 Days or Less).
CAUTION
If short term storage is to occur during times when air temperature may fall below 0F (-18C), long term storage procedures must be used. a. b. c. Fill fuel tank completely (TM 5-3895-379-10). Perform AFTER operation Preventive Maintenance Checks and Services (TM 5-3895-379-10). Park roller: (1) (2) (3) d. e. Park roller on a level surface; block roller to prevent movement; and ensure that roller is parked in a position to allow periodic movement and allow roller to be driven away after storage.
Perform final walk-around inspection to ensure that all panels, access doors, container caps, and fasteners are firmly secured. Every 45 to 60 days roller must be exercised:
0281-1
TM 5-3895-379-23-2
0281
STORAGE INSTRUCTIONS - Continued Perform BEFORE operation PMCS (TM 5-3895-379-10). f. g. h. i. j. Ensure all fluid levels are correct (TM 5-3895-379-10). Start engine (TM 5-3895-379-10). Allow engine to warm at idle speed for approximately 10 minutes. Observe warning and indicator lights (TM 5-3895-379-10). When engine is warm, throttle up roller to operating rpm (TM 5-3895-379-10). Operate all roller controls (TM 5-3895-379-10). Steering, brakes, propulsion, vibratory, lights, and horn systems must be operated. Stop roller movement often and restart. Operation should last a minimum of 30 minutes. Park roller (TM 5-3895-379-10). Repeat Step (a) through Step (d).
k. 2.
Long Term Storage (Greater Than 90 Days). a. b. c. d. e. f. Perform a complete operational check. Operate propulsion, vibratory, and steering systems and water spray (TM 5-3895-379-10). If any system is found to be faulty, troubleshoot (Volume 1, WP 0004) and (Volume 1, WP 0005). Thoroughly clean roller. Remove all grease, dirt, rocks, tar, and other foreign debris. Visually inspect all metal components to locate areas to be repainted. Drum surfaces do not require painting. Repaint as required (TM 43-0139). With the exception of procedures involving fuel tank and engine crankcase, perform all Operator PMCS (TM 5-3895-379-10) and Field Maintenance PMCS (Volume 1, WP 0071). Prepare engine: (1) (2) (3) (4) (5) (6) Drain fuel tank (Volume 1, WP 0124). Spray inside of fuel tank with Lube Oil MIL-L-46002/0. Coat threaded surface of fuel tank drain plug with Lube Oil, MIL-L-46002/0. Remove and clean fuel filler cap. Coat inside of fuel filler cap with Lube Oil, MIL-L-46002/0. Install fuel tank drain plug and fuel filler cap.
NOTE
A two compartment portable container with a three position valve is required when preserving roller fuel system for long term storage. The container is needed to supply fuel and preservative oil to engine during preservation procedures. One side of container must contain diesel fuel and other side must contain Lube Oil, MIL-L-46002/0. (7) (8) (9) Disconnect fuel line from fuel/water separator on the "in from fuel tank" side (Volume 1, WP 0129). Connect fuel/preservative hose to fuel/water separator. Disconnect fuel return hose from fuel filter (Volume 1, WP 0127) and place in container for collecting fuel and preservative oil with a 55 gallon (200 liter) capacity.
(10) Open valve on fuel/preservative container to FUEL position. (11) Start engine (TM 5-3895-379-10) and allow to operate at fast idle until engine is warm. (12) Set throttle to run engine at 2100 rpm (TM 5-3895-379-10).
0281-2
TM 5-3895-379-23-2
0281
STORAGE INSTRUCTIONS - Continued (13) Turn fuel/preservative valve to PRESERVATIVE position. (14) Visually inspect fluid flowing from return line. When fluid is undiluted preservative oil, turn engine off (TM 5-3895-379-10). (15) Turn fuel/preservative valve to OFF position. (16) Disconnect fuel/preservative hose from fuel/water separator. (17) Connect fuel supply line to fuel/water separator (Volume 1, WP 0129). (18) Connect fuel return line to fuel filter (Volume 1, WP 0127). (19) Discard fuel/preservative mixture collected from fuel return line IAW local regulations. (20) Drain oil from crankcase (Volume 1, WP 0100). (21) Fill crankcase with Lube Oil, MIL-L-46002/0. (22) Attach tag to engine oil fill tube stating "THIS CRANKCASE IS FILLED TO CAPACITY WITH PRESERVATIVE OIL. DRAIN AND REFILL CRANKCASE WITH ENGINE OIL BEFORE OPERATION OF ENGINE." g. h. i. Apply protective sealant or equivalent to all exposed electrical wires, cables, and connectors. Coat steering cylinder chrome rod with Lube Oil, MIL-L-46002/0 and then cover with barrier material. Prepare air intake assembly: (1) (2) Disassemble air cleaner assembly (Volume 1, WP 0118). Fog inside of air cleaner canister with Lube Oil, MIL-L-46002/0.
CAUTION
Preservation oil will damage non-metallic air filter parts. Care should be used when applying preservative oil to air filter non-metallic parts. (3) (4) (5) (6) (7) (8) j. Dip removed air cleaner components in Lube Oil, MIL-L-46002/0. Install air cleaner elements and components (Volume 1, WP 0118). Wrap air intake restriction indicator in barrier material. Loosen hose clamp at turbo air inlet and pull off air inlet hose (Volume 1, WP 0121). Spray inside of air inlet hose and turbocharger inlet impeller with Lube Oil, MIL-L-46002/0. Attach air inlet hose and tighten clamp (Volume 1, WP 0121).
Prepare exhaust system: (1) (2) (3) (4) (5) Remove muffler (Volume 1, WP 0134). Clean and paint any unpainted area on muffler and exhaust pipe (TM 43-0209). Spray inside of exhaust pipe leading from engine with Lube Oil, MIL-L-46002/0. Install muffler (Volume 1, WP 0134). Place barrier material over exhaust exit. Secure with tape.
0281-3
TM 5-3895-379-23-2
0281
STORAGE INSTRUCTIONS - Continued k. Prepare water spray system: (1) Remove water line at bottom of tanks and drain all water (TM 5-3895-379-10).
WARNING
Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT direct compressed air against human skin. Failure to follow this warning may cause injury or death. Make sure air stream is directed away from user and other personnel in the area. To prevent injury, user must wear protective goggles or face shield. (2) (3) (4) (5) (6) Disconnect water supply lines at water pumps (WP 0270) and blow lines out with low pressure air (30 psi or less). With lines still disconnected from pumps turn water pumps on for a short time to purge water from pumps. Remove water strainers, drain, and install (WP 0271). Connect water supply lines to water pumps (WP 0270). Connect water line to bottom of tanks (TM 5-3895-379-10).
CAUTION
To prevent damage to alternator ensure that plug-in lead to alternator is disconnected. l. Disconnect plug-in lead to alternator (Volume 1, WP 0151) and tape.
CAUTION
Discharged batteries will be damaged if stored in below freezing temperatures. m. n. o. p. Remove batteries (Volume 1, WP 0191) and tape battery cable ends. Store batteries where they can be checked periodically and recharged. Cover seat with barrier material. Tag roller as "STORED LONG TERM". List all work done on roller on the tag. Check roller every 45 to 60 days for signs of damage or deterioration. Repeat procedures if damage is detected.
0281-4
TM 5-3895-379-23-2
0281
STORAGE INSTRUCTIONS - Continued 3. Removing Roller from Long Term Storage. a. b. c. d. e. Remove all coverings and tape. Install fully charged batteries or new batteries (Volume 1, WP 0191). Connect plug-in lead to alternator (Volume 1, WP 0151). Perform all Operator PMCS (TM 5-3895-379-10) and Field Maintenance PMCS (Volume 1, WP 0071). On first day of operation, check roller periodically for leaks and proper operation. Troubleshoot as required (Volume 1, WP 0004) and (Volume 1, WP 0005).
END OF TASK SHIPMENT INSTRUCTIONS 1. 2. 3. Completely drain front and rear water tanks (TM 5-3895-379-10). Perform Operator PMCS procedures (TM 5-3895-379-10). Prepare roller to point required by distance and duration of shipment. If duration of shipment will last more than three months, roller should be prepared for storage.
0281-5/6 blank
TM 5-3895-379-23-2
0282
FIELD MAINTENANCE LUBRICATION INSTRUCTIONS
INITIAL SETUP: Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0288, Table 1, Item 12) Rag, Wiping (WP 0288, Table 1, Item 60) Tag, Marker (WP 0288, Table 1, Item 70) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-10
LUBRICATION INSTRUCTIONS
NOTE
Refer to TM 5-3895-379-10 for detailed, illustrated instructions on proper lubrication. The following are some general practices to remember: 1. 2. 3. 4. Use the correct lubricant. Keep lubricants clean. Clean all fittings prior to lubrication. Lubricate clean disassembled and new parts to prevent rust.
STANDARD TOOL REQUIREMENTS 1. The following are general practices regarding the use of tools: a. b. c. d. e. f. 2. Always use the proper tool kit and tools for the procedure being performed. Ensure that tools are clean and lubricated to reduce wear and to prevent rust. Keep track of tools. Do not be careless with them. Return tools to toolbox when finished with repair or maintenance. Return toolboxes and tools to tool storage when not in use. Inventory tools before and after each use.
Some maintenance tasks may require special or fabricated tools. The "Initial Setup" of the procedure will specify any special or fabricated tools needed to perform that procedure. Use these special tools only for the maintenance procedures for which they are designed or called out. If you are unfamiliar with a required tool, see your supervisor.
TAGGING WIRES AND HOSES 1. Use marker tags to identify all electrical wires, fuel, oil, coolant, and hydraulic lines, and any other parts which may be hard to identify or replace later. Fasten tags to parts during removal by wrapping wire fasteners around or through parts and twisting ends together. Position tags to be out of the way during cleaning, inspection, and repair. Mark tags with a pencil, pen, or marker.
0282-1
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TM 5-3895-379-23-2
0282
TAGGING WIRES AND HOSES - Continued 2. Whenever possible, identify electrical wires with the number of the terminal or wire to which it connects. If no markings can be found, tag both wires or wire and terminal, and use the same identifying mark for both. If you cannot tag a wire because it must fit through a small hole or you cannot reach it, write down the description of the wire and the point to which it connects or draw a simple diagram on paper. Be sure to write down enough information so you will be able to properly connect the wires during assembly. If you need to identify a loose wire, look for identifying number near end of the wire, stamped on a permanent metal tag. Compare the number to wire numbers on the appropriate electrical schematic. Identify fuel, oil, coolant, and hydraulic lines when you are taking off more than one line at the same time. Mark tags with points to which lines and hoses must be connected. If it is not obvious which end of a line goes where, tag each end of the line. Identify and tag other parts as required by name and installed location.
3.
4.
LINES AND PORTS To keep dirt from contaminating fluid systems when removing and installing fuel, oil, coolant, and hydraulic lines, perform the following steps: a. b. Clean fittings and surrounding area before disconnecting lines. Cover, cap, plug, or tape lines and ports after disconnecting lines. When these are not available, use plastic bags and rubber bands, clean rags, duct tape, or other similar materials to prevent dirt from entering system. Ensure that new and used parts are clean before installing. Replace all clamps and tiedown straps. Wait to remove cover, cap, plug, or tape from lines and ports until just before installing lines.
c. d. e.
FLUID DISPOSAL
NOTE
When servicing this vehicle, performing maintenance, or disposing of materials such as engine coolant, hydraulic fluid, lubricants, battery acids, or batteries, consult your unit/local hazardous waste disposal center or safety office for local regulatory guidance. If further information is needed, please contact The Army Environmental Hotline at 1-800-872-3845. Dispose of contaminated drained fluids IAW Standard Operating Procedures (SOP) of your unit. END OF WORK PACKAGE
0282-2
03/15/2011 Rel(1.8) root(lubewp) wpno(M00220)
TM 5-3895-379-23-2
0283
FIELD MAINTENANCE ILLUSTRATED LIST OF MANUFACTURED ITEMS
INITIAL SETUP: References TM 5-3895-379-23P Volume 1, WP 0195 WP 0242 References (cont.) WP 0273 WP 0291
ILLUSTRATED LIST OF MANUFACTURED ITEMS INTRODUCTION 1. 2. 3. This work package includes complete instructions for making items authorized to be manufactured or fabricated by Field Maintenance. A part number index (Table 1. Manufactured Items Part Number Index) in alphanumeric order is provided for cross-referencing part number of manufactured item to figure where fabrication criteria is covered. All bulk materials needed for manufacture of an item are listed by part number or specification number in a tabular list on illustration. Table 1. Manufactured Items Part Number Index. Part No. 3P-2181 5P-0753 5P-3619 Nomenclature Lead Storage Battery Water Spray Lines Tubing, Wiring Harness Hose, Nonmetallic Tubing, Wiring Harness Hose Assembly, Nonmetallic Battery Cable Lead, Electrical Cable Assembly, Spec Seat Trim Sheet Nonmetallic, P Edging (Channel) Battery Cable Cable Assembly, Spec Battery Cable Page No. 2 22 23
5P-5112
23
5Y-1423 9V-6943 9X-2092 091-847 106-0539
2 2 22 23 2
108-0405
0283-1
03/15/2011 Rel(1.8) root(manuwp) wpno(M00221)
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued BATTERY CABLE FABRICATION
NOTE
This illustration is provided as reference. Actual appearance of components may vary.
PROTECTOR C
CUTOFF LENGTH TERMINAL A PROTECTOR D
BULK CABLE
TERMINAL B
M0282SWR
Figure 1.
Battery Cable.
NOTE
1. Obtain all components required to fabricate desired battery cable. Refer to TM 5-3895-379-23P for component part numbers. 2. Use a fine-toothed hacksaw blade or suitable cutting device, and cut cable to indicated length. 3. Remove about 1 in. (25 mm) of insulation from each end of cable. 4. Slide terminal protectors C and D on cable as indicated. 5. Place battery cable terminals A and B on cable as indicated. 6. Crimp battery cable terminals on cable. Table 2. Battery Cable LOCATION Cutoff Length In. (mm) Battery Cables and Components. Battery Cable Terminal B YES Terminal Protector C YES Terminal Protector D YES
Battery Cable Terminal A YES
Battery Disconnect 24 (610) Switch to Battery Battery Disconnect 13 (330) Switch to Frame Battery to Battery NATO Connector to Starter 8 (200)
YES
YES
NO
NO
YES
YES YES
YES NO
YES NO
67 (1700) YES
0283-2
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued BATTERY CABLE FABRICATION - Continued Table 2. Battery Cable LOCATION Battery to NATO Connector Cutoff Length In. (mm) 23 (580) Battery Cables and Components - Continued. Battery Cable Terminal B YES Terminal Protector C YES Terminal Protector D YES
Battery Cable Terminal A YES
WIRING HARNESS FABRICATION 1. 2. 3. 4. Wiring harnesses are procured as assemblies. The following information is provided as reference to aid in repair of individual wires and circuits within harnesses. Refer to (Volume 1, WP 0195) for wiring harness repair procedures. Refer to (WP 0291) for circuit identification. Refer to TM 5-3895-379-23P for specific part numbers. Table 3. Engine Wiring Harness. Table 4. Main Wiring Harness. Table 5. Front Wiring Harness. Table 6. Rear Wiring Harness. Table 7. Harness Assembly. Table 8. Instrument Wiring Harness.
Color Code Abbreviations Black Blue Brown Gray BK BU BR GY Green Pink Purple Orange Table 3. GN PK PU OR Engine Wiring Harness. Length in Termination Circuit Ident GA Inches 6 56 mm 1422 Color RD Circuit Ident 101B Termination Alternator Circuit Breaker Alternator Circuit Breaker Red White Yellow RD WH YL
Starter
101A
Main Harness P9
109A
104
2642
OR
109B
0283-3
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued WIRING HARNESS FABRICATION - Continued Table 3. Engine Wiring Harness - Continued. Length in Termination Circuit Ident GA Inches 6 6 90 54 mm 2206 1372 Color OR OR 109F Alternator Circuit Breaker Circuit Ident Termination
Alternator Starter Relay
109C 109E
R5-22 Hour Meter P18-2 Speed Sensor P12-1 Ground R5-33 Ground Frame Hydraulic Charge Relay P17-A Ground R-16-5
123A 123C 123D
16 16 16
8 58 20
203 1473 508
WH WH WH 123B Splice
200A 200C 200K
16 12 16
15 9 7
381 229 178
BK BK BK 200B Splice
200T
16 16 16 16
16 48 17 29
406 1219 431 737
BK BK BK BK 200E 200F Fuel Solenoid P17-2 Water Temperature Sending Unit Engine Oil Pressure Switch
Splice
200D 16 20 508 BK 200G
16 2-Speed Valve P20-2 Brake Valve P19-2 Vibratory Continuous Valve P23-2 200I 16
62 33
1574 838
BK BK 200H Splice
200J 200L
16 16
35 17
889 432
BK BK
0283-4
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued WIRING HARNESS FABRICATION - Continued Table 3. Engine Wiring Harness - Continued. Length in Termination Circuit Ident GA Inches 16 16 16 11 8 19 mm 279 203 483 Color BK BK BK Circuit Ident Termination
Vibratory Pump A-2 200M Vibratory Pump B-2 200N Vibratory Continuous Valve P22-2 200O
16 16 Splice 200P 16 16 R5-9 220A 16
58 15
1473 381
BK BK 200Q Hydraulic Temperature Sending Unit Fuel Sending Unit P21-2 Starter Relay Engine Oil Pressure Switch Water Temperature Sending Unit Hydraulic Temperature Switch R5-15
80 9 76
2032 229 1930
BK BK BK
200R 200S 220B
R5-24
221A
16
91
2311
BK
221B
R5-23
226A
16
136
3454
BK
226B
Hydraulic Charge Relay P17-B Starter R5-6 R5-7 R5-13
276B
16
22
559
BK
276A
304A 306A 309A 321A
6 16 16 16
53 131 108 27
1346 3327 2743 686
WH GN GY BR
304B 306B 309B 321B
Starter Relay Starter Relay Alt (R) Terminal P12-4 Backup Alarm P14 Warning Horn-5
R5-17
322A
16
27
686
GY
322B
0283-5
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued WIRING HARNESS FABRICATION - Continued Table 3. Engine Wiring Harness - Continued. Length in Termination Circuit Ident GA Inches 16 79 mm 2007 Color PU Circuit Ident 326B Termination Fuel Shut-off Solenoid Starting Aid P-1801 Hour Meter P14 Vibratory Sensor-7 P12 Vibratory Sensor-3 Fuel Sending Unit P12-2 (Unused) R16-4 (Unused) R16-3 (Unused) R16-5 (Unused)
R5-10
326A
R5-11 R5-25 R5-14
377A 400A B439A
16 16 16
141 65 27
3581 1651 686
OR GN RD
377B 400B B439B
R5-18
B440A
16
27
686
RD
B44CB
R5-8 R5-12 R5-40 R5-29 R5-30 R5-21 Working Lights P12-5 R16-1 R5-27 Working Lights P14-6 (Unused) R16-2 R5-26 R5-36 R5-35
447A 449A 604A 605A 606A 608A 608C
16 16 16 16 16 16 16
201 27 30 30 30 27 13
5105 686 762 762 762 686 330
PK RD OR YL GY GN GN
447B 449B 604B 605B 606B
608B
Splice
608D 619A 619C
16 16 16
16 8 20
406 203 508
GN GN GN 619B Splice
619D 614A C729A C730A
16 16 16 16
23 30 27 27
584 762 686 686
GN PU BU BR 614B C729B C730B R16-7 (Unused) P14-4 (Unused) P14-3 (Unused)
0283-6
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued WIRING HARNESS FABRICATION - Continued Table 3. Engine Wiring Harness - Continued. Length in Termination Circuit Ident GA Inches 16 106 mm 2692 Color GN Circuit Ident 751B Termination P20-4 2-Speed Valve Brake Valve Solenoid P14-8 Water Pump P12-6 Water Pump Vibratory Pump Connector A-1 Vibratory Pump Connector B-1 P22-1 Vibratory Continuous Valve P23-1 Vibratory Continuous Valve P14 Drum Offset Valve-2 P14 Drum Offset Valve-1 Throttle P38-A Throttle P38-B Throttle P38-C
R5-34
751A
R5-3
777A
16
108
2743
PU
777B
R5-20 R5-19 R5-2
C922A C923A C924A
16 16 16
27 27 128
686 686 3251
BR OR YL
C922B C923B C924B
R5-1
C925A
16
125
3175
GN
C925B
R5-4
C926A
16
136
3454
BU
C926B
R5-5
C927A
16
134
3403
PU
C927B
R5-32
C928A
16
27
686
GY
C928B
R5-31
C929A
16
27
686
WH
C929B
R5-37 R5-38 R5-16
A919A A920A A983A
16 16 16
87 87 87
2210 2210 2210
BU BR BU
A919B A920B A983B
0283-7
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued WIRING HARNESS FABRICATION - Continued Table 4. Main Wiring Harness. Length in Termination Circuit Ident GA Inches 16 73 mm 1854 Color GY Circuit Ident Termination
Throttle Control R3-6 Throttle Control Relay Terminal 1 Throttle Control Timer Terminal + Hot Throttle Control Breaker
181A
181B
16
19
483
GY 181E Splice
181 C
16
16
406
GY
181D
16
19
483
GY
16 Splice 200C 16 16 Splice 200X 16 16 16 16
10 12 63 100 19 4 19
254 305 1600 2540 483 102 483
BK BK BK BK BK BK BK
200A 200D
R2-12 Ground P8-2 (Unused)
200E
Splice
200H 200I
P11-2 Main Relay Spray Timer Terminal 2 (Unused) Brake Relay 1 Terminal 5 (Unused)
Splice
200G
16 16
17 15
432 381
BK BK
200J 200K
16 16 Brake Relay 2 Terminal 5 Connector 200 M 16
7 11 6
178 279 152
BK BK BK
200Y
200L
Splice
0283-8
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued WIRING HARNESS FABRICATION - Continued Table 4. Main Wiring Harness - Continued. Length in Termination Circuit Ident GA Inches 16 9 mm 229 Color BK Circuit Ident Termination
Neutral Start Relay 1 Terminal 2 Connector Neutral Start Relay 2 Terminal 5 Connector
200O
200N
16
203
BK
Warning Light Relay 200P Terminal 2 Connector Throttle Control Relay Terminal 5 Hydraulic Charge Oil Press Relay Terminal 3 200Z
16
37
940
BK
16
12
305
BK
200AA
16
11
279
BK
Warning Light Relay 200Q Terminal 4 Connector
16
20
508
BK 200E Splice
16 16
15 10
381 254
BK BK 200S Indicator Light Relay Terminal 2 Hydraulic Temperature Relay Terminal 3 Coolant Temperature Relay Terminal 3 Engine Oil Pressure Relay Terminal 3 Park Brake Switch P5-33 Ground
16
178
BK
200T
Splice
200R 16 7 178 BK 200U
16
229
BK
200V
16 Splice 200X 16
19 4
483 102
BK BK
200W 200F
0283-9
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued WIRING HARNESS FABRICATION - Continued Table 4. Main Wiring Harness - Continued. Length in Termination Circuit Ident GA Inches 16 126 mm 3200 Color BK Circuit Ident 220B Termination Engine Oil Pressure Relay Terminal 5 Coolant Temperature Relay Terminal 5 Hydraulic Temperature Relay Terminal 5 Hydraulic Charge Oil Pressure Relay Terminal 5 Neutral Start Relay 1 Terminal 1 Neutral Start Relay 1 Terminal 4
Engine Oil Pressure 220A Switch P5-9 Engine Coolant Temperature Switch P5-24 Hydraulic Temperature Switch P5-23 221A
16
125
3175
BK
221B
226A
16
122
3098
BK
226B
Hydraulic Charge 276A Oil Pressure Switch P5-15 Starter Relay P5-6 306A
16
125
3175
BK
276B
16
124
3150
GN
306B
Engine Start Switch 307A P1-1 Alternator Light P1-2 Resistor Fuel Solenoid Main Relay P11-1 Alternator Light P1-3 Backup Alarm P5-13 Warning Horn P5-17 Fuel Shut-off Solenoid P5-10 Resistor Fuel Solenoid 308A
16
85
2159
OR
307B
16
59
1499
YL
308C
16
42
1067
YL
308B
Splice
308D 309A
16 16
23 87
584 2210
YL GY 309B 5-7 Alternator
321A
16
138
3505
BR
321B
Backup Alarm Pressure Switch Horn Switch
322A
16
139
3530
GY
322B
326A
16
66
1676
PU 326B Splice
326C
16
79
2007
PU
0283-10
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued WIRING HARNESS FABRICATION - Continued Table 4. Main Wiring Harness - Continued. Length in Termination Circuit Ident GA Inches 16 24 mm 610 Color PU Circuit Ident Termination
Engine Start Switch 326D R2-1 Control Lever P10-8 330C Neutral Start Relay 2 Terminal 2 Connector Neutral Start Relay 1 Terminal 5 Connector Starting Aid Switch P1-4 Starting Aid P5-11 330D
16 16
33 19
838 483
YL YL 330R Splice
330E
16
21
533
YL
376A
16
81
2057
GN
376B
Starting Aid Resistor Starting Aid Resistor
377A
16
120
3048
OR
377R
Fuse Holder-VIB R2-8
103A
16
87
4750
YL
Control Lever P10-6 103C Drum Select Switch 103D Terminal 5 Engine Start Switch 105A R2-3
16 16
10 17
254 432
YL YL
103B
Splice
16
21
533
BR
105B
P8-1 (Unused)
6 Splice 109C
32
813
OR
109A
R44 Engine Start Switch R9 Main Relay
6 6
66 58 103
1676 1473 2616
OR OR GN
109D 109E
Fuse Holder Water Spray R2-9
110A
16
110B Water Spray Switch 110C Terminal 5 16 6 152 GN
Water Spray Switch Terminal 2
0283-11
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued WIRING HARNESS FABRICATION - Continued Table 4. Main Wiring Harness - Continued. Length in Termination Circuit Ident GA Inches 6 6 Lights Circuit Breaker 112C 16 90 6 3 mm 2286 152 76 Color PU 112B PU PU 112D Throttle Control Breaker Light Circuit Breaker Main Relay Circuit Ident Termination
Fuses P4
112A
Lights Switch
114A
12
64
1625
GN
114B
Fuse Holder 121A Backup Alarm R4-2 Backup Alarm Pressure Switch Horn Switch Power Instruments R2-11 Hour Meter Press Switch P5-22 Hydraulic Charge Oil Press Relay Terminal 2 121C
16
89
2261
YL
16
10
254
YL
121B
Splice
121E 123A
16 16
13 29
330 737
YL WH
123C
16
58
1473
WH 123B Splice
123I
16
60
1524
WH
16 16
52 10
1321 254
WH WH 123E Indicator Light Relay Terminal 1 Hydraulic Temperature Relay Terminal 2 Coolant Temperature Relay Terminal 2 Engine Oil Pressure Relay Terminal 2
16 Splice 123D
178
WH
123F
178
WH
123G
16
229
WH
123H
0283-12
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued WIRING HARNESS FABRICATION - Continued Table 4. Main Wiring Harness - Continued. Length in Termination Circuit Ident GA Inches 16 29 mm 736 Color PK Circuit Ident Termination
Fuse Holder Brake R2-6 Neutral Start Relay 2 Terminal 1
155A
155C
16
56
1422
PK
155B
Splice
16 16 16 Splice 155D 16
61 12 12 11
1549 305 305 279
PK PK PK PK 155E 155F 155G P10-7 Control Lever 2-Speed Switch Park Brake Switch Terminal 1 Park Brake Switch Terminal 3 (Unused)
16
10
254
PK
155H
(Unused) R2-10 (Unused) R2-7
173A 175A 175C
16 16 16 16 16 16 16
96 107 4 21 123 126 26
2438 2718 107 533 3124 3200 660
YL PK
173B
175B PK YL BU BR GR 176B A919B A920B B920B
(Unused)
(Unused) R2-5 (Unused) P5-37 (Unused) P5-38 Low/High Amp P10-11 Low/High Amp P10-12 Water Pump Front P5-20
176A A919A A920A B920A
P8-5 (Unused) (Unused) (Unused) Low/High Amp Switch Terminal 3 Low/High Amp Switch Terminal 1
B921A
16
26
660
WH
B921B
C922A
16
104
2641
BR C922B Splice
Water Spray Switch C922C Terminal 3
16
43
1092
BR
0283-13
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued WIRING HARNESS FABRICATION - Continued Table 4. Main Wiring Harness - Continued. Length in Termination Circuit Ident GA Inches 16 14 mm 357 Color BR Circuit Ident Termination
Front Interrupt Relay Terminal 4 Connector Water Spray Diode AS Connector Water Pump Rear P5-19
C922D
C922E
16
13
330
BR
C923A
16
104
2642
OR
Water Spray Switch C923C Terminal 6 RR Interrupt Relay C923D Terminal Connector Vibratory Control Valve P5-2 C924A
16
42
1067
OR
C923B
Splice
16
13
330
OR
16
124
3150
YL
Control Lever P10-5 C924C Auto/Man Switch Terminal 3 Vibratory Control Valve P5-1 Vibratory Select Valve P5-4 Vibratory Select Valve P5-5 Drum Offset Valve P5-32 Drum Offset Valve P5-31 C924D
16 16
10 15
254 381
YL YL
C924B
Splice
C925A
16
130
3302
GN
C925B
P10-2 Control Lever
C926A
16
141
3581
BU
C926B
Drum Select Switch Terminal 4 Drum Select Switch Terminal 6 Drum Offset Switch Terminal 3 Drum Offset Switch Terminal 1 Splice
C927A
16
141
3581
PU
C927B
C928A
16
144
3657
GY
C928B
C929A
16
144
3657
57WH
C929B
Indicator Light P1-7 C930A
16
72
1829
BR
C930B
0283-14
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued WIRING HARNESS FABRICATION - Continued Table 4. Main Wiring Harness - Continued. Length in Termination Circuit Ident GA Inches 16 11 mm 279 Color BR Circuit Ident Termination
Indicator Light Relay Terminal 3 Connector
C930C
Warning Light Relay C930D Terminal 5 Connector Warning Light R3-3 C931A
16
12
305
BR
16
88
2235
OR
C931B
Warning Light Relay Terminal 1
Indicator Light P1-8 C932A Control Lever P10-1 C932C Auto/Man Switch Terminal 2 Auto/Man P10-10 Low/High Amp Switch Terminal 2 Auto/Man Switch Terminal 3 Auto/Man Switch Terminal 1 C932D
16 16 16
87 12 13
2210 305 330
YL YL YL C932B Splice
C933A C933B
16 16
20 7
508 178
GR GR C933D Splice
C933C
16
127
GR
C934A
16
24
610
BU
C934B
P10-4 Control Lever
Water Spray Switch C935A Terminal 1 Water Spray Diode Connector Front Interrupt Relay Terminal 5 Connector Front Interrupt Relay Terminal 1 Connector C935C
16
50
1270
PU
16
203
PU
C935D
16
152
PU
C935B
Splice
C935E
16
152
PU
0283-15
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued WIRING HARNESS FABRICATION - Continued Table 4. Main Wiring Harness - Continued. Length in Termination Circuit Ident GA Inches 16 45 mm 1143 Color GY Circuit Ident Termination
Water Spray Switch C936A Terminal 4 Spray Timer Terminal 3 RR Interrupt Relay Terminal 5 Connector RR Interrupt Relay Terminal 1 Connector Spray Timer Terminal 1 RR Interrupt Relay Terminal 2 Connector Front Interrupt Relay Terminal 2 Connector Warning Diode As, Terminal 1 Connector Warning Horn C936C
16
27
686
GY
C936D
16
229
GY
C936B
Splice
C936E
16
229
GY
C937A
16
23
584
WH
C937C
16
203
WH C937B Splice
C937D
16
229
WH
C938A
16
14
356
BR
C938B C938C 16 16 16 Splice C938D 16 4 102 BR C938F 26 68 4 660 1727 102 BR BR BR C938E
Splice
Indicator Light Relay Terminal 5 Indicator Light Relay Terminal 4 (Unused) (Unused)
(Unused) (Unused) R3-7
A953A A982A
16 16
29 88
737 2235
PK BR
A953B A982B
0283-16
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued WIRING HARNESS FABRICATION - Continued Table 4. Main Wiring Harness - Continued. Length in Termination Circuit Ident GA Inches 16 16 16 16 123 12 11 80 mm 3124 305 279 2032 Color BU GN GN 400B Hour Meter Pressure Switch P5-25 400D GN Splice Circuit Ident A983B Termination (Unused)
(Unused) P5-16 Hour Meter R3-8
A983A 400A
Warning Diode P6-8 400C
Warning Light R3-5 405A Warning Diode P7-4 405C Engine Oil Pressure 405D Relay Terminal 1 Connector Warning Light R3-1 406A Warning Diode P7-1 406C Coolant Temp Relay Terminal 1 Connector Park Brake Switch Terminal 4 406D
16 16 16
12 11 80
305 279 2032
GY GY 405B GY Splice
16 16 16
12 11 78
305 279 1981
PU PU 406B PU Splice
419A
16
127
YL 419B Park Brake Switch Terminal +
16 16 Splice 419C
47 9
1194 229
YL YL 419D Brake Relay 2 Terminal 4 Brake Relay 2 Terminal 2 Brake Relay Terminal 2
16
229
YL
419E
16
203
YL
419F
Warning Light R3-4 428A Warning Diode P6-4 428C
16 16
15 14
381 356
OR 428B OR Splice
0283-17
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued WIRING HARNESS FABRICATION - Continued Table 4. Main Wiring Harness - Continued. Length in Termination Circuit Ident GA Inches 16 72 mm 1829 Color OR Circuit Ident Termination
Hydraulic Temperature Relay Terminal 1 Connector
428D
Indicator Light P1-6 B438A Water Spray Diode Connector Water Spray Diode Front Vibratory Sensor P5-14 Vibratory Tach P1-11 (Unused) P8-6 Rear Vibratory Sensor P5-18 B438C
16 16
73 5
1854 127
OR OR B438B Splice
B438D B439A
16 16
5 144
127 3658
OR RD B439B Drum Select Switch Terminal 1
B440A
16
51
RD
B440C B440E
16 16
17 86
432 2184
RD B440B RD Splice
16 Drum Select Switch Terminal 2 E440F 16
103 4
2616 102
RD GN B440G Drum Select Switch Terminal 3 P5-8 Fuel Sensor
Fuel Gauge P1-10 (Unused) P1-12 (Unused) P8-3 (Unused) P5-12
447A 449A 449C 449D
16 16 16 16 16
87 8 12 86 4
2210 203 305 2184 102
PK RD RD RD OR
447B
449B
Splice
Hydraulic Charge 465A Oil Pressure Switch R3-2 Warning Diode P41-4 465C
465D 16 13 330 OR
Splice
0283-18
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued WIRING HARNESS FABRICATION - Continued Table 4. Main Wiring Harness - Continued. Length in Termination Circuit Ident GA Inches 16 86 mm 2184 Color OR Circuit Ident Termination
Hydraulic Charge Oil Pressure Relay Terminal 1 (Unused) Warning Alarm
465B
537A 568A
16 16 16 16 16 16
70 24 5 5 5 6
1778 610 127 127 127 152
GN GN GN GN GN GN
537B
(Unused)
Warning Diode P6-5 568C Warning Diode P7-5 568D Warning Diode Warning Diode P41-5 (Unused) P5-40 (Unused) P5-29 (Unused) P5-30 Lights P5-21 Lights P5-26 Light Switch Terminal "T-D" (Unused) P1-5 Lights P5-27 568E 568F
568B
Splice
604A 605A 606A 608A 614A 614C
16 16 16 16 16 16
140 138 140 22 66 80
3556 3505 3556 559 1676 2032
OR YL GY GN PU PU
604B 605B 606B 608B
(Unused) (Unused) (Unused) Light Switch
614B
Splice
614D 619A
16 16
22 140
559 3556
PU GN 619B Light Switch Terminal "H" Flasher Brake Relay 2, Terminal 1
Indicator Light P1-9 635A Neutral Start Relay 2, Terminal 3 Connector (Unused) P5-36 C720A
16 16
94 10
2380 254
BR BU
635B C720B
C729A
16
145
3683
BU
C729B
(Unused)
0283-19
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued WIRING HARNESS FABRICATION - Continued Table 4. Main Wiring Harness - Continued. Length in Termination Circuit Ident GA Inches 16 16 16 145 138 54 mm 3683 3505 1372 Color BR GN BR Circuit Ident C730B 751B B765B Termination (Unused) 2-Speed Switch Brake Relay 1, Terminal 1 Brake Relay 1, Terminal 3
(Unused) P5-35 2-Speed P5-34 Park Brake Switch Terminal 2 Brake Valve P5-3
C730A 751A B765A
777A
16
119
3023
PU
777B
Table 5.
Front Wiring Harness. Length in
Termination
Circuit Ident
GA Inches 12 7 7 117 12 mm 178 178 2972 305 Color BK BK BK BK
Circuit Ident 200A 200J
Termination Ground R28-5 Ground
Splice
200B
16 12
Vibratory Sensor P31-1
200D
16
200C
Splice
12 16 Splice 200E 16 16 16 Horn Switch R14-5 Vibratory Gauge R14-7 Spray Relay R14-8 322A B439A 16 16
81 24 15 51 51 227 135
2057 610 381 1295 1295 5766 3429
BK BK BK BK BK GY RD 200F 200G 200H 200I 322B B439B Warning Horn P15-2 Water Pump Light LH Front Light RH Front Warning Horn P31-2 Vibratory Sensor P15-1 Water Pump
C922A
16
218
5537
BR
C922B
0283-20
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued WIRING HARNESS FABRICATION - Continued Table 5. Front Wiring Harness - Continued. Length in Termination Circuit Ident GA Inches 16 16 16 16 16 16 207 49 54 7 7 7 mm 5258 1245 1372 178 178 178 Color GN GN GN BU BR GY C729B C730B C928B R28-4 (Unused) R28-3 (Unused) R28-2 Valve Drum Offset R28-1 Valve Drum Offset 619B Splice Circuit Ident Termination
Light Switch R14-6 Light LH Front Light RH Front (Unused) R14-4 (Unused) R14-3 (Unused) R14-2
619A 619C 619D C729A C730A C928A
(Unused) R14-1
C929A
16
178
WH
C929B
Table 6.
Rear Wiring Harness. Length in
Termination
Circuit Ident
GA Inches 16 12 269 7 93 29 mm 6832 178 2362 737 Color WH BK BK BK
Circuit Ident 123B 200A
Termination P30-A (Unused) Ground
Fuse R12-1
123A
Splice
200B 12
Vibratory Sensor P29-1
200D
16
200C
Splice
12 16 Splice 200F 16 16 16
89 24 15 51 17
2261 610 381 1295 432
BK BK BK BK BK 200G 200H 200J 200K Warning Horn P13-2 Water Pump Work Light L-Rear Splice
0283-21
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued WIRING HARNESS FABRICATION - Continued Table 6. Rear Wiring Harness - Continued. Length in Termination Circuit Ident GA Inches 16 16 69 38 mm 1753 965 Color BK BK Circuit Ident Termination
(Unused) P-30-C Work Light RightRear Pressure Switch P12-4 Vibratory Gauge R12-3 Vibratory Relay R12-2 Spray Relay R12-6 Light Switch R12-5 Work Light, RightRear Work Light, LeftRear
200E 200I
321A
16
212
5385
BR
321B
Warning Horn
B440A
18
122
3099
RD
B440B
P29-2 Vibratory Sensor P30-B Speed Sensor P13-1 Water Pump
449A
18
269
6833
RD
449B
C923A 608A 608C
16 16 16
203 191 51
5165 4851 1295
OR GN GN
C923B
608B 608D 16 54 1372 GN
Splice
Table 7.
Harness Assembly. Length in
Termination
Circuit Ident
GA Inches 16 10 mm 254 Color YL
Circuit Ident 103B
Termination R40-6 Drum Select
VIB-On/Off Switch P40-6
103A
Neutral Start Switch 155A P40-7 Neutral Start Switch 330A P40-8 Amplitude Switch R40-11 B920A
16
10
254
PK
155B
R40-7 Brake Switch
16
10
254
YL
330B
R40-8 Neutral Start Relay R40-5 Vibratory Control A
16
203
GN
B920B
0283-22
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued WIRING HARNESS FABRICATION - Continued Table 7. Harness Assembly - Continued. Length in Termination Circuit Ident GA Inches 16 8 mm 203 Color WH Circuit Ident B921B Termination R40-2 Vibratory Control B R40-1 Auto/Man Switch R40-4 Auto/Man Switch
Amplitude Switch R40-12 VIB-On/Off Switch P40-1 Auto Vibratory Switches P40-4 Auto/Man Switch R40-10 Auto Vibratory Switch P40-2 Auto Vibratory Switch P40-5
B921A
C932A
16
10
254
YL
C932B
C934A
16
10
254
BU
C934B
C933A
16
152
GN
C933C
16
102
GN
C933B
Splice
C933D
16
102
GN
Table 8.
Instrument Wiring Harness. Length in
Termination
Circuit Ident
GA Inches 16 47 mm 1194 Color YL
Circuit Ident 103B
Termination Fuse Holder-VIBE
Vibratory Select Connector (Unused) Connector Fuse Holder KEY START
103A
105A
16
36
914
BR
105C
16
178
BR
105B
Splice
Engine Start Switch 105D Terminal B Circuit Bkr R44 Light Connector Fuse Holder KEY START 109A
16
26
660
BR
34
864
OR 109C Splice
109B
16
10
254
OR
0283-23
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued WIRING HARNESS FABRICATION - Continued Table 8. Instrument Wiring Harness - Continued. Length in Termination Circuit Ident GA Inches 16 12 mm 305 Color OR Circuit Ident Termination
Fuse Holder BACKUP ALARM
109D
Water Spray Switch 110A Connector Main Relay Connector 112A
16
46
1168
GN
110B
Fuse Holder WATER SPRAY
39
991
PU
Fuse Holder START 112C AID Fuse Holder BRAKE Fuse Holder WATER SPRAY Fuse Holder VIBE Fuse Holder GAUGES (Unused) (Unused) (Unused) Switch-Warning Horn Connector Warning Relays Connector Vibration Tach Terminal I (Unused) Splice 112E
16
203
PU
16
10
254
PU
112F
16
10
254
PU 112B Splice
112G 112H
16 16
12 12
305 305
PU PU
112I 112J 112K 121A
16 16 16 16
13 13 15 44
330 330 381 1118
PU PU PU YL 121B Fuse Holder BACKUP ALARM
123A
16
33
838
WH
123C
16
10
254
WH 123B Splice
123D 123E
16 16
12 3
305 76
WH WH
0283-24
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued WIRING HARNESS FABRICATION - Continued Table 8. Instrument Wiring Harness - Continued. Length in Termination Circuit Ident GA Inches 16 12 mm 305 Color WH Circuit Ident 123F Termination Fuse Holder GAUGES
16 Warning Light Terminal 4 Connector Fuel GaugeTerminal 1 Brake Switch Connector (Unused) Connector (Unused) Connector (Unused) Connector Ground Connector Indicator Light Terminal 4 Connector123H 18
10 8
254 203
WH WH 123G Splice
123I
16
15
381
WH
155A
16
45
1143
PK
155B
Fuse Holder BRAKE (Unused)
173A
16
48
1219
YL
173B
175A
16
50
1270
PK
175B
(Unused)
176A
16
49
1245
YL
176B
(Unused)
200A 200C
16 18
17 24
432 610
BK BK 200B Splice
16 16 Splice 200 D 16 16 Hour Meter Fuel GaugeTerminal G 200H 200I 16 16
7 8
178 203
BK BK 200E Vibratory TachTerminal G (Unused)
9 21 7 15
229 533 178 381
BK BK BK BK
200F
200G
Splice
0283-25
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued WIRING HARNESS FABRICATION - Continued Table 8. Instrument Wiring Harness - Continued. Length in Termination Circuit Ident GA Inches 16 64 mm 1626 Color OR Circuit Ident 307B Termination Engine Start Switch Terminal S
Neutral Start Relay Connector Main Relay Connector Alternator Light Engine Start Switch-Terminal R Alternator Connector Fuel Shut-off Solenoid P2-1 Start Aid Resistor Connector Hour Meter Pressure Switch Connector Diode Connector
307A
308A
16
48
1219
YL
308C 308D
16 16
9 16
229 406
YL YL
308B
Splice
309A
16
56
1422
GY
309B
Alternator Light
326A
16
62
1574
PU
326B
Engine Start Switch Terminal C Switch Start Aid Terminal 1 Hour Meter
376A
16
57
1448
GN
376B
400
16
50
1270
GN
400B
405A
18
51
1295
GY
405B
Warning Light ConnectorTerminal 1 Warning Light ConnectorTerminal 6 Warning Light ConnectorTerminal 2 Indicator Light ConnectorTerminal 5 Vibratory Tach Terminal S
Diode Connector
405A
18
51
1295
GY
406B
Hydraulic Temperature Relay Connector Diode Connector
428A
18
51
1295
OR
428B
B438A
18
43
1092
OR
B438B
Drum Select Switch B110A Connector
16
32
813
GN
B440B
0283-26
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued WIRING HARNESS FABRICATION - Continued Table 8. Instrument Wiring Harness - Continued. Length in Termination Circuit Ident GA Inches 16 63 mm 1600 Color PK Circuit Ident 447B Termination Fuel GaugeTerminal S Warning Light ConnectorTerminal 5 (Unused)
Fuel Sending Unit Connector Connector
447A
465A
18
51
1295
OR
465B
Rear Speed Sensor 449A Connector Flasher Terminal 4 Connector 635A
16
32
813
BU
449B
18
43
1092
BR
635B
Indicator Light ConnectorTerminal 1
Light Switch Connector (Unused) Vibratory Tach Fuel Gauge Indicator Light Terminal 6 Connector Indicator Light Connector
614A
16
22
559
PU
614C 614D 614E 614F
16 16 16 18
7 11 34 21
178 279 864 533
PU PU PU GN 614B Splice
C930A
18
43
1092
BR
C930B
Indicator Light Connector Terminal 3 Warning Light Connector Terminal 3 Indicator Light Connector Terminal 2 Switch-Start Aid Terminal 2
Relay Warning Light C931A Connector
18
51
1295
OR
C931B
Relay Diode Connector
C932A
18
43
1092
YL
C932B
Fuse Holder START 148A AID
16
23
584
WH
148B
0283-27
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued WIRING HARNESS FABRICATION - Continued Table 8. Instrument Wiring Harness - Continued. Length in Termination Circuit Ident GA Inches 16 63 mm 1600 Color GY Circuit Ident 181B Termination Throttle Control Switch Throttle Control Switch
P3-6
181A
P3-7
A982A
16
63
1600
BR
A982B
SEAT TRIM FABRICATION The seat trim is fabricated by cutting a 93 11/16 in. (238 cm) length of bulk trim stock, part number 9X-2092 (11083) with a fine tooth hacksaw blade. Refer to (WP 0242). WATER SPRAY LINE FABRICATION The water spray lines are fabricated by cutting a length (listed in Table 9) from tubing stock, part number 5P0753 (11083) with a fine tooth hacksaw blade. Refer to (WP 0273). Table 9. From Water Spray Tank Water Spray Strainer Water Spray Pump Tee Water Spray Bar Tee (Front) Tee (Rear) Water Spray Lines. To Water Spray Strainer Water Spray Pump Tee Water Spray Bar Check Valve (Tank) Tie Line Valve Tie Line Valve Cut Length Inches (mm) 8 (200) 8 (200) 5 (125) 67 (1700) 14 (350) 221 (5620) 147 (3730)
WIRING HARNESS TUBING FABRICATION The wiring harness tubing is fabricated by cutting a length from tubing stock (listed in Table 10 and Table 11) with a fine tooth hacksaw blade.
0283-28
TM 5-3895-379-23-2
0283
ILLUSTRATED LIST OF MANUFACTURED ITEMS - Continued WIRING HARNESS TUBING FABRICATION - Continued Table 10. Location By Speed Sensor Connector By Vibratory Sensor Connector By Main Harness Connector 5P3619 5P5112 5P5112 Rear Harness Tubing. Part Number Cut Length Inches (mm) 13 (320) 11 (270) 22-1/2 (572)
Table 11. Location By Vibratory Sensor Connector By Main Harness Connector EDGING (CHANNEL) FABRICATION 5P5112 5P5112
Front Harness Tubing. Part Number Cut Length Inches (mm) 13 (330) 67 (1702)
The edging is fabricated by cutting a length from channel stock (listed in Table 12) with a fine tooth hacksaw blade. Table 12. Location On ROPS Gusset Water Line Protector on Front and Rear Bumper Assemblies 091-8487 091-8487 Edging Channel. Cut Length Inches (mm) 12 3/16 (310) 6 1/2 (165)
Part Number
END OF WORK PACKAGE
0283-29/30 blank
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0284
FIELD MAINTENANCE GENERAL TORQUE LIMITS
HOW TO USE THE TORQUE TABLE This work package provides general torque limits for the different fasteners used on the Roller, Motorized, Vibrating Tandem Steel Drums: Caterpillar Models CB534B and CB534C. The general torque limits shall be used when specific torque limits are not indicated in the maintenance procedure. Some component installations and fasteners may have special torque considerations as follows: These general torque limits cannot be applied to screws that retain rubber components. The rubber components will be damaged before the torque limit is reached. Tighten the screw until it touches the metal bracket, then tighten it one more turn. Do not use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically. Shear bolts are designed to fail under predetermined loads. Replace shear bolts only with fasteners of the identical property class. Fasteners should be replaced with the same or higher property class. If higher property class fasteners are used, these should only be tightened to the strength of the original fastener. Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening. Tighten plastic insert or crimped steel-type locknuts to approximately 50 percent of the dry torque shown in the table, applied to the nut, not to the bolt head. Tighten toothed or serrated-type locknuts to the full torque value. Tighten cap screws having locknuts to approximately 50 percent of amount shown in table. Use only metric tools on metric hardware. Other tools may not fit properly. Using a thread pitch gage, determine fastener size and thread pitch and find torque values in the tables as follows: 1. Measure the diameter of the screw being installed with the bolt and thread gage.
M1317SWR
Figure 1.
Bolt and Thread Gage.
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03/15/2011 Rel(1.8) root(torquewp) wpno(M00222)
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0284
HOW TO USE THE TORQUE TABLE - Continued 2. Measure thread pitch with thread pitch gage.
M1318SWR
Figure 2.
Thread Pitch Gage.
3. Under the heading, SIZE, look down the left-hand column until the diameter of the screw being installed is found (there will usually be two lines beginning with the same size). 4. In the second column under SIZE, find the number of threads per inch that matches the number of threads per inch counted in Step (2) (not required for metric screws). 5. To find the grade of screw, match the markings on the head with the correct picture of CAPSCREW HEAD MARKINGS on the torque table. 6. Look down the column under the picture found in Step (5) until the torque limit (lb-ft or Nm) for the diameter and threads per inch of the screw is found. 7. Use of adapters, crows foot, or other tools extending from the center of the torque wrench drive require that a torque correction formula be used. Corrected torques are determined by the use of the following formula:
0284-2
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HOW TO USE THE TORQUE TABLE - Continued
M1316SWR
Figure 3.
Torque Correction Formula.
0284-3
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0284
GENERAL TORQUE VALUES Wet Torque Values 1. Table 1 lists the torque limits for wet flange nuts. Table 1. Spiralock Flange Nut Markings Grade 8 in. 1/4 5/16 3/8 1/2 Figure 4. Wet Flange Nut. 5/8 3/4 2. Wet Flange Nut Torque Limits. Threads mm 6.35 7.94 9.53 12.70 15.88 19.05 Per Inch 20 18 16 13 11 10 lb-ft 15 25 45 110 210 375 Torque Nm 20 34 61 149 285 508
Diameter
Table 2 lists the torque limits for wet socket head screws. Table 2. Wet Socket Head Screw Torque Limits. Socket Head Socket Head or 12-Point or 12-Point Torque lb-ft 10-24
SOCKET HEAD/12 PT.
Capscrews Lubricated
Size
Socket Flat Head Torque lb-ft 2.5 6 12 22
Socket Flat Head Torque Nm 3.4 8.1 16.3 29.8
Torque Nm 6.8 16.3 33.9 59.7
5 12 25 44
1/4-20 5/16-18 3/8-16
Figure 5. Socket Head Capscrew.
0284-4
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GENERAL TORQUE VALUES - Continued Wet Torque Values - Continued Table 2. Wet Socket Head Screw Torque Limits - Continued. Socket Head Socket Head or 12-Point or 12-Point Torque lb-ft 1/2-13 70 106 212 375 781 Torque Nm 94.9 143.7 287.4 508.4 1058.9 Socket Flat Head Torque lb-ft 36 53 106 187 Socket Flat Head Torque Nm 48.8 71.8 143.7 253.5
Capscrews Lubricated
Size
SOCKET FLAT HEAD
9/16-12 5/8-11 3/4-10
Figure 6. Socket Head Capscrew.
1-8
Metric Bolt and Cap Screw Torque Values In Figure 7 the top row is property class and head markings, the bottom row is property class and nut markings.
M1322SWR
Figure 7.
Metric Screw Head and Nut Markings. Metric Screw Torque Values. Class 10.9 Class 12.9
Table 3. Class 4.8 Thread Size M6 M8
Class 8.8 or 9.8
Lubricate Lubricate Lubricate Lubricate Dry b Dry b Dry b Dry b da da da da lb-ft (Nm) lb-ft (Nm) lb-ft (Nm) lb-ft (Nm) lb-ft (Nm) lb-ft (Nm) lb-ft (Nm) lb-ft (Nm) 3.5 (4.7) 8.5 (11.5) 4.4 (6) 10.7 (14.5) 6.6 (9) 16 (22) 8.5 (11.5) 20.5 (28) 9.5 (13) 23.5 (32) 12.2 (16.5) 11.5 (15.5) 14.5 (19.5) 29.5 (40) 27.5 (37) 35 (47)
0284-5
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0284
GENERAL TORQUE VALUES - Continued Metric Bolt and Cap Screw Torque Values - Continued Table 3. Class 4.8 Thread Size M10 M12 M14 M16 M18 M20 M22 M24 Metric Screw Torque Values - Continued. Class 8.8 or 9.8 Class 10.9 Class 12.9
Lubricate Lubricate Lubricate Lubricate Dry b Dry b Dry b Dry b da da da da lb-ft (Nm) lb-ft (Nm) lb-ft (Nm) lb-ft (Nm) lb-ft (Nm) lb-ft (Nm) lb-ft (Nm) lb-ft (Nm) 17 (23) 29.5 (40) 46 (63) 74 (100) 100 (135) 140 (190) 195 (265) 245 (330) 21 (29) 37 (50) 59 (80) 92 (125) 125 (170) 180 (245) 245 (330) 315 (425) 32 (43) 55 (75) 88 (120) 140 (190) 195 (265) 275 (375) 375 (510) 480 (650) 40 (55) 70 (95) 110 (150) 175 (240) 245 (330) 350 (475) 480 (650) 600 (820) 46 (63) 80 (110) 130 (175) 200 (275) 275 (375) 390 (530) 535 (725) 680 (920) 59 (80) 105 (140) 165 (220) 255 (350) 350 (475) 500 (675) 680 (920) 55 (75) 95 (130) 150 (205) 235 (320) 325 (440) 460 (625) 625 (850) 70 (95) 120 (165) 190 (260) 300 (400) 410 (560) 580 (790) 800 (1080) 1000 (1350) 1475 (2000) 2000 (2700) 2730 (3700) 3500 (4750)
850 (1150) 800 (1080)
M27
360 (490)
460 (625)
700 (950)
885 (1200)
1000 (1350) 1350 (1850) 1850 (2500) 2350 (3200)
1250 (1700) 1700 (2300) 2325 (3150) 3000 (4050)
1160 (1580) 1580 (2140) 2150 (2900) 2770 (3750)
M30
490 (660)
625 (850)
950 (1290)
1200 (1630) 1625 (2200) 2100 (2850)
M33
665 (900)
850 (1150)
1300 (1750) 1650 (2250)
M36
850 (1150)
1075 (1450)
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. "Dry" means plain or zinc plated without any lubrication.
Tolerance is 10% unless otherwise specified.
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GENERAL TORQUE VALUES - Continued
Additional Metric Screw Torque Values Figure 8 shows additional markings on metric screws.
M1323SWR
Figure 8. Table 4. T-Bolt Nominal Dia 8 10 12 14 16 18 20 22 24 27 30 33 36 lb-ft 21 46 80 130 195 289 398 542 687 1012 1410 1890 2314 Nm 29 63 108 176 265 392 539 735 931 1372 1911 2548 3136
Additional Metric Screws.
Metric Screw Torque Values. H-Bolt lb-ft 15 33 65 101 152 217 289 398 506 759 1049 1410 1772 Nm 20 45 88 137 206 294 392 539 686 1029 1421 1911 2401 lb-ft 7 15 25 40 58 87 125 159 202 289 398 542 687 M-Bolt Nm 10 20 34 54 78 118 167 216 274 392 539 735 931
Torque tolerance is 10%.
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Unified Inch Bolt and Cap Screw Torque Values The top row of Figure 9 is SAE grade and head markings, the bottom is SAE grade and nut markings.
M1324SWR
Figure 9.
Unified Inch Screw Markings.
Table 5. Unified Inch Screw Torque Values. Grade 1 (No Mark) Lubricate db lb-ft (Nm) 2.8 (3.8) 5.7 (7.7) Dry c lb-ft (Nm) 3.5 (4.7) 7.2 (9.8) Grade 2 a (No Mark) Lubricate db lb-ft (Nm) 4.4 (6) 9 (12) Dry c lb-ft (Nm) 5.5 (7.5) 11.5 (15.5) 20 (27.5) 32.5 (44) 49 (67) 70 (95) 100 (135) 175 (240) 175 (240) 265 (360) Grade 5, 5.1, or 5.2 Lubricate db lb-ft (Nm) 7 (9.5) 14.5 (19.5) 26 (35) 41 (56) 63 (85) 92 (125) 125 (170) 220 (300) 360 (490) 540 (730) Dry c lb-ft (Nm) 9 (12) 18.5 (25) Grade 8 or 8.2 Lubricate db lb-ft (Nm) 10 (13.5) 20.5 (28) Dry c lb-ft (Nm) 12.5 (17) 26 (35)
Thread Size
1/4 5/16
3/8 7/16 1/2 9/16 5/8 3/4 7/8 1
10 (13.5) 16 (22) 25 (34) 35.5 (48) 49 (67) 88 (120) 140 (190) 210 (285)
13 (17.5) 20.5 (28) 31 (42) 45 (60) 63 (85) 110 (150) 175 (240) 265 (360)
16 (22) 26 (35) 39 (53) 56 (76) 77 (105) 140 (190) 140 (190) 210 (285)
32.5 (44) 52 (70) 80 (110) 115 (155) 160 (215) 280 (380) 455 (615) 680 (920)
36 (49) 59 (80) 88 (120) 130 (175) 175 (240) 315 (425) 510 (690) 760 (1030)
46 (63) 74 (100) 115 (155) 165 (220) 225 (305) 400 (540) 640 (870) 960 (1300)
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0284
GENERAL TORQUE VALUES - Continued Unified Inch Bolt and Cap Screw Torque Values - Continued Table 5. Grade 1 (No Mark) Lubricate db lb-ft (Nm) 300 (400) Dry c lb-ft (Nm) 375 (510) Unified Inch Screw Torque Values - Continued. Grade 2 a (No Mark) Lubricate db lb-ft (Nm) 300 (400) Dry c lb-ft (Nm) 375 (510) Grade 5, 5.1, or 5.2 Lubricate db lb-ft (Nm) 670 (910) Dry c lb-ft (Nm) 850 (1150) 1200 (1630) 1580 (2140) 2100 (2850) Grade 8 or 8.2 Lubricate db lb-ft (Nm) 1075 (1450) 1500 (2050) 2000 (2700) 2650 (3600) Dry c lb-ft (Nm) 1350 (1850) 1920 (2600) 2500 (3400) 3350 (4550)
Thread Size
1-1/8
1-1/4
420 (570)
535 (725)
420 (570)
535 (725)
945 (1280) 1250 (1700) 1650 (2250)
1-3/8
550 (750)
700 (950)
550 (750)
700 (950)
1-1/2
730 (990)
930 (1250)
730 (990)
930 (1250)
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long, and for all other types of bolts and screws of any length.
b
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. "Dry" means plain or zinc plated without any lubrication.
*Tolerance is 10% unless otherwise specified.
0284-9
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0284
Outside Diameter and Inside Diameter Measurement for Fittings 1. Figure 10 shows outside diameter measurement using a caliper.
M1325SWR
Figure 10. 2.
Outside Diameter Measurement.
Figure 11 shows inside diameter measurement using a caliper.
M1326SWR
Figure 11. Inside Diameter Measurement.
0284-10
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0284
GENERAL TORQUE VALUES - Continued Outside Diameter and Inside Diameter Measurement for Fittings - Continued 3. Figure 12 shows how to find the sealing surface angle. Use a protractor and measure the sealing surface parallel to the centerline of the fitting.
M1327SWR
Figure 12.
Sealing Surface Angle Measurement.
37 Degree Flare and 30 Degree Cone Seat Connectors Service Recommendations 1. 2. 3. 4. 5. 6. Inspect flare and flare seat. They must be free of dirt or obvious defects. Defects in tube flare cannot be repaired. Overtightening a defective flared fitting will not stop leaks. Align tube with fitting before attempting to start nut. Lubricate male threads with clean oil. Refer to LO 5-3805-294-13 Index angle fittings and tighten by hand. Tighten fitting or nut to torque value shown on torque table. Do not allow hoses to twist when tightening fittings.
M1328SWR
Figure 13. Table 6. Thread Size 3/8 - 24 UNF 7/16 - 20 UNF 1/2 - 20 UNF 9/16 - 18 UNF
37 Degree Flare and 30 Degree Cone Seat Connectors. Straight Fitting or Special Nut Torque Values. lb-ft 6 9 12 18 Nm 8 12 16 24
0284-11
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0284
GENERAL TORQUE VALUES - Continued 37 Degree Flare and 30 Degree Cone Seat Connectors Service Recommendations - Continued Table 6. Straight Fitting or Special Nut Torque Values - Continued. Thread Size 3/4 - 16 UNF 7/8 - 14 UNF 1-1/16 - 12 UN 1-3/16 - 12 UN 1-5/16 - 12 UN 1-5/8 - 12 UN 1-7/8 - 12 UN lb-ft 34 46 75 90 105 140 160 Nm 46 62 102 122 142 190 217
Torque tolerance is 10% unless otherwise specified. O-Ring Boss Fittings Service Recommendations 1. Inspect fitting (Figure 14, Item 1) and O-ring boss sealing surfaces and O-ring (Figure 14, Item 2). They must be free of dirt, scratches, nicks, or burrs. O-ring must be free of dirt, cuts, cracks, swelling or flatten condition.
1 2 4
5 3 3
6 2
M1329SWR
Figure 14. 2.
O-Ring Boss Straight and Adjustable Fittings.
Back the stud end (Figure 14, Item 3) hex nut (Figure 14, Item 4) off as far as possible. Push backup washer (Figure 14, Item 5) towards the nut to fully expose the turn down section of stud end. Washer must fit turned down section and not be too loose. Wrap electrical tape over threads to protect O-ring. Slide O-ring over the tape into turned down section. Remove tape. Apply appropriate lubricant to the threads of stud end, turned down section, and O-ring. Turn fitting into the boss by hand until face of nut or backup washer squeezes O-ring into the seat and contacts face of boss. Loosen an adjustable fitting (Figure 14, Item 6) no more than one turn for alignment. Tighten straight fitting or hex nut to the torque value given. Hold body of adjustable fitting using a second wrench when tightening hex nut.
3. 4. 5.
0284-12
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0284
GENERAL TORQUE VALUES - Continued O-Ring Boss Fittings Service Recommendations - Continued 6. Hold fitting head-end with a wrench and tighten locknut and back-up washer to proper torque value. Table 7. Thread Size 3/8 - 24 UNF 7/16 - 20 UNF 1/2 - 20 UNF 9/16 - 18 UNF 3/4 - 16 UNF 7/8 - 14 UNF 1-1/16 - 12 UN 1-3/16 - 12 UN 1-5/16 - 12 UN 1-5/8 - 12 UN 1-7/8 - 12 UN * Torque tolerance is 10%. Straight Fitting or Special Nut Torque Values*. lb-ft 6 9 12 18 34 46 75 90 105 140 160 Nm 8 12 16 24 46 62 102 122 142 190 217
7.
Table 8 lists the O-Ring Boss Straight and Adjustable Fitting Stud End Nut Torque Values. Table 8. O-Ring Boss Straight and Adjustable Fitting Stud End Nut Torque Values.
Metric thread in aluminum housing torque values. Tolerance is 10% unless other wise specified. Thread Size M12 x 1.5 M14 x 1.5 M16 x 1.5 M22 x 1.5 M27 x 2 Hex Nut Size (mm) 17 19 22 27 32 lb-ft (Nm) 29 (39) 29 (39) 41 (55) 55 (75) 81 (110)
0284-13
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GENERAL TORQUE VALUES - Continued O-Ring Boss Fittings Service Recommendations - Continued Table 8. O-Ring Boss Straight and Adjustable Fitting Stud End Nut Torque Values - Continued.
Metric thread in aluminum housing torque values. Tolerance is 10% unless other wise specified. Thread Size M30 x 2 M33 x 2 M38 x 2 M42 x 2 Hex Nut Size (mm) 36 41 46 50 lb-ft (Nm) 104 (141) 122 (165) 122 (165) 203 (275)
8.
Table 9 lists the O-Ring Boss Straight and Adjustable Fitting Stud End Nut Torque Values. Table 9. O-Ring Boss Straight and Adjustable Fitting Stud End Nut Torque Values.
Inch thread in aluminum housing torque values. Tolerance is 10% unless other wise specified. Thread Size (in.) 1/8 1/4 3/8 1/2 3/4 1 1-1/8 1-1/4 1-3/8 1-1/2 1-3/4 2 191 (259) 243 (330) lb-ft (Nm) 20 (28) 29 (39) 55 (75) 93 (126) 122 (165)
9.
Table 10 lists the O-Ring Boss Straight Nut Torque Values.
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GENERAL TORQUE VALUES - Continued O-Ring Boss Fittings Service Recommendations - Continued
Table 10.
O-Ring Boss Straight Nut Torque Values.
Inch thread in aluminum housing torque values. Tolerance is 10% unless other wise specified. Thread Size (in.) 1/8 1/4 3/8 1/2 3/4 1 1-1/4 1-1/2 2 lb-ft (Nm) 5.80 (7.8) 8.70 (11.8) 17 (23) 29 (39) 41 (55) 64 (86) 93 (126) 116 (157) 150 (204)
Flared Connections-Straight or Tapered Threads Service Recommendations 1. 2. 3. 4. 5. 6. 7. Inspect flare and flare seat. They must be free of dirt or obvious defects. Defects in the tube flare cannot be repaired. Overtightening a defective flared fitting will not stop leaks. Align the tube with the fitting before attempting to start the nut. Lubricate the male threads with clean oil. Refer to LO 5-3805-294-13. Index angle fittings and tighten by hand. Tighten fitting or nut to torque value shown on the table. Do not allow hoses to twist when tightening fittings. Figure 15 shows the Straight Thread fitting configuration.
M1330SWR
Figure 15.
Straight Thread.
0284-15
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0284
GENERAL TORQUE VALUES - Continued Flared Connections-Straight or Tapered Threads Service Recommendations - Continued 8. Figure 16 shows the Tapered Thread fitting configuration.
M1331SWR
Figure 16. Table 11.
Tapered Thread.
Straight or Tapered Threads Torque Values a. Straight Thread b Tapered Thread lb-ft 33 51 69 130 253 398 434 Nm 45 69 93 176 343 539 588
Thread Size 1/8 1/4 3/8 1/2 3/4 1 1-1/2 2

a
lb-ft 11 15 21 36 51 116 145 188
Nm 15 20 29 49 69 157 196 255
Torque tolerance is 10%. With seat face.
NOTE: If female thread is cast iron (control valves, brake valves motors, etc.), torque must be reduced approximately 10%.
0284-16
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GENERAL TORQUE VALUES - Continued Flat Face O-Ring Seal Fittings Service Recommendations
NOTE
Tighten fittings to 150% of listed torque value if indexing is necessary or if fitting is attached to an actuating devise. Tighten fittings to 50% of listed torque value if used in aluminum housing. 1. 2. 3. 4. Inspect the fitting sealing surfaces and O-ring. They must be free of dirt or defects. Lubricate O-rings and install into grove using clean oil to hold in place. Refer to LO 5-3805-294-13. Index angle fittings and tighten by hand pressing joint together to ensure O-ring remains in place. Tighten fitting or nut to torque value shown on the table. Do not allow hoses to twist when tightening fittings, use backup wrench on straight hose couplings.
M1332SWR
Figure 17.
Flat Face O-Ring Seal.
0284-17
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GENERAL TORQUE VALUES - Continued Flat Face O-Ring Seal Fittings Service Recommendations - Continued 5. Table 12 lists the Flat Face O-Ring Seal Fitting Torque Values. Table 12. Nominal Tube OD in. 0.250 0.375 0.500 0.625 0.750 0.875 1.000 1.250 1.500 mm 6.35 9.52 12.70 15.88 19.05 22.22 25.40 31.75 38.10 Flat Face O-Ring Seal Fitting Torque Values*. Swivel Nut lb-ft 12 18 37 51 75 75 105 140 160 Nm 16 24 50 69 102 102 142 190 217 Bulkhead Nut lb-ft 9 18 34 46 75 75 105 140 160 Nm 12 24 46 62 102 102 142 190 217
Thread Size in. 9/16-18 11/16-16 13/16-16 1-14 1-3/16-12 1-3/16-12 1-7/16-12 1-11/16-12 2-12
* Torque tolerance is +15 -20% unless otherwise specified.
6.
Table 13 lists the Stud End O-Ring Seal Torque Values for Straight and Adjustable Fittings. Table 13. Thread Size inch 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 Stud End O-Ring Seal Torque Values for Straight and Adjustable Fittings*. Straight Hex Size inch 5/8 5/8 3/4 3/4 7/8 1-1/16 Locknut Hex Size inch 9/16 5/8 11/16 3/4 15/16 1-1/16 Straight Fitting or Locknut Torque lb-ft 9 15 19 25 55 76 Nm 12 21 26 34 73 104
0284-18
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GENERAL TORQUE VALUES - Continued Flat Face O-Ring Seal Fittings Service Recommendations - Continued Table 13. Stud End O-Ring Seal Torque Values for Straight and Adjustable Fittings* - Continued. Straight Hex Size inch 1-1/4 1-3/8 1-1/2 Locknut Hex Size inch 1-3/8 1-1/2 1-5/8 Straight Fitting or Locknut Torque lb-ft 130 170 210 Nm 176 230 285
Thread Size inch 1-1/16-12 1-3/16-12 1-5/16-12
* Torque tolerance is +15 -20%, unless otherwise specified. O-Ring Face Seal Fittings With SAE Inch Hex Nut and Stud End For High-Pressure Service Recommendations 1. 2. 3. 4. 5. 6. 7. 8. Inspect fitting and connector sealing surfaces and the O-rings. They must be free of dirt, scratches, nicks, and burrs. O-ring must be free of dirt, cuts, cracks, swelling or flatten condition. Back the stud end hex nut off as far as possible. Push backup washer towards the nut to fully expose the turn down section. Washer must fit turned down section and not be too loose. Lubricate O-rings using a thin film of clean oil as needed to hold O-ring in place. Refer to LO 5-3805-294-13. Install O-ring into groove making sure it is seated at the bottom. Excess oil will prevent seating of O-ring and cause it to pop out. To protect an O-ring from threads, wrap electrical tape over the threads. Slide O-ring over the tape into the turned down section. Remove the tape. Turn fitting into the boss by hand until face of nut or washer squeezes the O-ring into the seat and contacts face of boss. Loosen adjustable fittings no more than one turn for alignment. Hold connections together while tightening nut to ensure O-ring remains in place. Tighten fitting or nut to torque value shown. Use a second wrench to hold the fitting in position or to keep hose from twisting while tightening nut.
90 Degree Swivel Elbow
90 Degree Adjustable Stud Elbow
Straight Stud and Tube Nut
Bulkhead Union and Nut
M1333SWR
Figure 18.
O-Ring Face Seals.
0284-19
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0284
GENERAL TORQUE VALUES - Continued O-Ring Face Seal Fittings With SAE Inch Hex Nut and Stud End For High-Pressure Service Recommendations - Continued 9. Table 14 lists the O-Ring Face Seal Fittings with SAE Inch Hex Nut and Stud End Torque Values. Table 14. O-Ring Face Seal Fittings with SAE Inch Hex Nut and Stud End Torque Values. O-Ring Face Seal Hose or Tube Swivel Nut Thread Size in. Hex Size in. Torque lb-ft (Nm) Bulkhead Nut
Nominal Tube OD or Hose ID Metric Tube OD mm 5 Inch Tube OD or Hose ID Dash Size -3 in. (mm) 0.188 (4.78) 0.250 (6.35) 0.312 (7.92) 0.375 (9.53) 0.500 (12.70) 0.625 (15.88) 0.750 (19.05) 0.875 (22.23) 1.000 (25.40) 1.250 (31.75) 1.500 (38.10)
Hex Size in. -
Torque lb-ft (Nm) -
-4
9/16-18
11/16
18 (24)
13/16
24 (32)
-5
10
-6
11/16-16
13/16
27 (37)
31 (42)
12
-8
13/16-16
15/16
55 (75)
1-1/8
69 (93)
16
-10
1-14
1-1/8
76 (103)
1-5/16
87 (118)
20
-12
1-3/16-12
1-3/8
112 (152)
1-1/2
129 (175)
22
-14
1-3/16-12
112 (152)
129 (175)
25
-16
1-7/16-12
1-5/8
158 (214)
1-3/4
182 (247)
32
-20
1-11/16-12
1-7/8
211 (286)
242 (328)
38
-24
2-12
2-1/4
240 (326)
2-3/8
276 (374)
O-Ring face seal fittings with SAE inch hex nut and stud end for high-pressure, above 4,000 psi (27,600 kPa) (276 bar), torque values. Tolerance is +15 -20%, unless otherwise specified.
0284-20
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0284
GENERAL TORQUE VALUES - Continued O-Ring Face Seal Fittings With SAE Inch Hex Nut and Stud End For High-Pressure Service Recommendations - Continued 10. Table 15 lists the O-Ring Face Seal Fittings with SAE Inch Hex Nut and Stud End Torque Values. Table 15. O-Ring Face Seal Fittings with SAE Inch Hex Nut and Stud End Torque Values. Straight Hex Size (in.) 5/8 5/8 3/4 3/4 7/8 1-1/16 1-1/4 1-3/8 1-1/2 1-3/4 2-1/8 Adjustable Nut Hex Size (in.) 9/16 5/8 11/16 3/4 15/16 1-1/16 1-3/8 1-1/2 1-5/8 1-7/8 2-1/8 Steel or Gray Iron Torque lb-ft (Nm) 13 (18) 18 (24) 22 (30) 27 (37) 55 (75) 76 (103) 131 (177) 170 (231) 199 (270) 211 (286) 240 (326)
Thread Size (in.) 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1-1/16-12 1-3/16-12 1-5/16-12 1-5/8-12 1-7/8-12
O-Ring straight, adjustable, and external hex plug with SAE inch stud end for high-pressure, above 4,000 psi (27,600 kPa) (276 bar), torque values. Tolerance is +15 -20% unless otherwise specified. O-Ring Face Seal Fittings With Metric Hex Nut and Stud End For Standard Pressure Service Recommendations 1. 2. 3. 4. 5. Inspect fitting and connector sealing surfaces and the O-rings. They must be free of dirt, scratches, nicks, and burrs. O-ring must be free of dirt, cuts, cracks, swelling or flatten condition. Back the stud end hex nut off as far as possible. Push backup washer towards the nut to fully expose the turn down section. Washer must fit turned down section and not be too loose. Lubricate O-rings using a thin film of clean oil as needed to hold O-ring in place. Refer to LO 5-3805-294-13. Install O-ring into groove making sure it is seated at the bottom. Excess oil will prevent seating of O-ring and cause it to pop out. To protect an O-ring from threads, wrap electrical tape over the threads. Slide O-ring over the tape into the turned down section. Remove the tape.
0284-21
TM 5-3895-379-23-2
0284
GENERAL TORQUE VALUES - Continued O-Ring Face Seal Fittings With Metric Hex Nut and Stud End For Standard Pressure Service Recommendations - Continued 6. 7. 8. 9. Turn fitting into the boss by hand until face of nut or washer squeezes the O-ring into the seat and contacts face of boss. Loosen adjustable fittings no more than one turn for alignment. Hold connections together while tightening nut to ensure O-ring remains in place. Tighten fitting or nut to torque value shown. Use a second wrench to hold the fitting in position or to keep hose from twisting while tightening nut. Figure 19 shows the O-Ring Face Seal Fittings with Metric Hex Nut and Stud End for Standard Pressure.
Straight Stud
External Hex Stud End Plug
M1334SWR
Figure 19. O-Ring Face Seal Fittings with Metric Hex Nut and Stud End for Standard Pressure. 10. Table 16 lists the O-Ring Face Seal Fittings with Metric Hex Nut and Stud End Torque Values. Table 16. O-Ring Face Seal Fittings with Metric Hex Nut and Stud End Torque Values. O-Ring Face Seal Hose or Tube Swivel Nut Thread Size in. Hex Size mm Torque lb-ft (Nm) Bulkhead Nut
Nominal Tube OD or Hose ID Metric Tube OD mm 4 Inch Tube OD or Hose ID Dash Size -2 in. (mm) 0.125 (3.18) 0.188 (4.78) 0.250 (6.35) 0.312 (7.92)
Hex Size mm -
Torque lb-ft (Nm) -
-3
-4
9/16-18
17
12 (16)
22
24 (32)
-5
0284-22
TM 5-3895-379-23-2
0284
GENERAL TORQUE VALUES - Continued O-Ring Face Seal Fittings With Metric Hex Nut and Stud End For Standard Pressure Service Recommendations - Continued Table 16. O-Ring Face Seal Fittings with Metric Hex Nut and Stud End Torque Values - Continued. Nominal Tube OD or Hose ID Metric Tube OD mm 10 Inch Tube OD or Hose ID Dash Size -6 in. (mm) 0.375 (9.53) 0.500 (12.70) 0.625 (15.88) 0.750 (19.05) 0.875 (22.23) 1.000 (25.40) 1.250 (31.75) 1.500 (38.10) 2.000 (50.80) O-Ring Face Seal Hose or Tube Swivel Nut Thread Size in. 11/16-16 Hex Size mm 22 Torque lb-ft (Nm) 18 (24) Bulkhead Nut
Hex Size mm 27
Torque lb-ft (Nm) 31 (42)
12
-8
13/16-16
24
37 (50)
30
69 (93)
16
-10
1-14
30
51 (69)
36
87 (118)
20
-12
1-3/16-12
36
75 (102)
41
129 (175)
22
-14
1-3/16-12
36
75 (102)
41
129 (175)
25
-16
1-7/16-12
41
105 (142)
46
182 (247)
28 32
-20
1-11/16-12
50
140 (190)
50
242 (328)
38
-24
2-12
60
160 (217)
60
276 (374)
50
-32
O-Ring face seal and fittings with metric hex nut and stud end for standard pressure, below 4,000 psi (27,600[Undefined Entity: nbsp]kPa) (275.8 bar), torque values. Tolerance is +15 -20%, unless otherwise specified.
0284-23
TM 5-3895-379-23-2
0284
GENERAL TORQUE VALUES - Continued O-Ring Face Seal Fittings With Metric Hex Nut and Stud End For Standard Pressure Service Recommendations - Continued 11. Table 17 lists the O-Ring Straight, Adjustable, and External Hex Plug with Metric Stud End Torque Values. O-Ring Straight, Adjustable, and External Hex Plug with Metric Stud End Torque Values. Straight Hex Size b (mm) 12 14 17 19 22 24 27 32 36 41 46 50 55 65 Adjustable Nut Hex Size (mm) 12 14 17 19 22 24 27 32 36 41 46 50 55 65 Steel or Gray Iron Torque lb-ft (Nm) 6 (8) 11 (15) 18 (25) 30 (40) 33 (45) 37 (50) 51 (69) 74 (100) 96 (130) 118 (160) 130 (176) 155 (210) 192 (260) 232 (315) Aluminum or Brass Torque lb-ft (Nm) 4 (5) 7 (10) 12 (17) 20 (27) 22 (30) 25 (33) 34 (46) 49 (67) 64 (87) 79 (107) 87 (117) 103 (140) 128 (173) 155 (210)
Table 17.
Thread Size a (mm)
M8 x 1 M10 x 1 M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5 M22 x 1.5 M27 x 2 M30 x 2 M33 x 2 M38 x 2 M42 x 2 M48 x 2 M60 x 2
a
Stud end threads identified as metric by and identification groove in the hex nut next to the O-ring.
Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size. O-Ring straight, adjustable, and external hex plug and metric stud end for standard pressure, below 4,000[Undefined Entity: nbsp]psi (27,600 kPa) (275.8 bar), torque values. Tolerance is +15 -20%, unless otherwise specified.
0284-24
TM 5-3895-379-23-2
0284
O-Ring Face Seal Fittings With Metric Hex Nut and Stud End For High-Pressure Service Recommendations 1. 2. 3. 4. 5. 6. 7. 8. 9. Inspect fitting and connector sealing surfaces and the O-rings. They must be free of dirt, scratches, nicks, and burrs. O-ring must be free of dirt, cuts, cracks, swelling or flatten condition. Back the stud end hex nut off as far as possible. Push backup washer towards the nut to fully expose the turn down section. Washer must fit turned down section and not be too loose. Lubricate O-rings using a thin film of clean oil to hold O-ring in place. Refer to LO 5-3805-294-13. Install O-ring into groove making sure it is seated at the bottom. Excess oil will prevent seating of O-ring and cause it to pop out. To protect an O-ring from threads, wrap electrical tape over the threads. Slide O-ring over the tape into the turned down section. Remove the tape. Turn fitting into the boss by hand until face of nut or washer squeezes the O-ring into the seat and contacts face of boss. Loosen adjustable fittings no more than one turn for alignment. Hold connections together while tightening nut to ensure O-ring remains in place. Tighten fitting or nut to torque value shown. Use a second wrench to hold the fitting in position or to keep hose from twisting while tightening nut. Figure 20 shows the O-Ring Face Seal Fitting with Metric Hex Nut and Stud End for High-Pressure Service.
Straight Stud
External Hex Stud End Plug
M1335SWR
Figure 20.
O-Ring Face Seal Fitting with Metric Hex Nut and Stud End for High-Pressure Service.
0284-25
TM 5-3895-379-23-2
0284
GENERAL TORQUE VALUES - Continued O-Ring Face Seal Fittings With Metric Hex Nut and Stud End For High-Pressure Service Recommendations - Continued 10. Table 18 lists the O-Ring Face Seal Fittings with Metric Hex Nut and Stud End Torque Values. Table 18. O-Ring Face Seal Fittings with Metric Hex Nut and Stud End Torque Values. O-Ring Face Seal Hose or Tube Swivel Nut Thread Size in. Hex Size mm Torque lb-ft (Nm) Bulkhead Nut
Nominal Tube OD or Hose ID Metric Tube OD mm 4 Inch Tube OD or Hose ID Dash Size -2 in. (mm) 0.125 (3.18) 0.188 (4.78) 0.250 (6.35) 0.312 (7.92) 0.375 (9.53) 0.500 (12.70) 0.625 (15.88) 0.750 (19.05) 0.875 (22.23) 1.000 (25.40) -
Hex Size mm -
Torque lb-ft (Nm) -
-3
-4
9/16-18
17
18 (24)
22
24 (32)
-5
10
-6
11/16-16
22
27 (37)
27
31 (42)
12
-8
13/16-16
24
55 (75)
30
69 (93)
16
-10
1-14
30
76 (103)
36
87 (118)
20
-12
1-3/16-12
36
112 (152)
41
129 (175)
22
-14
1-3/16-12
36
112 (152)
41
129 (175)
25
-16
1-7/16-12
41
158 (214)
46
182 (247)
28
0284-26
TM 5-3895-379-23-2
0284
GENERAL TORQUE VALUES - Continued O-Ring Face Seal Fittings With Metric Hex Nut and Stud End For High-Pressure Service Recommendations - Continued Table 18. O-Ring Face Seal Fittings with Metric Hex Nut and Stud End Torque Values - Continued. Nominal Tube OD or Hose ID Metric Tube OD mm 32 Inch Tube OD or Hose ID Dash Size -20 in. (mm) 1.250 (31.75) 1.500 (38.10) O-Ring Face Seal Hose or Tube Swivel Nut Thread Size in. 1-11/16-12 Hex Size mm Torque lb-ft (Nm) 211 (286) Bulkhead Nut
Hex Size mm 50
Torque lb-ft (Nm) 242 (328)
38
-24
2-12
240 (326)
60
276 (374)
O-Ring face seal and fittings with metric hex nut and stud end for high-pressure, above 4,000[Undefined Entity: nbsp]psi (27,600 kPa) (275.8 bar), torque values. Tolerance is +15 -20%, unless otherwise specified.
11.
Table 19 shows the O-Ring Straight, Adjustable, and External Hex Plug with Metric Stud End for High-Pressure Torque Values.
Table 19. O-Ring Straight, Adjustable, and External Hex Plug with Metric Stud End for High-Pressure Torque Values. Thread Size a (mm) M8 x 1 M10 x 1 M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5 M22 x 1.5 M27 x 2 M30 x 2 M33 x 2 Straight Hex Size b (mm) 12 14 17 19 22 24 27 32 36 41 Adjustable Nut Hex Size (mm) 12 14 17 19 22 24 27 32 36 41 Steel or Gray Iron Torque lb-ft (Nm) 6 (8) 11 (15) 26 (35) 33 (45) 41 (55) 52 (70) 74 (100) 125 (170) 159 (215) 192 (260)
0284-27
TM 5-3895-379-23-2
0284
GENERAL TORQUE VALUES - Continued O-Ring Face Seal Fittings With Metric Hex Nut and Stud End For High-Pressure Service Recommendations - Continued Table 19. O-Ring Straight, Adjustable, and External Hex Plug with Metric Stud End for High-Pressure Torque Values - Continued. Thread Size a (mm) M38 x 2 M42 x 2 M48 x 2
a
Straight Hex Size b (mm) 46 50 55
Adjustable Nut Hex Size (mm) 46 50 55
Steel or Gray Iron Torque lb-ft (Nm) 236 (320) 266 (360) 310 (420)
Stud end threads are identified as metric by an identification groove in the hex nut next to the O-ring.
Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size. O-Ring straight, adjustable, and external hex plug with metric stud end for high-pressure, above 4,000 psi (27,600 kPa) (275.8 bar), torque values. Tolerance is +15 -20%, unless otherwise specified.
0284-28
TM 5-3895-379-23-2
0284
Metric Series Four Bolt Flange Fitting Service Recommendations
CAUTION
1. 2. 3. Clean sealing surfaces (Figure 21, Item 1). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion. If defects cannot be polished out, replace component. Install O-ring (and backup washer if required) into groove using clean oil to hold it in place. Refer to LO 5-3805-294-13. Split flange: Loosely assemble split flange (Figure 21, Item 2) halves. Make sure split is centrally located and perpendicular to the port. Hand tighten cap screws to hold parts in place. Do not pinch O-ring (Figure[Undefined Entity: nbsp]21,[Undefined Entity: nbsp]Item[Undefined Entity: nbsp]3). Single piece flange (Figure 21, Item 4): Place hydraulic line in center of flange and install four cap screws. Flange must be centrally located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring. After components are properly positioned and cap screws are hand tightened, tighten one cap screw, then tighten the diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap screws as specified in the table.
4
4. 5.
1 3
M1336SWR
Figure 21. Metric Series Four Bolt Flange Fitting.
0284-29
TM 5-3895-379-23-2
0284
GENERAL TORQUE VALUES - Continued Metric Series Four Bolt Flange Fitting Service Recommendations - Continued
Table 20. Thread b M6 M8 M10 M12 M14 M16 M18 M20

a
Metric Series Four Bolt Flange Fitting Torque Values a. lb-ft 9 22 42 70 116 160 246 318 Nm 12 30 57 95 157 217 334 421
Tolerance is 10%. The torques given are enough for the given size connection with the recommended working pressure. Increasing cap screw torque beyond these amounts will result in flange and cap screw bending and connection failures.
b
Metric standard thread.
0284-30
TM 5-3895-379-23-2
0284
Inch Series Four Bolt Flange Fittings Service Recommendations
CAUTION
1. 2. 3. 4. 5. Clean sealing surfaces (Figure 22, Item 1). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion. If defects cannot be polished out, replace component. Install O-ring (Figure 22, Item and backup washer if required) into groove using clean oil to hold it in place. Refer to LO 5-3805-294-13. Split flange: Loosely assemble split flange (Figure 22, Item 2) halves. Make sure split is centrally located and perpendicular to port. Hand tighten cap screws to hold parts in place. Do not pinch O-ring (Figure 22, Item 3). Single piece flange (Figure 22, Item 4): Place hydraulic line in center of flange and install cap screws. Flange must be centrally located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring. After components are properly positioned and cap screws are hand tightened, tighten one cap screw, then tighten the diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap screws as specified in the table.
4
1 3
M1337SWR
Figure 22.
Inch Series Four Bolt Flange Fitting.
0284-31
TM 5-3895-379-23-2
0284
GENERAL TORQUE VALUES - Continued Inch Series Four Bolt Flange Fittings Service Recommendations - Continued
Table 21. Inch Series Four Bolt Flange Fitting Torque Values. Nominal Flange Size 1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 3-1/2 4 5 Cap Screw Size 5/6-18 UNC 3/8-16 UNC 3/8-16 UNC 7/16-14 UNC 1/2-13 UNC 1/2-13 UNC 1/2-13 UNC 5/8-11 UNC 5/8-11 UNC 5/8-11 UNC 5/8-11 UNC lb-ft Min Max 15 21 27 35 46 54 79 117 117 117 117 23 40 40 63 97 97 97 195 195 195 195 Nm Min Max 20 28 37 47 62 73 107 158 158 158 158 31 54 54 85 131 131 131 264 264 264 264
0284-32
TM 5-3895-379-23-2
0284
Inch Series Four Bolt Flange Fitting For High-Pressure Service
CAUTION
1. Clean sealing surfaces (Figure 23, Item 1). Inspect. Scratches, nicks, and burrs cause leaks. Roughness causes O-ring wear. Out-of-flat causes O-ring extrusion. If imperfection cannot be polished out, replace component. Install the O-ring (Figure 23, Item and backup ring, if used) into groove. Use clean oil to hold it in place. Refer to LO 5-3805-294-13. Split flange: Loosely assemble split flange (Figure 23, Item 2) halves. Make sure split is centrally located and perpendicular to port. Hand tighten cap screws to hold flange halves and line in place. Do not pinch O-ring (Figure 23, Item 3). Single piece flange (Figure 23, Item 4): Make sure flange is centrally located on port and line is centered in flange. Install the cap screws. Hand tighten cap screws to hold flange and line in place. Do not pinch O-ring. After components are properly positioned and cap screws are hand tightened, tighten one cap screw and then the diagonally opposite cap screw. Tighten the two remaining cap screws. Tighten all cap screws as specified in the table.
4
2. 3.
4. 5.
1 3
M1338SWR
Figure 23. Table 22.
Inch Series Four Bolt Flange Fitting for High-Pressure Service.
Inch Series Four Bolt Flange Fitting for High-Pressure Service Torque Values. Cap Screw Size a - inch 5/16-18 UNC 3/8-18 UNC 7/16-14 UNC 1/2-13 UNC 5/8-11 UNC Min - Max Torque lb-ft (Nm) 15-23 (20-31) 25-40 (34-54) 42-63 (57-85) 63-97 (85-131) 117-195 (159-264)
Nominal Flange Size - inch 1/2 3/4 1 1-1/4 1-1/2
0284-33
TM 5-3895-379-23-2
0284
GENERAL TORQUE VALUES - Continued Inch Series Four Bolt Flange Fitting For High-Pressure Service - Continued Table 22. Inch Series Four Bolt Flange Fitting for High-Pressure Service Torque Values - Continued. Nominal Flange Size - inch 2
a
Cap Screw Size a - inch 3/4-10 UNC
Min - Max Torque lb-ft (Nm) 200-345 (271-468)
JDM A17D, SAE Grade 5 or better cap screws with plated hardware. Lockwashers are permissible but not recommended.
b
Minimum torques given are enough for the given size connection with the recommended working pressure. Torques can be increased to the maximum shown for each cap screw size if desired. Increasing cap screw torque beyond the maximum will result in flange and cap screw bending and connection failures. Inch series four bolt flange fitting for above 6,000 psi (41,400 kPa) (414 bar), pressure series torque values. Tolerance is 10%, unless otherwise specified. Non-Restricted Banjo (Adjustable) Fittings Service Recommendations
NOTE
The L in the Tube Fitting OD Size column indicates "light" designed fitting and the S indicates "heavy" designed fitting. 1. 2. 3. 4. 5. 6. Inspect all fitting sealing surfaces. They must be free of dirt and defects. Inspect O-ring (Figure 24, Item 1). It must be free of damage or defects. Inspect sealing ring (Figure 24, Item 2) for damage or defects. Hold body in desired position while tightening stud by hand. Tighten stud (Figure 24, Item 3) to torque value shown on the table. Do not allow body to twist when tightening stud. Table 23 lists the Non-Restricted Banjo (Adjustable) Metric Fittings Torque Values.
1 2
M1339SWR
Figure 24. Non-Restricted Banjo (Adjustable) Fittings.
0284-34
TM 5-3895-379-23-2
0284
GENERAL TORQUE VALUES - Continued Non-Restricted Banjo (Adjustable) Fittings Service Recommendations - Continued Table 23. Non-Restricted Banjo (Adjustable) Metric Fittings Torque Values. Tube Fitting OD Size 6L 8L 10 L 12 L 15 L 18 L 22 L 28 L 35 L 42 L 6S 8S 10 S 12 S 14 S 16 S 20 S 25 S 30 S 38 S Metric Thread M10 x 1 M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5 M22 x 1.5 M26 x 1.5 M33 x 2 M42 x 2 M48 x 2 M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M27 x 2 M33 x 2 M42 x 2 M48 x 2 lb-ft 22 30 44 74 96 118 184 295 443 590 30 44 74 96 118 118 184 295 443 590 Nm 30 40 60 100 130 160 250 400 600 800 40 60 100 130 160 160 250 400 600 800
0284-35
TM 5-3895-379-23-2
0284
GENERAL TORQUE VALUES - Continued Non-Restricted Banjo (Adjustable) Fittings Service Recommendations - Continued 7. Table 24 lists the Non-Restricted Banjo (Adjustable) Inch Fittings Torque Values. Table 24. Tube Fitting OD Size 6L 8L 10 L 12 L 15 L 18 L 22 L 28 L 35 L 42 L 6S 8S 10 S 12 S 14 S 16 S 20 S 25 S 30 S 38 S Non-Restricted Banjo (Adjustable) Inch Fittings Torque Values. Inch Thread 1/8 1/4 1/4 3/8 1/2 1/2 3/4 1 1-1/4 1-1/2 1/4 1/4 3/8 3/8 1/2 1/2 3/4 1 1-1/4 1-1/2 lb-ft 18 37 37 66 96 111 184 295 443 590 37 37 66 74 96 111 184 295 443 590 Nm 25 50 50 90 130 150 250 400 600 800 50 50 90 100 130 150 250 400 600 800
0284-36
TM 5-3895-379-23-2
0284
Metric 24 O-Ring Seal DIN 20078 Service Recommendations
NOTE
In this style of fittings, there are "heavy" and "light" designs. Usually "heavy" is used for pressure lines and "light" for return lines. Some "heavy" and "light" sizes can be threaded together but do not seal properly. Be sure not to mix "heavy" and "light" fittings. These fittings are also referred to as EO and EO-2 Bite Type or Ermeto style fittings. 1. 2. 3. 4. 5. 6. Inspect the fitting sealing surfaces. They must be free of dirt scratches, nicks, and burrs. Inspect the O-ring. It must be free dirt, cuts, cracks, swelling or flatten condition. Lubricate O-rings using a thin film of clean oil. Refer to LO 5-3805-294-13. Align an adjustable fitting with the tube. Hold connections together while tightening nut to ensure proper seal. Tighten nut (Figure 25, Item 1) hand tight so O-ring contacts seat and then an additional 1/4-1/3 turn using a wrench.
1
M1340SWR
Figure 25. 7.
Metric 24 Degree O-Ring Seal DIN 20078.
Table 25 lists the Metric 24 Degree O-Ring Seal DIN 20078 Torque Values. Table 25. Metric 24 Degree O-Ring Seal DIN 20078 Torque Values. Torque (Turns) Hand tighten so O-ring contacts seat plus an additional 1/4-1/3 turn using a wrench.
Fitting Tube OD Size (mm) 6 8 10 12 14
Heavy Fitting Size (mm) Light Fitting Size (mm) M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5 -
0284-37
TM 5-3895-379-23-2
0284
GENERAL TORQUE VALUES - Continued Metric 24 O-Ring Seal DIN 20078 Service Recommendations - Continued Table 25. Fitting Tube OD Size (mm) 15 16 18 20 22 25 28 30 35 38 END OF TASK END OF WORK PACKAGE Metric 24 Degree O-Ring Seal DIN 20078 Torque Values - Continued. Heavy Fitting Size (mm) Light Fitting Size (mm) M24 x 1.5 M30 x 2 M36 x 2 M42 x 2 M52 x 2 M22 x 1.5 M26 x 1.5 M30 x 2 M36 x 2 M45 x 2 Torque (Turns)
0284-38
TM 5-3895-379-23-2
CHAPTER 6 SUPPORTING INFORMATION CB534B or CB534C ROLLER, MOTORIZED, VIBRATING TANDEM STEEL DRUMS NSN 3895-01-396-2822 AND 3895-01-502-4005
TM 5-3895-379-23-2
0285
FIELD MAINTENANCE REFERENCES
SCOPE This work package lists all forms, field manuals, technical bulletins, technical manuals and other publications referenced in this manual and which apply to maintenance of the CB534B and CB534C Rollers.
PUBLICATION INDEXES The following indexes should be consulted frequently for latest changes or revisions and fro new publications relating to material covered in this technical manual. DA Pam 750-8 The Army Maintenance Management System (TAMMS) Users Manual
FORMS Refer to DA Pam 750-8, The Army Maintenance Management System (TAMMS) User Manual, for instructions on the use of maintenance forms. DD Form 1397 DA Form 2028 DA Form 2404, DA Form 5988-E SF Form 368 Processing and Deprocessing Record for Shipment, Storage and Issue of Vehicles and Spare Engines Recommended Changes to Publications and Blank Forms Equipment Inspection and Maintenance Worksheet Product Quality Deficiency Report
FIELD MANUALS FM 4-25.11 FM 21-40 First Aid Chemical, Biological, and Nuclear Defense
TECHNICAL BULLETINS TB 43-0209 TB 750-651 Color, Marking, and Camouflage Painting of Military Vehicles, Construction Equipment and Materials Handling Equipment Use of Antifreeze Solutions and Cleaning Compounds in Engine Cooling Systems
TECHNICAL MANUALS TM 5-3895-379-10 Operator's Manual for CB534B and CB534C Rollers
0285-1
03/15/2011 Rel(1.8) root(refwp) wpno(S00005)
TM 5-3895-379-23-2
0285
TECHNICAL MANUALS - Continued TM 5-3895-379-23P TM 9-247 TM 9-6140-200-13 TM 43-0139 TM 750-244-6 TM 750-254 Field Maintenance (Unit and Direct Support Maintenance) RPSTL for CB534B and CB534C Rollers Related Materials Including Chemicals Maintenance Manual for Lead-Acid Storage Batteries Painting Instructions for Army Materiel Procedures for Destruction of Equipment to Prevent Enemy Use (Mobility Equipment Command) Cooling System, Tactical Vehicles
OTHER PUBLICATIONS AR 190-13 CTA 8-100 CTA 50-909 CTA 50-970 MIL-STD-12 The Army Physical Security Program Army Medical Department Expendable/Durable Items Army Doctrine and Training Publications Expendable/Durable Items (Except Medical, Class V, Repair Parts and Heraldic Items) Abbreviations for Use on Drawings, Specifications, Standards and Technical Documents
END OF WORK PACKAGE
0285-2
03/15/2011 Rel(1.8) root(refwp) wpno(S00005)
TM 5-3895-379-23-2
0286
FIELD MAINTENANCE INTRODUCTION FOR STANDARD TWO-LEVEL MAC
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION The Army Maintenance System MAC This introduction provides a general explanation of all maintenance and repair functions authorized at the two maintenance levels under the Two-Level Maintenance System concept. This MAC (immediately following the introduction) designates overall authority and responsibility for the performance of maintenance functions on the identified end item or component. The application of the maintenance functions to the end item or component shall be consistent with the capacities and capabilities of the designated maintenance levels, which are shown on the MAC in column (4) as: Field includes two subcolumns, Crew (C) and Maintainer (F). Sustainment includes two subcolumns, Below Depot (H) and Depot (D). The maintenance to be performed at field and sustainment levels is described as follows: 1. Crew maintenance. The responsibility of a using organization to perform maintenance on its assigned equipment. It normally consists of inspecting, servicing, lubricating, adjusting, and replacing parts, minor assemblies, and subassemblies. The replace function for this level of maintenance is indicated by the letter "C" in the third position of the SMR code. A "C" appearing in the fourth position of the SMR code indicates complete repair is possible at the crew maintenance level. 2. Maintainer maintenance. Maintenance accomplished on a component, accessory, assembly, subassembly, plug-in unit, or other portion either on the system or after it is removed. The replace function for this level of maintenance is indicated by the letter "F" appearing in the third position of the SMR code. An "F" appearing in the fourth position of the SMR code indicates complete repair is possible at the field maintenance level. Items are returned to the user after maintenance is performed at this level. 3. Below depot sustainment. Maintenance accomplished on a component, accessory, assembly, subassembly, plug-in unit, or other portion either on the system or after it is removed. The replace function for this level of maintenance is indicated by the letter "H" appearing in the third position of the SMR code. An "H" appearing in the fourth position of the SMR code indicates complete repair is possible at the below depot sustainment maintenance level. Items are returned to the supply system after maintenance is performed at this level. 4. Depot sustainment. Maintenance accomplished on a component, accessory, assembly, subassembly, plugin unit, or other portion either on the system or after it is removed. The replace function for this level of maintenance is indicated by the letter "D" or "K" appearing in the third position of the SMR code. Depot sustainment maintenance can be performed by either depot personnel or contractor personnel. A "D" or "K" appearing in the fourth position of the SMR code indicates complete repair is possible at the depot sustainment maintenance level. Items are returned to the supply systems after maintenance is performed at this level. The tools and test equipment requirements table (immediately following the MAC) lists the tools and test equipment (both special tools and common tool sets) required for each maintenance function as referenced from the MAC. The remarks table (immediately following the tools and test equipment requirements) contains supplemental instructions and explanatory notes for a particular maintenance function.
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MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION - Continued Maintenance Functions Maintenance functions are limited to and defined as follows: 1. Inspect. To determine the serviceability of an item by comparing its physical, mechanical, and/or electrical characteristics with established standards through examination (e.g., by sight, sound, or feel). This includes scheduled inspection and gaugings and evaluation of cannon tubes. 2. Test. To verify serviceability by measuring the mechanical, pneumatic, hydraulic, or electrical characteristics of an item and comparing those characteristics with prescribed standards on a scheduled basis, i.e., load testing of lift devices and hydrostatic testing of pressure hoses. 3. Service. Operations required periodically to keep an item in proper operating condition; e.g., to clean (includes decontaminate, when required), to preserve, to drain, to paint, or to replenish fuel, lubricants, chemical fluids, or gases. This includes scheduled exercising and purging of recoil mechanisms. The following are examples of service functions: a. Unpack. To remove from packing box for service or when required for the performance of maintenance operations. b. Repack. To return item to packing box after service and other maintenance operations. c. Clean. To rid the item of contamination.
d. Touch up. To spot paint scratched or blistered surfaces. e. Mark. To restore obliterated identification. 4. Adjust. To maintain or regulate, within prescribed limits, by bringing into proper position, or by setting the operating characteristics to specified parameters. 5. Align. To adjust specified variable elements of an item to bring about optimum or desired performance. 6. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments of test, measuring, and diagnostic equipment used in precision measurement. Consists of comparisons of two instruments, one of which is a certified standard of known accuracy, to detect and adjust any discrepancy in the accuracy of the instrument being compared. 7. Remove/Install. To remove and install the same item when required to perform service or other maintenance functions. Install may be the act of emplacing, seating, or fixing into position a spare, repair part, or module (component or assembly) in a manner to allow the proper functioning of an equipment or system. 8. Paint (ammunition only). To prepare and spray color coats of paint so that the ammunition can be identified and protected. The color indicating primary use is applied, preferably, to the entire exterior surface as the background color of the item. Other markings are to be repainted as original so as to retain proper ammunition identification. 9. Replace. To remove an unserviceable item and install a serviceable counterpart in its place. "Replace" is authorized by the MAC and assigned maintenance level is shown as the third position code of the Source, Maintenance and Recoverability (SMR) code. 10. Repair. The application of maintenance services, including fault location/troubleshooting, removal/ installation, disassembly/assembly procedures and maintenance actions to identify troubles and restore
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MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION - Continued serviceability to an item by correcting specific damage, fault, malfunction, or failure in a part, subassembly, module (component or assembly), end item, or system.
NOTE
The following definitions are applicable to the "repair" maintenance function: Services. Inspect, test, service, adjust, align, calibrate, and/or replace. Fault location/troubleshooting. The process of investigating and detecting the cause of equipment malfunctioning; the act of isolating a fault within a system or Unit Under Test (UUT). Disassembly/assembly. The step-by-step breakdown (taking apart) of a spare/ functional group coded item to the level of its least component, that is assigned an SMR code for the level of maintenance under consideration (i.e., identified as maintenance significant). Actions. Welding, grinding, riveting, straightening, facing, machining, and/or resurfacing. 11. Overhaul. That maintenance effort (service/action) prescribed to restore an item to a completely serviceable/ operational condition as required by maintenance standards in appropriate technical publications. Overhaul is normally the highest degree of maintenance performed by the Army. Overhaul does not normally return an item to like new condition. 12. Rebuild. Consists of those services/actions necessary for the restoration of unserviceable equipment to a like new condition in accordance with original manufacturing standards. Rebuild is the highest degree of material maintenance applied to Army equipment. The rebuild operation includes the act of returning to zero those age measurements (e.g., hours/miles) considered in classifying Army equipment/components. Explanation of Columns in the MAC Column (1) Group Number. Column (1) lists Functional Group Code (FGC) numbers, the purpose of which is to identify maintenance significant components, assemblies, subassemblies, and modules with the Next Higher Assembly (NHA). Column (2) Component/Assembly. Column (2) contains the item names of components, assemblies, subassemblies, and modules for which maintenance is authorized. Column (3) Maintenance Function. Column (3) lists the functions to be performed on the item listed in column (2). (For a detailed explanation of these functions refer to "Maintenance Functions" outlined above). Column (4) Maintenance Level. Column (4) specifies each level of maintenance authorized to perform each function listed in column (3), by indicating work time required (expressed as manhours in whole hours or decimals) in the appropriate subcolumn. This work time figure represents the active time required to perform that maintenance function at the indicated level of maintenance. If the number or complexity of the tasks within the listed maintenance function varies at different maintenance levels, appropriate work time figures are to be shown for each level. The work time figure represents the average time required to restore an item (assembly, subassembly, component, module, end item, or system) to a serviceable condition under typical field operating conditions. This time includes preparation time (including any necessary disassembly/assembly time), troubleshooting/fault location time, and quality assurance time in addition to the time required to perform the specific tasks identified for the maintenance functions authorized in the MAC. The symbol designations for the various maintenance levels are as follows:
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MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION - Continued Field : C Crew maintenance F Maintainer maintenance Sustainment : L Specialized Repair Activity (SRA) H Below depot maintenance D Depot maintenance
NOTE
The "L" maintenance level is not included in column (4) of the MAC. Functions to this level of maintenance are identified by work time figure in the "H" column of column (4), and an associated reference code is used in the REMARKS column (6). This code is keyed to the remarks and the SRA complete repair application is explained there. Column (5) Tools and Equipment Reference Code. Column (5) specifies, by code, those common tool sets (not individual tools), common Test, Measurement and Diagnostic Equipment (TMDE), and special tools, special TMDE and special support equipment required to perform the designated function. Codes are keyed to the entries in the tools and test equipment table. Column (6) Remarks Code. When applicable, this column contains a letter code, in alphabetical order, which is keyed to the remarks table entries. Explanation of Columns in the Tools and Test Equipment Requirements Column (1) - Tool or Test Equipment Reference Code. The tool or test equipment reference code correlates with a code used in column (5) of the MAC. Column (2) - Maintenance Level. The lowest level of maintenance authorized to use the tool or test equipment. Column (3) - Nomenclature. Name or identification of the tool or test equipment. Column (4) - National Stock Number (NSN). The NSN of the tool or test equipment. Column (5) - Tool Number. The manufacturer's part number. Explanation of Columns in the Remarks Column (1) - Remarks Code. The code recorded in column (6) of the MAC. Column (2) - Remarks. This column lists information pertinent to the maintenance function being performed as indicated in the MAC. END OF WORK PACKAGE
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FIELD MAINTENANCE MAINTENANCE ALLOCATION CHART (MAC) SUMMARY
Table 1. Maintenance Allocation Chart (MAC) Summary.

(1) (2) (3) FIELD CREW C 0000-00 PMCS BEFORE Inspect Service 0000-01 PMCS DURING PMCS AFTER PMCS WEEKLY Inspect 2.4 0.1 0.3 MAINTAINER F (4) MAINTENANCE LEVEL GROUP COMPONENT/ MAINTENANCE NUMBER ASSEMBLY FUNCTION SUSTAINMENT (5) TOOLS AND EQUIPMENT BELOW DEPOT DEPOT REFERENCE CODE H D (6)
REMARKS CODE
0000-02
Service
0.5
0000-03
Inspect Service
1.3 0.3 1.5 4.0 0.5 0.5 0.2 1.6 0.1 0.5 0.4 0.4 0.2 0.1
0000-04
PMCS - AT FIRST 250 H
Service Adjust Remove Replace
0000-05
PMCS - 250 H
Inspect Service
0000-06
PMCS - 500 H
Inspect Service Remove Replace
0000-07
PMCS QUARTERLY
Inspect Service
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Table 1.
(1) (2)
Maintenance Allocation Chart (MAC) Summary - Continued.

(3) FIELD CREW C MAINTAINER F 1.2 0.5 5.1 2.0 0.2 0.2 0.1 (4) MAINTENANCE LEVEL SUSTAINMENT (5) TOOLS AND EQUIPMENT BELOW DEPOT DEPOT REFERENCE CODE H D (6)
GROUP COMPONENT/ MAINTENANCE NUMBER ASSEMBLY FUNCTION
REMARKS CODE
0000-08
PMCS - 1,000 H
Inspect Test Service Adjust Remove Replace
0000-09
PMCS SEMIANNUAL LY
Inspect
Service Remove Replace 0000-10 PMCS - 2,000 H PMCS ANNUAL Service
0.5 0.4 0.4 3.1
0000-11
Inspect Test Service
2.3 0.5 4.7 10.5 21, 65, 66 66 46, 66
0100-00
ENGINE, TURBO, DIESEL
Remove
Replace Repair
10.5 40.0
46, 66 24, 25, 28, 66, 68 66, 68
0100-01
ENGINE LIFTING PLATE
Remove
0.5
Replace 0100-02 FRONT/REAR ENGINE MOUNTS Remove
0.5 2.0
66, 68 66, 68
Replace
2.0
66, 68
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Table 1.
(1) (2)

(3) FIELD CREW C MAINTAINER F (4) MAINTENANCE LEVEL SUSTAINMENT (5) TOOLS AND EQUIPMENT BELOW DEPOT DEPOT REFERENCE CODE H D 25.0 24, 25, 28, 66, 68 (6)
REMARKS CODE
0101-00
ENGINE BLOCK ASSEMBLY CYLINDER HEAD ASSEMBLY
Repair
0101-01
Remove
4.0
66, 68
Replace Repair
4.0 6.0
66, 68 5, 7, 9, 10, 20, 27, 36, 37, 38, 39, 61, 66, 68 1, 6, 43, 60, 66, 68 1, 6, 43, 60, 66, 68 3, 62, 66, 68 3, 62, 66, 68 5, 32, 33, 35, 66, 68
0102-00
CRANKSHAF T
Remove Replace
48.0 48.0
0102-01
CRANKSHAF T PULLEY
Remove Replace
2.0 2.0 5.0
0102-02
CRANKSHAF T FRONT/ REAR OIL SEALS
Remove
Replace
5.0
5, 32, 33, 35, 66, 68 3, 4, 22, 45, 66, 68 3, 4, 22, 45, 66, 68 41, 66, 68 41, 66, 68 48.0 48.0 6, 13, 54, 66, 68 6, 13, 54, 66, 68
0103-00
FLYWHEEL ASSEMBLY
Remove Replace
5.0 5.0
0103-01
FLYWHEEL HOUSING
Remove Replace
13.0 13.0
0104-00
PISTON ASSEMBLY
Remove Replace
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Table 1.
(1) (2)

(3) FIELD CREW C MAINTAINER F (4) MAINTENANCE LEVEL SUSTAINMENT (5) TOOLS AND EQUIPMENT BELOW DEPOT DEPOT REFERENCE CODE H D 48.0 48.0 2.0 6, 66, 68 6, 66, 68 66 (6)
REMARKS CODE
0104-01
CONNECTING Remove RODS Replace
0105-00
VALVES, INTAKE AND EXHAUST
Adjust
Remove Replace 0105-01 CAMSHAFT Remove Replace
5.0 5.0 4.0 4.0
66, 68 66, 68 6, 12, 66, 68, 70 6, 12, 66, 68, 70 66
0105-02
ROCKER SHAFT/ARM ASSEMBLY IDLER GEAR AND HUB
Repair
2.5
0105-03
Remove Replace
6.0 6.0 1.5 1.5 2.0 2.0 1.0 1.0 1.0
5, 52, 66, 68 5, 52, 66, 68 66, 68 66, 68 66, 68 66, 68 66, 68 66, 68 66, 68
0106-00
OIL PAN
Remove Replace
0106-01
ENGINE OIL PUMP
Remove Replace
0106-02
ENGINE OIL COOLER
Remove Replace
0106-03
ENGINE OIL COOLER LINES, FITTINGS AND HOSES
Remove
Replace 0106-04 ENGINE OIL SAMPLING Remove
1.0 0.3
66, 68 66, 68, 72
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Table 1.
(1) (2)

(3) FIELD CREW C MAINTAINER F (4) MAINTENANCE LEVEL SUSTAINMENT (5) TOOLS AND EQUIPMENT BELOW DEPOT DEPOT REFERENCE CODE H D (6)
REMARKS CODE
VALVE AND FITTINGS Replace 0106-05 GAUGE ROD (DIP STICK) TUBE ASSEMBLY Remove 0.3 0.4 66, 68, 72 66, 72
Replace 0106-06 OIL FILTER HEAD ASSEMBLY Remove
0.4 0.8
66, 72 66, 68
Replace 0106-07 OIL STRAINER AND SUCTION TUBE Remove
0.8 2.0
66, 68 66, 68, 72
Replace 0108-00 INTAKE MANIFOLD Remove Replace 0301-00 FUEL INJECTOR AND NOZZLE Remove
2.0 2.5 2.5 1.5
66, 68, 72 66, 68 66, 68 66, 72
Replace 0302-00 FUEL INJECTOR PUMP Remove
1.5 6.0
66, 72 66, 72
Replace Repair 0302-01 FUEL LINES AND FITTINGS AND HOSE Remove
6.0 16.5 1.0
66, 72 43, 44, 66, 68 66, 72
Replace
1.0
66, 72
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Table 1.
(1) (2)

(3) FIELD CREW C MAINTAINER F 1.0 1.0 0.2 (4) MAINTENANCE LEVEL SUSTAINMENT (5) TOOLS AND EQUIPMENT BELOW DEPOT DEPOT REFERENCE CODE H D 66, 68 66, 68 66, 68 (6)
REMARKS CODE
0302-02
FUEL LIFT PUMP
Remove Replace
0304-00
AIR CLEANER Remove ELEMENTS AND AIR CLEANER ASSEMBLY Replace
0.2 2.0
66, 68 66, 68
0304-01
AIR CLEANER Remove SUPPORT ASSEMBLY Replace
2.0 0.5
66, 68 66, 72
0304-02
AIR CLEANER Remove SERVICE INDICATOR Replace
0.5 5.5
66, 72 66, 72
0305-00
TURBOCHAR GER TURBOCHAR GER OIL LINES, HOSES AND FITTINGS
Repair
0305-01
Remove
2.5
66, 68, 72
Replace 0306-00 FUEL/ Remove HYDRAULIC OIL TANK AND DRAIN LINES Replace 0306-01 LINES, FITTINGS AND HOSES Remove
2.5 4.0
66, 68, 72 66, 68, 72
4.0 1.0
66, 68, 72 66, 72
Replace 0306-02 FUEL CAP ASSEMBLY Service
1.0 0.4
66, 72 66, 68
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Table 1.
(1) (2)

(3) FIELD CREW C MAINTAINER F 0.2 (4) MAINTENANCE LEVEL SUSTAINMENT (5) TOOLS AND EQUIPMENT BELOW DEPOT DEPOT REFERENCE CODE H D 66, 68 (6)
REMARKS CODE
0306-03
HYDRAULIC OIL CAP ASSEMBLY FUEL FILTER ASSEMBLY
Service
0309-00
Remove Replace
0.5 0.5 0.5
66, 68 66, 68 66, 68
0309-01
FUEL/WATER SEPARATOR ASSEMBLY
Remove
Replace 0311-00 COLD START HEATER Remove Replace 0312-00 THROTTLE CABLE/ CONTROL Remove
0.5 1.0 1.0 2.0
66, 68 66, 68, 72 66, 68, 72 66, 72
Replace 0401-00 MUFFLER Remove AND TAILPIPE Replace 0501-00 RADIATOR ASSEMBLY RADIATOR HOSES Repair
2.0 1.5 1.5 7.1
66, 72 66, 68, 72 66, 68, 72 29, 41, 53, 56, 66, 68 66 66 66, 68, 72 66, 68, 72 66, 68, 72 66, 68, 72 66, 72 66, 72
0501-01
Remove Replace
1.6 1.6 3.7 3.7 2.0 2.0 1.3 1.3
0502-00
FAN SHROUD Remove Replace
0503-00
THERMOSTA T HOUSING
Remove Replace
0504-00
WATER PUMP Remove Replace
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Table 1.
(1) (2)

(3) FIELD CREW C MAINTAINER F 1.0 (4) MAINTENANCE LEVEL SUSTAINMENT (5) TOOLS AND EQUIPMENT BELOW DEPOT DEPOT REFERENCE CODE H D 66, 68, 72 (6)
REMARKS CODE
0505-00
FAN ASSEMBLY AND GUARD
Remove
Replace 0505-01 FAN DRIVE HOUSING ASSEMBLY Remove
1.0 1.5
66, 68, 72 66, 72
Replace 0505-02 FAN V-BELTS Remove Replace 0601-00 ALTERNATOR Remove Replace 0603-00 STARTER RELAY SWITCH ASSEMBLY Remove
1.5 1.0 1.0 1.5 1.5 0.5
66, 72 51, 64, 66 51, 64, 66 66, 68 66, 68 66
Replace 0603-01 STARTER Remove Replace 0607-00 RELAYS Remove Replace 0607-01 SWITCHES Remove Replace 0607-02 GAUGES Remove Replace 0601-01 ALTERNATOR Remove BRACKET Replace
0.5 2.5 2.5 1.0 1.0 1.0 1.0 1.0 1.0 2.0 2.0
66 66, 68 66, 68 66 66 66 66 66 66 66 66
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Table 1.
(1) (2)

REMARKS CODE
0607-03
HOURMETER PRESSURE SWITCH
Remove
Replace 0607-04 ALTERNATOR Remove CIRCUIT BREAKER Replace 0607-05 LIGHTS CIRCUIT BREAKER Remove
0.5 0.5
66, 68 66, 72
0.5 1.0
66, 72 66
Replace 0607-06 FUSE AND FUSE HOLDER Remove
1.0 0.1
66 66
Replace 0607-07 STARTING AID RESISTOR Remove
0.1 1.0
66 66
Replace 0607-08 ALTERNATOR Remove LIGHT Replace 0609-00 WORK LIGHTS ASSEMBLY Remove
1.0 0.4 0.4 0.5
66 66 66 66
Replace 0609-01 WORK LIGHTS BULB Remove Replace 0610-00 WATER TEMPERATU RE SENDING UNIT Remove
0.5 0.2 0.2 0.5
66 66 66 66, 68
Replace
0.5
66, 68
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Table 1.
(1) (2)

(3) FIELD CREW C MAINTAINER F 0.5 (4) MAINTENANCE LEVEL SUSTAINMENT (5) TOOLS AND EQUIPMENT BELOW DEPOT DEPOT REFERENCE CODE H D 66, 68, 72 (6)
REMARKS CODE
0610-01
ENGINE OIL PRESSURE SWITCH
Remove
Replace 0610-02 FUEL LEVEL SENDING UNIT Remove
0.5 0.5
66, 68, 72 66, 68
Replace 0610-03 VIBRATION SENSOR Remove Replace 0611-00 HORN AND BACKUP ALARM Remove
0.5 2.0 2.0 0.5
66, 68 66, 68 66, 68 66, 72
Replace 0612-00 BATTERY Remove Replace 0612-01 BATTERY CABLES Remove Replace 0612-02 GROUND CABLE Remove Replace 0613-00 ENGINE WIRING HARNESS FRONT CHASSIS WIRING HARNESS REAR CHASSIS WIRING HARNESS Repair
0.5 3.2 3.2 2.0 2.0 0.5 0.5 4.5
66, 72 66, 68 66, 68 66, 68 66, 68 66, 68 66, 68 66, 72
0613-01
Repair
3.0
66
0613-02
Repair
3.0
66
0287-10
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Table 1.
(1) (2)

REMARKS CODE
0613-03
INSTRUMENT WIRING HARNESS MAIN WIRING HARNESS HYDRAULIC PUMP (PROPEL)
Repair
0613-04
Repair
6.0
66
0721-00
Remove
8.5
41, 66
Replace Repair
8.5 8.5
41, 66 18, 41, 66, 67, 68 66
0721-01
HYDRAULIC FRONT MOTOR (PROPEL)
Remove
8.5
Replace Repair
8.5 8.5
66 18, 41, 66, 67, 68 66
0721-02
HYDRAULIC Remove REAR MOTOR (PROPEL) Replace Repair
8.5
8.5 8.5 4.0
66 41, 66, 67, 68 66
0721-03
PROPEL CONTROL VALVE, LEVER AND FITTINGS HYDRAULIC PUMP DRIVE
Repair
0721-04
Remove Replace
4.0 4.0 21.5
66 66 66, 68
0801-00
FRONT AND REAR
Remove
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Table 1.
(1) (2)

REMARKS CODE
PROPEL GEARBOX Replace Repair 21.5 30.0 66, 68 30, 41, 42, 45, 48, 49, 50, 59, 65, 66, 68, 71 41, 66, 68
0801-01
SEPARATE Service AND CONNECT PROPEL MOTOR AND TORQUE HUB UNIVERSAL JOINT AND SHAFTS BRAKE CONTROL VALVE BRAKE HOSES, LINES AND FITTINGS Repair
33.0
0900-00
14.0
66
1204-00
Repair
2.0
66, 68
1204-01
Remove
4.0
66, 68
Replace 1204-02 MANUAL BRAKE RELEASE PUMP BRAKE CONTROL VALVE COIL Repair
4.0 1.0
66, 68 66, 68
1204-03
Remove
0.5
66
Replace 1401-00 STEERING CONTROL UNIT (SCU) POWER STEERING PUMP Repair
0.5 2.5
66 66, 72
1410-00
Remove
2.0
66, 68
Replace
2.0
66, 68
0287-12
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Table 1.
(1) (2)

REMARKS CODE
1411-00
STEERING HOSES, LINES AND FITTINGS
Remove
Replace 1412-00 HYDRAULIC STEERING CYLINDERS STEERING PIVOT Repair
2.0 3.0
66, 68 66, 68
1501-00
Remove Replace
20.0 20.0 19.0 19.0 3.0
40, 66 40, 66 23, 66 23, 66 41, 66
1501-01
YOKE
Remove Replace
1501-02
FRONT AND REAR SUPPORTS (BUMPERS)
Remove
Replace 1501-03 REAR FRAME ASSEMBLY Remove Replace 1501-04 FRONT AND REAR DRUM DRIVE MOUNTING Remove
3.0 40.0 40.0 30.0
41, 66 66, 68 66, 68 66, 68
Replace 1501-05 DECONTAMIN Remove ATION KIT BRACKET Replace 1801-00 DOOR ASSEMBLY Repair
30.0 0.4
66, 68 66, 68
0.4 0.5
66, 68 66
1801-01
FRONT, LEFT- Remove AND RIGHT-
0.5
66, 68
0287-13
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Table 1.
(1) (2)

REMARKS CODE
SIDE HANDRAILS Replace 1801-02 ROLL OVER PROTECTIVE STRUCTURE (ROPS) ASSEMBLY Remove 0.5 1.0 66, 68 66, 68
Replace 1801-03 OPERATOR PLATFORM AND OPERATOR STATION Remove
1.0 10.0
66, 68 41, 66
Replace 1801-04 ROTATE LOCK Remove Replace 1801-05 OPERATOR PLATFORM MOUNT Remove
10.0 0.3 0.3 0.4
41, 66 66, 68 66, 68 66, 68
Replace 1806-00 SEAT BELT AND LANYARD Remove
0.4 1.0
66, 68 55, 66, 68
Replace 1806-01 SEAT ASSEMBLY SEAT SUSPENSION TOOLBOX Repair
1.0 1.0
55, 66, 68 55, 66, 68
1806-02
Repair
3.5
58, 66, 68, 72
1808-00
Remove Replace
0.2 0.2
66, 68 66, 68
0287-14
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Table 1.
(1) (2)

REMARKS CODE
1808-01
RIFLE MOUNTING BRACKET
Remove
Replace 2207-00 ENGINE BLOCK HEATING ELEMENT Remove
0.2 0.3
66, 72 66, 68
Replace 2210-00 DATA PLATE AND DECAL REPLACEME NT Remove
0.3 0.5
66, 68 57, 66, 68
Repair 2401-00 HYDRAULIC PUMP (VIBRATORY) Remove
0.5 4.0
57, 66, 68 41, 66
Replace Repair 2401-01 VIBRATORY CONTROL SOLENOID Remove
4.0 6.0 2.0
41, 66 30, 66, 68 66
Replace 2401-02 HYDRAULIC MOTOR (VIBRATORY) Remove
2.0 4.0
66 66, 68
Replace Repair 2401-03 VIBRATORY SHAFT ASSEMBLY Remove
4.0 6.0 8.5
66, 68 45, 66, 68 66, 68
Replace Repair 2402-00 VIBRATORY COOLING/ Repair 4.0
8.5 8.5
66, 68 66, 68 66, 68
0287-15
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Table 1.
(1) (2)

REMARKS CODE
CONTROL VALVE 2404-00 HYDRAULIC OIL SAMPLING VALVE Remove 1.5 66, 68
Replace 2406-00 HYDRAULIC FILTER ASSEMBLY Remove
1.5 2.5
66, 68 66, 68
Replace 2406-01 HYDRAULIC HOSES, LINES AND FITTINGS Remove
2.5 1.0
66, 68 66
Replace 2406-02 HYDRAULIC OIL COOLER Remove Replace 7302-00 ECCENTRIC WEIGHT ASSEMBLY DRUMS Repair
1.0 4.5 4.5 33.0
66 66, 68 66, 68 31, 41, 66, 72
7302-01
Remove Replace
17.0 17.0 21.0
66, 68 66, 68 41, 66
7302-02
RESILIENT DRUM MOUNTS
Remove
Replace 7302-03 DRUM SCRAPERS Remove Replace
21.0 0.7 0.7
41, 66 66, 68 66, 68
0287-16
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0287
Table 1.
(1) (2)

REMARKS CODE
7319-00
WATER Remove SPRAY PIPES ASSEMBLY Replace
1.0 2.0 2.0 1.0 1.0 0.5
66, 68 66, 68, 72 66, 68, 72 66, 68 66, 68 66, 68
7319-01
WATER TANKS
Remove Replace
7319-02
WATER SPRAY PUMP
Remove Replace
7319-03
WATER SPRAY STRAINER/ SCREEN ASSEMBLY
Remove
Replace 7319-04 WATER SPRAY TUBES AND FITTINGS Remove
0.5 0.5
66, 68 66
Replace 7319-05 WATER SPRAY CHECK VALVE Remove
0.5 0.5
66 66, 68
Replace 7319-06 WATER TANK STRAINER ASSEMBLY Remove
0.5 0.5
66, 68 66
Replace 7319-07 DRAIN COCK AND TEE Remove Replace
0.5 1.0 1.0
66 66, 68, 72 66, 68, 72
0287-17
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0287
Table 1.
(1) (2)

REMARKS CODE
7319-08
SIDE DRAIN COCK AND VALVE
Remove
Replace
1.0
66, 68
Table 2.
TOOL OR TEST EQUIPMENT REF CODE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 MAINTENANCE CATEGORY H F F F F H H F H H H H H F H H H F F F
MAC Tools.
NATIONAL/NATO STOCK NUMBER 5120-01-531-6624 5120-01-533-2027 3940-01-294-0606 5340-01-336-2459 5120-01-030-1626 5120-01-531-9759 5120-01-437-0476
NOMENCLATURE ADAPTER, TORQUE WRENCH ALIGNING TOOL, ROTATING MEMBERS BEAM, HOISTING BRACKET, MOUNTING BUSHING DRIVER SET COMPRESSOR, PISTON RING COMPRESSOR, VALVE SEAT COVER GUIDE CROSSARM, MECHANICAL PULLER CUTTER, VALVE SEAT DIAL, SCALE DRIVER KIT, BEARING EXPANDER, PISTON RING EXTRACTOR, VALVE SEAT EXTRACTOR, VALVE SEAT FLOAT, METER, FLOW RATE INDICATION FORCING SCREW, MECHANICAL PULLER GAGE KIT, PRESSURE TESTING GAGE, DIFFERENTIAL, DIAL INDICATING GAGE, DIFFERENTIAL, DIAL INDICATING
TOOL NUMBER 9U-6282 4C-4562 6V6146 FT0120 1P0510 1U-6684 9U-6195 9U-6199
5120-01-435-7179 5110-01-533-9156 5355-01-531-7752 4910-01-032-3128 5120-01-531-9760 5120-01-531-4515 5120-01-531-4855 6680-01-531-6913 5120-01-531-6873 5120-01-362-8593 6685-01-476-1424 6685-01-476-1427
1U-9895 157-3720 8T3052 8S2241 1U-6683 9U-6396 9U-6397 4C8689 6V-2183 4C-4890 8T-0855 8T-0861
0287-18
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Table 2.
TOOL OR TEST EQUIPMENT REF CODE 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 MAINTENANCE CATEGORY F F F H H F H H F H H F F F F H H H H F F H H H F F H H
MAC Tools - Continued.

NATIONAL/NATO STOCK NUMBER
NOMENCLATURE GAGE, COMPRESSION GUIDE SCREW, HEX HEAD, 1/2X4X20 GUIDE SCREW, HEX HEAD, M24 X 3 HANDLE ASSEMBLY HEAD, MECHANICAL PULLER HOIST, WIRE ROPE HOSE, NOMETALLIC INDICATOR TOOL GP INDICATOR, POINT SET, GROUP INSERTER AND REMOVE INSERTER, SEAL INSERTER, SEAL INSERTER, SEAL INSERTER, SEAL INSTALLER, COVER INSTALLER, VALVE GUIDE INSTALLER, VALVE SEAT INSTALLER, VALVE SEAT INSTALLER, VALVE SEAT JACK, DOLLY TYPE LINK MULTIPLIER, TORQUE WRENCH PARTS KIT, ENGINE TIMING PIN, SHOULDER, HEADLE PIN, STRAIGHT, THREADED PLATE, AUTOMOTIVE, INDIVIDUAL PLATE, MECHANICAL PULLER PLIERS, RETAINING RING
TOOL NUMBER
2540-01-038-3863 5120-00-024-9718 3950-00-329-3309 4720-01-474-3134 5120-01-124-1737 4940-01-268-2200 5120-01-533-2028 5120-01-533-2796 5120-01-286-4205 2815-01-435-7172 5120-01-437-0474 5120-01-437-0477 5120-01-537-2247 5120-01-537-2248 5120-01-537-2250 5120-01-537-2252 4910-00-289-7233 4940-01-268-2201 5120-01-296-4235 2805-01-435-7177 5315-01-531-3550 5315-01-435-7176 8345-01-294-0560 5120-01-435-7180 5120-01-534-2532
9S3095 5F-7347 144 9X2350 8T0455 9U7400 147-3497 141-3028 1U-6438 9U-6205 9U-6210 9U-6200 1U-9169 9U-6183 9U-6184 9U-6185 93660 1387573 6V-6080 9U6188 1503993 9U6238 9S7359 9U-6234 1P-1857
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Table 2.
TOOL OR TEST EQUIPMENT REF CODE 49 50 51 52 53 54 55 56 57 58 MAINTENANCE CATEGORY H H F F F H F F F F
MAC Tools - Continued.

NATIONAL/NATO STOCK NUMBER 5120-01-484-9391 5120-01-534-1729 5340-01-485-0959 5180-01-124-1903 2930-01-124-1739 5110-01-352-1337 5180-01-533-3638 5905-01-127-5428 5120-01-289-4310 5120-01-367-3539
NOMENCLATURE PLIERS, RETAINING RING PLIERS, RETAINING RING PLUG, ASSEMBLY, SEALING PULLER KIT, UNIVERSAL PUMP, GP COOL SYS REAMER, CYLINDER RIDGE REMOVER KIT, BOLT RESISTOR, THERMAL RIVETER, BLIND, HAND SCREWDRIVER ATTACHMENT, SOCKET WRENCH SOCKET, WRENCH, FACE SPANNER SPACER, PLATE SPACER, RING STAND SUBASSEMBLY, MAINTENANCE, AUTOMOTIVE ENGINE STRIP, METAL TENSIOMETER, DIAL INDICATION TEST SET, ELECTRONIC SYSTEMS (LINT77499) TOOL KIT, GENERAL MECHANIC'S: AUTOMOTIVE(LINT28688) TOOL OUTFIT, HYDRAULIC TOOL SET, FRS VACUUM PUMP, RECIPROCATING WRENCH, RACHET WRENCH, SPANNER WRENCH, TORQUE, 0-300 IN-LB
TOOL NUMBER 1P-1860 5P-5197 4C-4892 1U7600 9S8140 8S-2269 171-1085 4C6500 5120-01-289-4310 FTX55E
59 60 61 62
H H H F
5120-01-533-2795 5365-01-531-4529 5356-01-531-3914 4910-01-531-4019
184-7409 9U6198 9U6220 8S6691
63 64 65
H F F
9515-01-532-4115 6635-01-093-3710 6625-01-352-3060
9U6281 6673 A3185552
66
5180-01-548-7634
PD484
67 68 69 70 71 72
F F F H F F
4940-01-036-5784 4940-01-533-1621 4310-01-532-0363 5120-01-123-5881 5120-01-531-5082 5120-00-776-1841
1322IE6850 SC 4940-95-E42 1950761 8H-0684 1P-2852 9171561
0287-20
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0287
Table 3.
REMARK CODE
Remarks for the CB534 Roller.

REMARKS
A B C
SRA or Dealer for repair. Limited repair by replacement of cartridge only. Component parts, cuh as terminals and wires may be replaced or repaired by Field Level Maintenance. The assembly as a whole must be replaced by Field Support Maintenance. Propel control lever handle must be disassembled by Field Maintenance to replace on/off switch. Operator adds fluids only. Field Maintenance drains and fills assembly.
D E
END OF WORK PACKAGE
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0288
FIELD MAINTENANCE EXPENDABLE/DURABLE ITEMS LIST
INTRODUCTION Scope This work package lists expendable and durable items that you will need to operate and maintain the Roller, Motorized, Vibrating Tandem Steel Drum. This list is for information only and is not authority to requisition the listed items. These items are authorized to you by CTA 50-970, Expendable/Durable Items (Except Medical, Class V Repair Parts, and Heraldic Items), CTA 50-909, Field and Garrison Furnishings and Equipment or CTA 8-100, Army Medical Department Expendable/Durable Items. Explanation of Columns in the Expendable/Durable Items List Column (1) - Item No. This number is assigned to the entry in the list and is referenced in the narrative instructions to identify the item (e.g., Use brake fluid (WP 0098, Item 5)). Column (2) - Level. This column identifies the lowest level of maintenance that requires the listed item (F = Maintainer or ASB, D = Depot). Column (3) - National Stock Number (NSN). This is the NSN assigned to the item which you can use to requisition it. Column (4) - Item Name, Description, Part Number/(CAGEC). This column provides the other information you need to identify the item. The last line below the description is the part number and the Commercial and Government Entity Code (CAGEC) (in parentheses). Column (5) - U/I. Unit of Issue (U/I) code shows the physical measurement or count of an item, such as gallon, dozen, gross, etc.
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Table 1. (1) ITEM NO. (2) LEVEL (3)
Expendable/Durable Supplies and Materials List (4) ITEM NAME, DESCRIPTION, PART NUMBER/ (CAGEC) ADHESIVE (5) U/I
NATIONAL STOCK NUMBER (NSN)
8040-01-043-7537
ADHESIVE 49661 (05972) ADHESIVE, LOCKTITE 242
LB
8040-01-250-3969
ADHESIVE 242 (05972) ADHESIVE, GASKET CEMENT
OZ
8040-01-038-5043
ADHESIVE, GASKET CEMENT 5H2471 (11083) ADHESIVE, SILICONE RUBBER
CN
8040-00-142-9823
ADHESIVE, SILICONE RUBBER MIL-A-46106 (81349)
KIT
ANTIFREEZE: PERMANENT, ETHYLENE GLYCOL, INHIBITED 5 F 6850-01-464-9125 ANTIFREEZE: PERMANENT, ETHYLENE GLYCOL, INHIBITED 1 Gallon Bottle A-A-52624 (58536) ANTIFREEZE: PERMANENT, ETHYLENE GLYCOL, INHIBITED 5 Gallon Can MILA46153 (81349) ANTIFREEZE: PERMANENT, ETHYLENE GLYCOL, INHIBITED Inhibited 55 Gallon Drum A-A-52624 (58536) ANTISEIZE COMPOUND 8 F 8030-00-251-3980 ANTISEIZE COMPOUND C5-A (73165) BARRIER MAT 9 F 8135-00-292-9719 BARRIER MAT 300 Foot Roll MIL-B-121 (81349) RO LB GL
6850-00-181-7933
CN
6850-01-441-3223
DR
BRUSH, CLEANING, TOOL AND PARTS 10 F 7920-00-205-2401 BRUSH, CLEANING, TOOL AND PARTS 7920-00-205-2401 (80244) BRUSH, NYLON 11 F 7920-00-056-5525 BRUSH, NYLON A408848-2 (80020) EA EA
CAP SET, PROTECTIVE, DUST AND MOISTURE SEAL 12 F 5340-00-450-5718 CAP SET, PROTECTIVE, DUST AND MOISTURE SEAL 109354405 (19207) EA
0288-2
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Table 1. Expendable/Durable Supplies and Materials List - Continued (1) ITEM NO. (2) LEVEL (3) NATIONAL STOCK NUMBER (NSN) (4) ITEM NAME, DESCRIPTION, PART NUMBER/ (CAGEC) (5) U/I
CLEANING COMPOUND, SOLVENT 13 14 15 F F F 6850-01-474-2318 6850-01-474-2320 6850-01-474-2321 CLEANING COMPOUND, SOLVENT 1 Gallon Bottle MIL-PRF-680 (81349) CLEANING COMPOUND, SOLVENT 5 Gallon Can MIL-PRF-680 (81349) CLEANING COMPOUND, SOLVENT 55 Gallon Drum MIL-PRF-680 (81349) CLOTH, CLEANING 16 F 7920-00-044-9281 CLOTH, CLEANING 10 Pound Bale MIRACLEWIPEL001 (51200) DETERGENT, GP LIQUID 17 F 7930-00-282-9699 DETERGENT, GP LIQUID WS A 1 Gallon Can 7930-00-28/2-9699 (83421) DIESEL FUEL OIL DF1 B 18 19 20 F F F 9140-00-286-5286 9140-00-286-5287 9140-00-286-5288 DIESEL FUEL OIL DF1 B Bulk ASTM D 975 (81346) DIESEL FUEL OIL DF1 B 5 Gallon Can ASTM D 975 (81346) DIESEL FUEL OIL DF1 B 55 Gallon Drum ASTM D 975 (81346) DIESEL FUEL OIL DF2 B 21 22 23 F F F 9140-00-286-5294 9140-00-286-5295 9140-00-286-5296 DIESEL FUEL OIL DF2 B Bulk ASTM D 975 (81346) DIESEL FUEL OIL DF2 B 5 Gallon Can ASTM D 975 (81346) DIESEL FUEL OIL DF2 B 55 Gallon Drum ASTM D 975 (81346) GL CN DR GL CN DR BX BX GL BX DR
GREASE, AUTOMOTIVE AND ARTILLERY 24 F 9150-01-197-7688 GREASE, AUTOMOTIVE AND ARTILLERY 2-1/4 Ounce Tube M-10924-A (81349) GREASE AUTOMOTIVE A 1-3/4 Pound Can M-10924-C (81349) GREASE AUTOMOTIVE A 35 Pound Can M-10924-E (81349) GREASE AUTOMOTIVE A 14 Ounce Cartridge M-10924-B (81349) TU
25 26 27
F F F
9150-01-197-7690 9150-01-197-7692 9150-01-197-7693
CN CN CA
0288-3
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GREASE MOLYBDENUM DISULFIDE 28 F 9150-01-326-5424 GREASE MOLYBDENUM D 1062K97 (39428) OZ
LUBRICATING OIL, ENGINE, 15W40 GRADE 29 F 9150-01-518-9477 LUBRICATING OIL, ENGINE, 15W40 GRADE 1 Gallon Can MIL-PRF-2104 (81349) LUBRICATING OIL, ENGINE, 15W40 GRADE 5 Gallon Can MIL-PRF-2104 (81349) LUBRICATING OIL, ENGINE, 15W40 GRADE 55 Gallon Drum MIL-PRF-2104 (81349) LUBRICATING OIL, GEAR 32 33 34 F F F 9150-01-553-8658 9150-01-558-6122 9150-01-553-5449 LUBRICATING OIL, GEAR 1 Quart Can SHC 630 (19135) LUBRICATING OIL, GEAR 5 Gallon Can 4C6767 (15958) LUBRICATING OIL, GEAR 55 Gallon Drum Syntho Gear EP 220 (15958) QT CO QT QT
30
9150-01-421-1424
CN
31
9150-01-421-1432
DR
LUBRICATING OIL, GEAR, 75W90 GRADE 35 F 9150-01-035-5390 LUBRICATING OIL, GEAR, 75W90 GRADE 1 Quart Can MIL-PRF-2105 (81349) LUBRICATING OIL, GEAR, 75W90 GRADE 5 Gallon Can MIL-PRF-2105 (81349) QT
36
9150-01-035-5391
GL
LUBRICATING OIL, GEAR, 80W-90 GRADE 37 38 F F 9150-01-035-5392 9150-00-001-9395 LUBRICATING OIL, GEA 1 Gallon Can MIL-PRF-2105 (81349) LUBRICATING OIL, GEAR, 80W-90 GRADE 5 Gallon Can MIL-PRF-2105 (81349) LUBRICATING OIL, GEAR, 80W-90 GRADE 55 Gallon Drum MIL-PRF-2105 (81349) QT CN
39
9150-01-035-5394
DR
0288-4
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LUBRICATING OIL, GENERAL PURPOSE 40 F 9150-00-836-8641 LUBRICATING OIL, GENERAL PURPOSE 1/2 Ounce Can MIL-PRF-32033 (81349) LUBRICATING OIL, GENERAL PURPOSE 1 Ounce Can MIL-PRF-32033 (81349) LUBRICATING OIL, GENERAL PURPOSE 4 Ounce Can MIL-PRF-32033 (81349) LUBRICATING OIL, GENERAL PURPOSE 16 Ounce Aerosol Can MIL-PRF-32033 (81349) LUBRICATING OIL, GENERAL PURPOSE 1 Quart Can MIL-PRF-32033 (81349) LUBRICATING OIL, GENERAL PURPOSE 1 Gallon Can MIL-PRF-32033 (81349) LUBRICATING OIL, GENERAL PURPOSE 5 Gallon Can MIL-PRF-32033 (81349) LUBRICATING OIL, GENERAL PURPOSE 55 Gallon Drum MIL-PRF-32033 (81349) DZ
41
9150-00-261-8146
OZ
42
9150-00-273-2389
CN
43
9150-00-458-0075
CN
44 45
F F
9150-00-231-6689 9150-00-231-9045
QT GL
46
9150-00-231-9062
CN
47
9150-00-281-2060
DR
LUBRICATING OIL ICE SUB ZERO 48 49 50 F F F 9150-00-402-4478 9150-00-402-2372 9150-00-491-7197 LUBRICATING OIL ICE SUB ZERO 1 Quart Can MIL-L-46167 (81349) LUBRICATING OIL ICE SUB ZERO 5 Gallon Can MIL-PRF-46167 (81349) LUBRICATING OIL ICE SUB ZERO 55 Gallon Drum MIL-PRF-46167 (81349) QT CN DR
LUBRICATING OIL MIL-L-2104 OE/, 10 GRADE 51 52 F F 9150-00-189-6727 9150-00-186-6668 LUBRICATING OIL MIL-L-2104 OE/ 1 Gallon Can MIL-PRF-2104 (81349) LUBRICATING OIL MIL-L-2104 OE/, 10 GRADE 5 Gallon Can MIL-PRF-2104 (81349) LUBRICATING OIL MIL-L-2104 OE/, 10 GRADE 55 Gallon Drum MIL-PRF-2104 (81349) QT CN
53
9150-00-191-2772
DR
0288-5
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LUBRICATING OIL MIL-L-2104 OE/, 30 GRADE 54 F 9150-00-186-6681 LUBRICATING OIL MIL-L-2104 OE/, 30 GRADE 1 Quart Can MIL-PRF-2104 (81349) LUBRICATING OIL MIL-L-2104 OE/, 30 GRADE 1 Gallon Can MIL-PRF-2104 (81349) QT
55
9150-00-188-9858
GL
LUBRICATING OIL MIL-L-46002, 1 GRADE 56 F 9150-00-889-3523 LUBRICATING OIL MIL-L-46002, 1 GRADE 1 Quart Can MIL-PRF-46002 (81349) LUBRICATING OIL MIL-L-46002, 1 GRADE 5 Gallon Can MIL-PRF-46002 (81349) LUBRICATING OIL MIL-L-46002, 1 GRADE 55 Gallon Drum MIL-PRF-46002 (81349) PETROLATUM TECHNICAL 59 F 9150-00-250-0926 PETROLATUM TECHNICAL 1.75 Pound Can 14P1 (82146) RAG, WIPING 60 F 7290-00-205-1711 RAG, WIPING 50 Pound Bale 7920-00-205-1711 (64067) SEALING COMPOUND 61 F 8030-00-063-7276 SEALING COMPOUND 1890 (71984) CN LB CN QT
57
9150-00-985-7293
CN
58
9150-00-407-0973
DR
SEALING COMPOUND, LOCTITE 271 62 F 8030-00-148-9833 SEALING COMPOUND, LOCTITE 271 LOCTITE 271 (71984) BX
SEALING COMPOUND, PIPE THREAD 63 F 8030-01-054-0740 SEALING COMPOUND, PIPE THREAD 392030 (61603) SOAP, LAUNDRY 64 F 7930-00-634-3935 SOAP, LAUNDRY CHIP-WO RO 200 Pound Container 7930-00-634-3935 (80244) SODIUM CARBONATE TECH 65 F 6810-00-233-1715 SODIUM CARBONATE TECH D458 (81346) DR DR BX
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Table 1. Expendable/Durable Supplies and Materials List - Continued (1) ITEM NO. (2) LEVEL (3) NATIONAL STOCK NUMBER (NSN) (4) ITEM NAME, DESCRIPTION, PART NUMBER/ (CAGEC) SOLDER TIN ALLOY (WI) 66 F 3439-00-555-4629 SOLDER, TIN ALLOY (WI) 1 Pound Spool QQ-S-571 (81348) LB (5) U/I
STRAP, TIEDOWN, ELECTRICAL 67 F 5975-00-903-2284 STRAP, TIEDOWN, ELECT. 4 Inch Length, Black Package of 100 MS3367-4-0 (96906) STRAP, TIEDOWN, ELECT. 6 Inch Length, Black Package of 100 MS3367-1-0 (96906) STRAP, TIEDOWN, ELECT 13.35 Inch Minimum Length, Black Package of 100 MS3367-2-1 (96906) TAG, MARKER 70 F 9905-00-537-8954 TAG, MARKER Pack of 50 9905-00-537-8954 (64067) TAPE PSA-CLEAR-BACKING 71 F 7510-00-663-3732 TAPE PSA-CLEAR-BACKING 351 (52170) TAPE, TEFLON 72 F 9320-01-053-8266 TAPE, TEFLON 1/4 IN X .020 (20484) TURBINE FUEL, AVIATION 73 F 9130-01-031-5816 TURBINE FUEL, AVIATI MILT 83133 GR JP8 (81349) GL RL RL EA EA
68
5975-00-984-6582
EA
69
5975-00-935-5946
EA
END OF WORK PACKAGE
0288-7/8 blank
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0289
FIELD MAINTENANCE TOOL IDENTIFICATION LIST
INTRODUCTION Scope This work package lists all common tools and supplements and special tools/fixtures needed to maintain the (Steel Wheel Roller). Most PM-SKOT products have lifetime warranties and replacement capabilities and are supported world-wide through PM-SKOT. The PM-SKOT implemented a Web-based tool replacement and warranty program in May 2005 for tools authorized in SKO. User may access the online program by first accessing the PM-SKOT Web site at https:// pmskot.army.mil and clicking on the Tool Replacement/Warranty banner. Explanation of Columns in the Tool Identification List Column (1) - Item No. This number is assigned to the entry in the list and is referenced in the initial setup to identify the item (e.g., Extractor (WP 0090, item 32)). Column (2) - Item Name. This column lists the item by noun nomenclature and other descriptive features (e.g., Gage, belt tension). Column (3) - National Stock Number (NSN). This is the National Stock Number (NSN) assigned to the item; use it to requisition the item. Column (4) - Part Number/(CAGEC). Indicates the primary number used by the manufacturer (individual, company, firm, corporation, or Government activity) which controls the design and characteristics of the item by means of its engineering drawings, specifications, standards, and inspection requirements to identify an item or range of items. The manufacturer's Commercial and Government Entity Code (CAGEC) is also included. Column (5) - Reference. This column identifies the authorizing supply catalog or RPSTL for items listed in this work package. Table 1. (1) (2) Tool Identification List. (3) NATIONAL STOCK NUMBER (NSN) 5120-01-533-2027 (4) PART NUMBER /(CAGEC) 4C-4562 (11083) 6V6146 (11083) FT0120 (11083) 1P0510 (11083) 9U-6199 (5)
ITEM NO. 1
ITEM NAME Aligning Tool, Rotating Members
REFERENCE
Beam, Hoisting
3940-01-294-0606
Bracket, Mounting
5340-01-336-2459
Bushing Driver Set
5120-01-030-1626
Cover Guide
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Table 1. (1) (2)
Tool Identification List - Continued. (3) NATIONAL STOCK NUMBER (NSN) 5130-01-477-9534 (4) PART NUMBER /(CAGEC) DBTBC129 (55719) DW235G (00BM9) 495 (0T115) 8T-0855 (11083) 8T-0861 (11083) (5)
ITEM NO. 6
ITEM NAME Drill Bit Set Standard
REFERENCE FRS SC 4940-95E42 FRS SC 4940-95E42 FRS SC 4940-95E42
Drill, Hand
5130-01-454-2840
Funnel, Flexible Spout
7240-00-559-7364
Gage, Differential, Dial Indicating
6685-01-476-1424
10
Gage, Differential, Dial Indicating
6685-01-476-1427
11 12
Gage, Compression Gloves, Rubber
8415-00-266-8675 MILDTL-32066 (81349) ANSI Z87.1 (80204) FRS SC 4940-95E42
13
Goggles
4240-00-269-7912
FRS SC 4940-95E42
14 15
Guide Screw, Hex Head, M24 x 3 Hoist, Wire Rope
3950-00-329-3309 144 (98131) 9U7400 (11083) 1U-6438 (11083) 9U-6205 (11083) 141-3028 (11083) 9U-6200 (11083) 93660 (36251)
16
Indicator, Point Set, Group
4940-01-268-2200
17
Inserter, Seal
5120-01-286-4205
18
Inserter, Seal
2815-01-435-7172
19
Inserter, Seal
5120-01-533-2796
20
Installer, Cover
5120-01-437-0477
21
Jack, Dolly Type
4910-00-289-7233
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Table 1. Tool Identification List - Continued. (1) (2) (3) NATIONAL STOCK NUMBER (NSN) 4940-01-268-2201 (4) PART NUMBER /(CAGEC) 1387573 (11083) 75-762 FRS SC 4940-95E42 (5)
ITEM NO. 22 Link
ITEM NAME
REFERENCE
23
Pan, Drain, 5 Gal Cap.
24
Pin, Straight, Threaded
5315-01-435-7176
9U6238 (11083) 9S7359 (11083) 4C-4892 (11083) 1U7600 (11083) 9S8140 (11083) 171-1085 (11083) 4C6500 (11083) (80244) FTX55E (55719) 10106117 (18876) UL125 (70785) 8S6691 (11083) 6673 (33287) A3185552 (80063) FRS SC 4940-95E42 FRS SC 4940-95E42
25
Plate, Automotive, Individual
8345-01-294-0560
26
Plug Assembly, Sealing
5340-01-485-0959
27
Puller Kit, Universal
5180-01-124-1903
28
Pump, GP Cool SYS
2930-01-124-1739
29
Remover Kit, Bolt
5180-01-533-3638
30
Resistor, Thermal
5905-01-127-5428
31 32
Riveter, Blind, Hand Screwdriver Attachment, Socket Wrench Soldering Gun
5120-01-289-4310 5120-01-367-3539
33
3439-00-808-0528
34
Soldering Torch
3439-01-244-3421
35
Stand Subassembly, Maintenance, Automotive Engine Tensiometer, Dial Indication
4910-01-531-4019
36
6635-01-093-3710
37
Test Set, Electronic Systems (LINT77499)
6625-01-352-3060
0289-3
TM 5-3895-379-23-2
0289
Table 1. (1) (2)
Tool Identification List - Continued. (3) NATIONAL STOCK NUMBER (NSN) 6630-00-105-1418 (4) PART NUMBER /(CAGEC) 137584LO (3N5H5) PD484 (19200) DMC986 (F7391) 9171561 (18876) AS28431 (81343) AS28431 (81343) AS28431 (81343) FRS SC 4940-95E42 FRS SC 4940-95E42 FRS SC 4940-95E42 FRS SC 4940-95E42 (5)
ITEM NO. 38
ITEM NAME Tester, Electrolyte and Antifreeze
REFERENCE FRS SC 4940-95E42
39
Tool Kit, General Mechanic's: Automotive Tool Kit, Electrical Contact
5180-01-548-7634
40
5180-00-876-9336
41
Wrench, Torque, 0-300 in-lb
5120-00-776-1841
42
Wrench, Torque, 20-100 ft-lb
5120-01-400-0237
43
5120-01-400-0239
44
5120-01-400-0319
END OF WORK PACKAGE
0289-4
TM 5-3895-379-23-2
0290
FIELD MAINTENANCE MANDATORY REPLACEMENT PARTS LIST
INTRODUCTION General This work package is a cross-reference of item numbers to part numbers and is included for that purpose only. Explanation of Columns in the Mandatory Replacement Parts List The five table columns of have the following headings: Column (1) - Item No. This number is assigned to the entry in Table K-1 for cross-referencing to the part number. The item number appears in the "Materials/Parts" listing of each maintenance procedure. Column (2) - Part Number/(CAGEC). This is the primary number used by the manufacturer, which controls the design and characteristics of the item by means of its engineering drawings, specifications, standards, and inspection requirements, to identify an item or range of items. Column (3) - National Stock Number (NSN). When available, the national stock number is listed. Column (4) - Nomenclature. This is the name given to the item in the "Materials/Parts" listing and in the text of the maintenance procedure. Column (5) - Qty. Refer to the Materials/Parts section in the Initial Setup of the Maintenance Task for required quantities of item needed.
Table 1. MANDATORY REPLACEMENT PARTS LIST
ITEM NO. 1 PART NUMBER /(CAGEC) 1-16-23 (72447) 1001821 (1EFH8) 1013741 (11083) 1013743 (11083) 1071723 (11083) 108-0671 (11083) 108-0672 (11083) 1117052 (11083) 1206 NATIONAL STOCK NUMBER (NSN) 5330-00-069-5433 NOMENCLATURE Packing, Preformed QTY A/R
5310-01-352-2753
Lockwasher
A/R
5330-01-473-8725
Packing, Preformed
A/R
5330-01-428-9234
Seal
A/R
5330-01-471-5082
Gasket
A/R
2940-01-453-9515
Filter Element, Primary
A/R
2940-01-453-9526
Filter Element, Secondary
A/R
5331-01-474-2260
O-Ring
A/R
5310-00-187-7070
Lockwasher
A/R
0290-1
03/15/2011 Rel(1.8) root(mrplwp) wpno(S00008)
TM 5-3895-379-23-2
0290
Table 1. MANDATORY REPLACEMENT PARTS LIST - Continued

ITEM NO. PART NUMBER /(CAGEC) (U1453) 10 131-2509 ITEM 6 (11083) 1383097 (11083) 1383100 (11083) 1407515 (11083) 1408718 (11083) 1416188 (11083) 1422426 (11083) 16-886 (55841) 1612161 (11083) 1620236 (11083) 1622088 (11083) 172-4844 (11083) 1930499 (F0774) 1H3244 (11083) 2-018N674-70 (2697) 200-6374 (11083) 2018745 (11083) 207126 (81495) 5310-01-449-6353 Locknut A/R NATIONAL STOCK NUMBER (NSN) NOMENCLATURE QTY
11
Packing, Preformed
A/R
12
2910-01-454-2190
Seal
A/R
13
5331-01-471-4712
O-Ring
A/R
14
5310-01-471-4640
Washer
A/R
15
5330-01-471-5561
Seal
A/R
16
5330-01-531-3538
Gasket
A/R
17
5310-00-905-5454
Lockwasher
A/R
18
5331-01-479-1493
O-Ring
A/R
19
5325-01-471-5434
Ring
A/R
20
5330-01-529-5584
Gasket
A/R
21
5331-01-505-5508
O-Ring
A/R
22
O-Ring
A/R
23
5310-01-062-9898
Lockwasher
A/R
24
5331-01-058-4030
O-Ring
A/R
25
5330-01-505-7382
Gasket
A/R
26
5330-01-517-3400
Gasket
A/R
27
5331-01-282-9507
O-Ring
A/R
0290-2
TM 5-3895-379-23-2
0290

ITEM NO. 28 PART NUMBER /(CAGEC) 207133 (81495) 2318A664 (13446) 2411154 (13446) 2415928 (13446) 2415A053 (13446) 2415H201 (13446) 2630420 (F0774) 26560916 (13446) 273924 (11083) 28-804-1 (18108) 2K4973 (11083) 2K8199 (11083) 2M-9780 (11083) 2P1279 (11083) 310249 (11083) 337291 (11083) 33811112 (13446) 33811115 (13446) 33813131 NATIONAL STOCK NUMBER (NSN) 5331-01-268-6812 Wear Ring NOMENCLATURE QTY A/R
29
5310-01-425-5410
Locknut
A/R
30
5310-01-425-6199
Washer
A/R
31
5310-01-425-5408
Washer
A/R
32
5331-01-336-3148
Packing, Preformed
A/R
33
5331-01-336-3149
O-Ring
A/R
34
O-Ring
A/R
35
Packing, Preformed
A/R
36
5310-01-471-4750
Locknut
A/R
37
O-Ring
A/R
38
5310-01-058-8071
Locknut
A/R
39
5331-00-937-5155
O-Ring
A/R
40
5331-00-939-0687
O-Ring
A/R
41
5310-00-186-9550
Locknut
A/R
42
4730-01-471-3774
Locknut
A/R
43
5340-01-023-2529
Rivet
A/R
44
4730-01-099-0189
Sleeve
A/R
45
4730-01-098-6757
Bushing
A/R
46
5330-01-235-6518
Gasket
A/R
0290-3
TM 5-3895-379-23-2
0290

ITEM NO. PART NUMBER /(CAGEC) (13446) 47 3681A032 (13446) 3681P019 (13446) 3681T018 (13446) 36832137 (13446) 36832138 (13446) 36832144 (13446) 3683D006 (13446) 36843154 (13446) 3684N009 (13446) 36851123 (13446) 3685F005 (13446) 3686289 (13446) 3687H005 (11083) 3687M018 (13446) 3687W008 (13446) 3687W017 (13446) 36885008 (13446) 3688C018 (13446) 5330-01-428-8818 Gasket A/R NATIONAL STOCK NUMBER (NSN) NOMENCLATURE QTY
48
5330-01-441-3517
Gasket
A/R
49
5330-01-423-6483
Gasket
A/R
50
5330-01-551-3991
Gasket
A/R
51
5330-01-388-7882
Gasket
A/R
52
5330-01-441-4973
Gasket
A/R
53
5330-01-276-5830
Gasket
A/R
54
5330-01-398-6356
Gasket
A/R
55
5330-01-434-0843
Gasket
A/R
56
5330-01-321-9741
Gasket
A/R
57
5330-01-208-5303
Gasket
A/R
58
5330-01-406-3768
Gasket
A/R
59
5330-01-428-9201
Gasket
A/R
60
5330-01-163-5635
Gasket
A/R
61
5330-01-336-3153
Gasket
A/R
62
Packing, Preformed
A/R
63
5330-01-272-1371
Gasket
A/R
64
5330-01-428-8814
Gasket
A/R
0290-4
TM 5-3895-379-23-2
0290

ITEM NO. 65 PART NUMBER /(CAGEC) 368H006 (13446) 3B4501 (11083) 3B4506 (11083) 3D-2824 (11083) 3E9860 (11083) 3E9862 (11083) 3G0361 (11083) 3J1907 (11083) 3K0360 (11083) 3K6060 (11083) 3L8187 (11083) 400-821-4490-41 (U1068) 48-014 (93784) 4B5324 (11083) 4B5423 (11083) 4H2494 (11083) 4J5477 (11083) 4W5359 (11083) 53-90B NATIONAL STOCK NUMBER (NSN) 5330-01-428-8825 Gasket NOMENCLATURE QTY A/R
66
5310-01-236-9974
Lockwasher
A/R
67
5310-00-514-6849
Lockwasher
A/R
68
5331-00-944-8281
O-Ring
A/R
69
5310-01-466-7712
Locknut
A/R
70
5310-01-471-5131
Locknut
A/R
71
5330-01-123-6209
Gasket
A/R
72
5331-01-333-6444
O-Ring
A/R
73
5331-00-948-6482
O-Ring
A/R
74
5310-01-113-4047
Locknut
A/R
75
5310-01-429-5217
Lockwasher
A/R
76
5330-99-876-0431
Gasket
A/R
77
Packing, Preformed
A/R
78
5310-01-063-0687
Lockwasher
A/R
79
5330-00-143-8713
Gasket
A/R
80
3120-00-900-5359
Bushing
A/R
81
5331-00-855-8059
O-Ring
A/R
82
5330-01-364-0427
Gasket
A/R
83
5331-01-296-2654
O-Ring
A/R
0290-5
TM 5-3895-379-23-2
0290

ITEM NO. PART NUMBER /(CAGEC) (93784) 84 53630B (93784) 536950 (11083) 54069 (29201) 566003 (13446) 568-014-4200-70 (77308) 586-014-4200-71 (77308) 5A3604 (11083) 5F9144 (11083) 5K9090 (11083) 5L4758 (78640) 5P6718 (11083) 676085 (11083) 676900 (11083) 68606 (11083) 6D-0047 (11083) 6I0298 (11083) 6I2604 (11083) 6R-0552 (11083) Backup Ring A/R NATIONAL STOCK NUMBER (NSN) NOMENCLATURE QTY
85
5330-01-471-4786
Seal
A/R
86
5330-01-092-6540
Gasket
A/R
87
4730-01-185-2132
Damper
A/R
88
5331-01-580-6583
O-Ring
A/R
89
5331-00-580-6583
O-Ring
A/R
90
5306-01-429-3088
Packing, Preformed
A/R
91
5331-00-591-3112
O-Ring
A/R
92
5330-01-438-1387
Gasket
A/R
93
5330-00-547-4068
Packing, Preformed
A/R
94
5331-01-181-4951
O-Ring
A/R
95
5130-01-425-4106
Washer, Flat
A/R
96
5365-01-471-5689
Bushing
A/R
97
5325-01-471-4795
Ring, Retaining
A/R
98
5310-01-471-3633
Locknut
A/R
99
5330-01-471-5770
Gasket
A/R
100
5330-01-429-1983
Gasket
A/R
101
5310-01-471-3776
Washer
A/R
0290-6
TM 5-3895-379-23-2
0290

ITEM NO. 102 PART NUMBER /(CAGEC) 6V7687 (11083) 6V8367 (11083) 7M8485 (11083) 7T2037 (11083) 7W2326 (11083) 809680 (11083) 8L2786 (78640) 8T-4224 (11083) 8T4896 (11083) 900462 (33827) 950826 (11083) 9526843 (11083) 990492 (11083) 9F5644 (11083) 9H6454 (11083) 9L9814 (11083) 9X7457 (11083) AD64BSLF (7707) NATIONAL STOCK NUMBER (NSN) 5310-01-364-6645 Locknut NOMENCLATURE QTY A/R
103
5310-01-181-2505
Lockwasher
A/R
104
5330-00-930-9407
O-Ring
A/R
105
5330-01-209-8731
Gasket
A/R
106
2910-01-462-8885
Filter, Oil
A/R
107
5330-00-464-7347
Packing, Preformed
A/R
108
5331-00-973-8301
O-Ring
A/R
109
5310-01-359-8806
Lockwasher
A/R
110
5310-01-286-6079
Lockwasher
A/R
111
5310-01-053-6999
Locknut
A/R
112
5310-01-454-9354
Lockwasher
A/R
113
5310-01-454-1330
Gasket
A/R
114
5310-01-439-7139
Locknut
A/R
115
5310-01-063-5822
Lockwasher
A/R
116
5330-00-848-9950
Gasket
A/R
117
5310-01-061-7921
Locknut
A/R
118
5325-01-530-6547
Seal
A/R
119
5320-01-264-8505
Rivet
A/R
0290-7
TM 5-3895-379-23-2
0290

ITEM NO. 120 PART NUMBER /(CAGEC) ASTM D2000 M6BG910 (81346) CB534-060 (11083) M83248/2-214 (81349) MS21044N08 (80205) MS35333-38 (80205) MS35333-39 (80205) MS35333-47 (80205) MS35335-31 (96906) MS35335-32 (80205) MS35338-44 (80205) N0674 2-012 (2697) PS500016-GP (77122) U5MK0600 (13446) NATIONAL STOCK NUMBER (NSN) 5331-01-049-1292 O-Ring NOMENCLATURE QTY A/R
121
Gasket
A/R
122
5331-01-017-6535
O-Ring
A/R
123
5310-00-811-3494
Locknut
A/R
124
5310-00-559-0070
Lockwasher
A/R
125
5310-00-576-5752
Lockwasher
A/R
126
5310-00-550-3714
Lockwasher
A/R
127
5310-00-596-7693
Lockwasher
A/R
128
5310-00-596-7691
Washer, Lock
A/R
129
5310-00-582-5965
Washer, Lock
A/R
130
5331-00-579-6495
O-Ring
A/R
131
5310-01-187-6105
Push On Nut
A/R
132
5330-01-439-3259
Gasket
A/R
END OF WORK PACKAGE
0290-8
TM 5-3895-379-23-2
0291
FIELD MAINTENANCE SCHEMATICS
GENERAL 1. 2. 3. 4. For CB534B electrical system schematics, refer to Figure 1 (Sheets 1 to 9), and (Volume 1, WP 0004). For CB534B hydraulic system schematics, refer to Figure 2 (Sheets 1 and 2). Simplified schematics for use with troubleshooting procedures are located in (Volume 1, WP 0004). CB534C schematics are provided as foldouts at the end of this manual.
ELECTRICAL SYSTEM
NOTE
This organizational relationship of electrical schematics is provided for reference.
SHEET 2 OF 9
SHEET 3 OF 9
SHEET 4 OF 9
SHEET 5 OF 9
SHEET 6 OF 9
SHEET 7 OF 9
SHEET 8 OF 9
SHEET 9 OF 9
D0001SWR
Figure 1.
Electrical Schematic.
0291-1
03/15/2011 Rel(1.8) root(genwp) wpno(D00001)
TM 5-3895-379-23-2
0291
ELECTRICAL SYSTEM - Continued
D0002SWR
Figure 2. Electrical Schematic.
0291-2
TM 5-3895-379-23-2
0291
D0003SWR
Figure 3.
0291-3
TM 5-3895-379-23-2
0291
DOOO4SWR
Figure 4. Electrical Schematic. 0291-4

TM 5-3895-379-23-2
0291
D0005SWR
Figure 5.
0291-5
TM 5-3895-379-23-2
0291
D0006SWR
Figure 6. Electrical Schematic.
0291-6
TM 5-3895-379-23-2
0291
D0007SWR
Figure 7.
Electrical Schematic. 0291-7

TM 5-3895-379-23-2
0291
D0008SWR
Figure 8. Electrical Schematic. 0291-8
TM 5-3895-379-23-2
0291
D0009SWR
Figure 9.
TM 5-3895-379-23-2
0291
HYDRAULIC SYSTEM
D0010SWR
Figure 10.
TM 5-3895-379-23-2
0291
HYDRAULIC SYSTEM - Continued
D0011SWR
Figure 11. END OF WORK PACKAGE
0291-11/12 blank
TM 5-3895-379-23-2
INDEX
Subject WP Sequence No.-Page No.
A
AIR CLEANER CAP REPLACEMENT.................................................................................... AIR CLEANER ELEMENTS AND AIR CLEANER ASSEMBLY REPLACEMENT.................. AIR CLEANER SERVICE INDICATOR REPLACEMENT....................................................... AIR CLEANER SUPPORT ASSEMBLY REPLACEMENT...................................................... ALTERNATOR BRACKET REPLACEMENT.......................................................................... ALTERNATOR CIRCUIT BREAKER REPLACEMENT........................................................... ALTERNATOR INDICATOR IS ON......................................................................................... ALTERNATOR IS NOISY........................................................................................................ ALTERNATOR LIGHT REPLACEMENT................................................................................. ALTERNATOR REPLACEMENT............................................................................................ ALTERNATOR TEST.............................................................................................................. AMPLITUDE SELECT SWITCH REPLACEMENT.................................................................. WP 0117-1 WP 0118-1 WP 0120-1 WP 0119-1 WP 0150-1 WP 0151-1 WP 0023-1 WP 0024-1 WP 0176-1 WP 0148-1 WP 0149-1 WP 0160-1
B
BACKUP ALARM DOES NOT WORK.................................................................................... BACKUP ALARM REPLACEMENT........................................................................................ BACKUP ALARM SENDING UNIT REPLACEMENT.............................................................. BATTERY CABLE REPLACEMENT....................................................................................... BATTERY DISCONNECT SWITCH REPLACEMENT............................................................ BATTERY MAINTENANCE..................................................................................................... BRAKE CONTROL VALVE COIL REPLACEMENT................................................................ BRAKE CONTROL VALVE REPAIR....................................................................................... BRAKE CONTROL VALVE REPLACEMENT......................................................................... BRAKE HOSES, LINES, AND FITTINGS REPLACEMENT................................................... WP 0025-1 WP 0187-1 WP 0181-1 WP 0192-1 WP 0191-1 WP 0190-1 WP 0220-1 WP 0217-1 WP 0216-1 WP 0218-1
C
COLD START HEATER REPLACEMENT.............................................................................. COOLANT IN ENGINE OIL/ENGINE OIL IN COOLANT........................................................ COOLANT SYSTEM PRESSURE TEST................................................................................ COOLANT SYSTEM SERVICE............................................................................................... CRANKSHAFT FRONT OIL SEAL REPLACEMENT.............................................................. CRANKSHAFT PULLEY REPLACEMENT............................................................................. CRANKSHAFT REAR OIL SEAL REPLACEMENT................................................................ CYLINDER HEAD REPLACEMENT....................................................................................... WP 0130-1 WP 0006-1 WP 0135-1 WP 0139-1 WP 0084-1 WP 0083-1 WP 0085-1 WP 0082-1
D
DATA PLATE AND DECAL REPLACEMENT......................................................................... DECONTAMINATION KIT BRACKET REPLACEMENT......................................................... DOOR ASSEMBLY MAINTENANCE...................................................................................... DRAIN COCK AND TEE REPLACEMENT............................................................................. DRUM ASSEMBLY REPAIR................................................................................................... DRUM ASSEMBLY REPLACEMENT..................................................................................... DRUM SCRAPER REPLACEMENT....................................................................................... DRUM SELECT SWITCH REPLACEMENT............................................................................ WP 0249-1 WP 0230-1 WP 0231-1 WP 0277-1 WP 0264-1 WP 0265-1 WP 0263-1 WP 0158-1
E
ELECTRICAL GENERAL MAINTENANCE INSTRUCTIONS................................................. ENGINE ASSEMBLY REPLACEMENT.................................................................................. WP 0280-1 WP 0078-1
Index-1
03/15/2011 Rel(1.8) root(aindx) wpno(INDEX)
TM 5-3895-379-23-2
INDEX - Continued
E
ENGINE BLOCK HEATING ELEMENT REPLACEMENT....................................................... ENGINE CRANKS BUT WILL NOT START OR IS HARD TO START................................... ENGINE EXHAUST SMOKES EXCESSIVELY (BLACK OR GRAY SMOKE)........................ ENGINE EXHAUST SMOKES EXCESSIVELY (WHITE OR BLUE SMOKE)......................... ENGINE IS SLUGGISH........................................................................................................... ENGINE IS UNUSUALLY NOISY............................................................................................ ENGINE IS USING MORE FUEL THAN USUAL.................................................................... ENGINE IS USING MORE OIL THAN USUAL........................................................................ ENGINE LIFTING PLATES REPLACEMENT......................................................................... ENGINE MISFIRES OR IDLES ROUGH................................................................................. ENGINE OIL COOLER LINES AND FITTINGS REPLACEMENT (CB534B).......................... ENGINE OIL COOLER LINES AND FITTINGS REPLACEMENT (CB534C)......................... ENGINE OIL COOLER REPLACEMENT................................................................................ ENGINE OIL FILLER REPLACEMENT................................................................................... ENGINE OIL PRESSURE IS LOW (WARNING LIGHT AND WARNING HORN ON)............ ENGINE OIL PRESSURE SWITCH REPLACEMENT............................................................ ENGINE OIL PUMP REPLACEMENT..................................................................................... ENGINE OIL SAMPLING VALVE AND FITTINGS REPLACEMENT...................................... ENGINE OIL SERVICE........................................................................................................... ENGINE OPERATING TEMPERATURE IS TOO HIGH (WARNING LIGHT AND WARNING HORN ON).............................................................................................................................. ENGINE START SWITCH REPLACEMENT........................................................................... ENGINE STARTS BUT WILL NOT KEEP RUNNING............................................................. ENGINE SURGES (SPEED CHANGES)................................................................................ ENGINE VIBRATES EXCESSIVELY...................................................................................... ENGINE WILL NOT STOP RUNNING.................................................................................... ENGINE WIRING HARNESS REPLACEMENT...................................................................... ENGINE, TURBO, DIESEL TESTS......................................................................................... EQUIPMENT DESCRIPTION AND DATA.............................................................................. EXHAUST MANIFOLD REPLACEMENT (CB534B)............................................................... EXHAUST MANIFOLD REPLACEMENT (CB534C)............................................................... EXPENDABLE/DURABLE ITEMS LIST.................................................................................. WP 0247-1 WP 0007-1 WP 0008-1 WP 0009-1 WP 0010-1 WP 0011-1 WP 0012-1 WP 0013-1 WP 0079-1 WP 0014-1 WP 0096-1 WP 0097-1 WP 0095-1 WP 0100-1 WP 0015-1 WP 0172-1 WP 0094-1 WP 0098-1 WP 0077-1 WP 0016-1 WP 0166-1 WP 0017-1 WP 0018-1 WP 0019-1 WP 0020-1 WP 0196-1 WP 0076-1 WP 0002-1 WP 0106-1 WP 0107-1 WP 0288-1
F
FAN ASSEMBLY AND GUARD REPLACEMENT.................................................................. FAN DRIVE HOUSING ASSEMBLY REPLACEMENT........................................................... FAN V-BELTS MAINTENANCE.............................................................................................. FEET PER MINUTE (FPM) METER DOES NOT WORK (CB534C)....................................... FLYWHEEL ASSEMBLY REPLACEMENT............................................................................. FLYWHEEL HOUSING REPLACEMENT............................................................................... FRONT AND REAR PROPEL GEARBOX SERVICE............................................................. FRONT AND REAR SUPPORTS (BUMPERS) REPLACEMENT........................................... FRONT ENGINE MOUNT REPLACEMENT........................................................................... FRONT HANDRAIL ASSEMBLY REPLACEMENT................................................................. FRONT WIRING HARNESS REPLACEMENT....................................................................... FUEL CAP ASSEMBLY REPAIR............................................................................................ FUEL FILTER ASSEMBLY REPLACEMENT.......................................................................... FUEL GAUGE DOES NOT WORK......................................................................................... FUEL INJECTION PUMP GEAR REPLACEMENT................................................................. WP 0146-1 WP 0145-1 WP 0147-1 WP 0026-1 WP 0086-1 WP 0087-1 WP 0213-1 WP 0229-1 WP 0080-1 WP 0233-1 WP 0197-1 WP 0126-1 WP 0127-1 WP 0027-1 WP 0111-1
Index-2
TM 5-3895-379-23-2
INDEX - Continued
F
FUEL INJECTION PUMP REPLACEMENT............................................................................ FUEL INJECTION PUMP TEST AND ADJUSTMENT (CB534B)........................................... FUEL INJECTOR AND NOZZLE REPLACEMENT (CB534B)................................................ FUEL INJECTOR AND NOZZLE REPLACEMENT (CB534C)................................................ FUEL INJECTOR AND NOZZLE TEST.................................................................................. FUEL INJECTOR LINES AND FITTINGS REPLACEMENT (CB534B).................................. FUEL INJECTOR LINES AND FITTINGS REPLACEMENT (CB534C).................................. FUEL LEVEL GAUGE REPLACEMENT................................................................................. FUEL LEVEL SENDING UNIT REPLACEMENT.................................................................... FUEL LIFT PUMP REPLACEMENT........................................................................................ FUEL SOLENOID RESISTOR REPLACEMENT.................................................................... FUEL/HYDRAULIC OIL TANK AND DRAIN LINES REPLACEMENT.................................... FUEL/HYDRAULIC OIL TANK DRAIN/FILL............................................................................ FUEL/WATER SEPARATOR ASSEMBLY SERVICE............................................................. FUNCTIONAL INDICATOR LIGHT ASSEMBLY REPLACEMENT......................................... FUSE AND FUSE HOLDER REPLACEMENT........................................................................ WP 0112-1 WP 0113-1 WP 0109-1 WP 0110-1 WP 0108-1 WP 0114-1 WP 0115-1 WP 0168-1 WP 0183-1 WP 0116-1 WP 0175-1 WP 0125-1 WP 0124-1 WP 0129-1 WP 0177-1 WP 0164-1
G
GAUGE ROD (DIPSTICK) TUBE ASSEMBLY REPLACEMENT............................................ GENERAL INFORMATION..................................................................................................... GENERAL MAINTENANCE INSTRUCTIONS........................................................................ GENERAL TORQUE LIMITS.................................................................................................. GENERAL WIRING REPAIR................................................................................................... GROUND CABLE REPLACEMENT........................................................................................ WP 0099-1 WP 0001-1 WP 0279-1 WP 0284-1 WP 0195-1 WP 0194-1
H
HORN ASSEMBLY REPLACEMENT...................................................................................... HORN DOES NOT WORK...................................................................................................... HORN SWITCH REPLACEMENT........................................................................................... HOURMETER PRESSURE SWITCH REPLACEMENT......................................................... HYDRAULIC FILTER ASSEMBLY REPLACEMENT.............................................................. HYDRAULIC HOSES, LINES, AND FITTINGS REPLACEMENT........................................... HYDRAULIC OIL CAP ASSEMBLY MAINTENANCE............................................................. HYDRAULIC OIL COOLER AND FAN SHROUD REPLACEMENT....................................... HYDRAULIC OIL FILTER REPLACEMENT............................................................................ HYDRAULIC OIL PRESSURE IS LOW (WARNING LIGHT AND WARNING HORN ON)..... HYDRAULIC OIL SAMPLING................................................................................................. HYDRAULIC OIL SAMPLING VALVE REPLACEMENT......................................................... HYDRAULIC OIL TEMPERATURE IS HIGH (WARNING LIGHT AND WARNING HORN ON).......................................................................................................................................... HYDRAULIC OIL TEMPERATURE SENSOR REPLACEMENT............................................. HYDRAULIC PUMP DRIVE REPLACEMENT........................................................................ HYDRAULIC STEERING CYLINDERS REPLACEMENT....................................................... HYDRAULIC VIBRATORY TESTS......................................................................................... WP 0189-1 WP 0028-1 WP 0188-1 WP 0171-1 WP 0258-1 WP 0259-1 WP 0261-1 WP 0260-1 WP 0257-1 WP 0038-1 WP 0256-1 WP 0255-1 WP 0039-1 WP 0185-1 WP 0212-1 WP 0225-1 WP 0250-1
I
IDLER GEAR AND HUB REPLACEMENT.............................................................................. ILLUSTRATED LIST OF MANUFACTURED ITEMS.............................................................. WP 0091-1 WP 0283-1
Index-3
TM 5-3895-379-23-2
INDEX - Continued
I
INSTRUMENT WIRING HARNESS REPLACEMENT............................................................ INTAKE MANIFOLD REPLACEMENT.................................................................................... INTERMITTENT WATER SPRAY TIMER REPLACEMENT................................................... INTRODUCTION FOR STANDARD TWO-LEVEL MAC......................................................... WP 0199-1 WP 0105-1 WP 0163-1 WP 0286-1
L
LEFT AND RIGHT-SIDE HANDRAIL ASSEMBLIES REPLACEMENT.................................. LIGHTS CIRCUIT BREAKER REPLACEMENT...................................................................... LOW IDLE SPEED ADJUSTMENT......................................................................................... LUBRICATION INSTRUCTIONS............................................................................................ WP 0232-1 WP 0173-1 WP 0132-1 WP 0282-1
M
MAIN RELAY REPLACEMENT............................................................................................... MAIN WIRING HARNESS REPLACEMENT (CB534B).......................................................... MAIN WIRING HARNESS REPLACEMENT (CB534C).......................................................... MAINTENANCE ALLOCATION CHART (MAC) SUMMARY.................................................. MANDATORY REPLACEMENT PARTS LIST........................................................................ MANUAL BRAKE RELEASE PUMP MAINTENANCE............................................................ MUFFLER AND TAILPIPE REPLACEMENT.......................................................................... WP 0154-1 WP 0200-1 WP 0201-1 WP 0287-1 WP 0290-1 WP 0219-1 WP 0134-1
N
NATO CONNECTOR REPLACEMENT.................................................................................. NO POWER TO ACCESSORIES WITH THE ENGINE RUNNING......................................... NO SPRAY AT EITHER DRUM WHEN WATER SPRAY SWITCH IS IN INTERMITTENT SPRAY POSITION.................................................................................................................. NOISY VIBRATORY MOTOR................................................................................................. NOZZLE SPRAY PATTERN IS INCONSISTENT................................................................... WP 0193-1 WP 0029-1 WP 0065-1 WP 0054-1 WP 0066-1
O
OIL FILTER HEAD ASSEMBLY REPLACEMENT (CB534B)................................................. OIL FILTER HEAD ASSEMBLY REPLACEMENT (CB534C)................................................. OIL LEAKING FROM EXHAUST............................................................................................. OIL PAN REPLACEMENT...................................................................................................... OIL STRAINER AND SUCTION TUBE REPLACEMENT....................................................... OPERATOR PLATFORM AND OPERATOR STATION REPLACEMENT............................. OPERATOR PLATFORM MOUNT REPLACEMENT.............................................................. WP 0102-1 WP 0103-1 WP 0021-1 WP 0093-1 WP 0104-1 WP 0236-1 WP 0238-1
P
PARKING BRAKE DOES NOT DISENGAGE WHEN PARKING BRAKE SWITCH IS PULLED UP............................................................................................................................................ PARKING BRAKE DOES NOT ENGAGE WHEN PARKING BRAKE SWITCH IS PUSHED DOWN..................................................................................................................................... PARKING BRAKE SWITCH REPLACEMENT........................................................................ POWER STEERING PUMP MAKES NOISE AND STEERING CYLINDER RODS DO NOT MOVE SMOOTHLY................................................................................................................. POWER STEERING PUMP REPLACEMENT........................................................................ PREPARATION FOR STORAGE AND SHIPMENT............................................................... WP 0044-1 WP 0045-1 WP 0156-1 WP 0040-1 WP 0223-1 WP 0281-1
Index-4
TM 5-3895-379-23-2
INDEX - Continued
P
PRESSURE OVERRIDE RELIEF (POR) VALVE PRESSURE TEST (CB534C).................... PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (QUARTERLY)............ PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (ANNUAL) .................. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (BIENNIAL)................. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION........ PRIMING FUEL SYSTEM....................................................................................................... PROPEL AND SPEED CONTROL VALVE REPAIR............................................................... PROPEL AND VIBRATORY VALVE TESTS AND ADJUSTMENTS...................................... PROPEL CONTROL LEVER ASSEMBLY MAINTENANCE................................................... PROPEL CONTROL LEVER TENSION ADJUSTMENT........................................................ PROPEL CONTROL LEVER VIBRATORY SYSTEM ENGAGEMENT STOPS ADJUSTMENT........................................................................................................................ PROPEL MOTOR AND TORQUE HUB REPLACEMENT...................................................... PROPEL MOTOR IS NOISY................................................................................................... PROPEL MOTOR LEAKS OIL................................................................................................ PROPEL SPEED RANGE SWITCH REPLACEMENT............................................................ PROPEL SYSTEM DOES NOT CHANGE SPEEDS WHEN PROPEL SPEED SWITCH IS MOVED................................................................................................................................... PROPEL SYSTEM ENGAGES VERY QUICKLY WHEN MAKING A SHIFT.......................... PROPEL SYSTEM ENGAGES VERY SLOWLY WHEN MAKING A SHIFT........................... PROPEL SYSTEM OPERATES IN FORWARD SPEEDS ONLY........................................... PROPEL SYSTEM OPERATES IN REVERSE SPEEDS ONLY............................................ WP 0210-1 WP 0072-1 WP 0073-1 WP 0074-1 WP 0071-1 WP 0128-1 WP 0211-1 WP 0209-1 WP 0206-1 WP 0208-1 WP 0207-1 WP 0205-1 WP 0046-1 WP 0047-1 WP 0161-1 WP 0048-1 WP 0049-1 WP 0050-1 WP 0051-1 WP 0052-1
R
RADIATOR ASSEMBLY REPAIR........................................................................................... RADIATOR ASSEMBLY REPLACEMENT.............................................................................. RADIATOR HOSES REPLACEMENT.................................................................................... RAISE/LOWER OPERATOR PLATFORM ASSEMBLY......................................................... REAR ENGINE MOUNT REPLACEMENT.............................................................................. REAR PROPEL MOTOR REPLACEMENT............................................................................. REAR WIRING HARNESS REPLACEMENT.......................................................................... REFERENCES........................................................................................................................ RELAY REPLACEMENT......................................................................................................... RESILIENT DRUM MOUNTS REPLACEMENT...................................................................... RIFLE MOUNTING BRACKET REPLACEMENT.................................................................... ROCKER ARM ASSEMBLY REPAIR..................................................................................... ROCKER SHAFT ASSEMBLY REPLACEMENT.................................................................... ROLLER DOES NOT TURN WHEN STEERING WHEEL IS TURNED.................................. ROLLER HAS NO ELECTRICAL POWER.............................................................................. ROLLER TURNS SLOWLY IN BOTH DIRECTIONS.............................................................. ROLLER WILL NOT MOVE WHEN PROPEL CONTROL LEVER IS OPERATED................ ROLLOVER PROTECTION STRUCTURE (ROPS) ASSEMBLY REPLACEMENT............... ROTATE LOCK REPLACEMENT........................................................................................... WP 0137-1 WP 0136-1 WP 0138-1 WP 0235-1 WP 0081-1 WP 0204-1 WP 0198-1 WP 0285-1 WP 0155-1 WP 0266-1 WP 0246-1 WP 0090-1 WP 0089-1 WP 0041-1 WP 0030-1 WP 0042-1 WP 0053-1 WP 0234-1 WP 0237-1
S
SCHEMATICS......................................................................................................................... SEAT ASSEMBLY REPAIR.................................................................................................... SEAT ASSEMBLY REPLACEMENT....................................................................................... WP 0291-1 WP 0242-1 WP 0241-1
Index-5
TM 5-3895-379-23-2
INDEX - Continued
S
SEAT BELT AND LANYARD REPLACEMENT....................................................................... SEAT SUSPENSION REPAIR................................................................................................ SEAT SUSPENSION REPLACEMENT................................................................................... SEPARATE AND CONNECT PROPEL MOTOR AND TORQUE HUB.................................. SEPARATE AND CONNECT VIBRATORY AND PROPEL PUMPS...................................... SERVICE METER REPLACEMENT....................................................................................... SERVICE UPON RECEIPT..................................................................................................... SIDE DRAIN COCK AND VALVE REPLACEMENT............................................................... SPRAY DOES NOT OCCUR IN EITHER DRUM WHEN WATER SPRAY SWITCH IS IN CONTINUOUS SPRAY POSITION......................................................................................... STARTER CONTINUES TO RUN AFTER ENGINE START SWITCH KEY IS RELEASED............................................................................................................................. STARTER DOES NOT TURN OR TURNS SLOWLY............................................................. STARTER RELAY SWITCH ASSEMBLY REPLACEMENT................................................... STARTER REPLACEMENT.................................................................................................... STARTER TURNS, BUT DOES NOT CRANK ENGINE......................................................... STARTING AID RESISTOR REPLACEMENT........................................................................ STARTING AID SWITCH DOES NOT WORK........................................................................ STARTING AID SWITCH REPLACEMENT............................................................................ STEERING CONTROL UNIT (SCU) MAINTENANCE............................................................ STEERING CYLINDER REPAIR............................................................................................. STEERING HOSES, LINES, AND FITTINGS REPLACEMENT............................................. STEERING PIVOT REPLACEMENT...................................................................................... STEERING WHEEL AND COLUMN REPLACEMENT........................................................... WP 0240-1 WP 0244-1 WP 0243-1 WP 0214-1 WP 0202-1 WP 0169-1 WP 0075-1 WP 0278-1 WP 0067-1 WP 0031-1 WP 0032-1 WP 0153-1 WP 0152-1 WP 0033-1 WP 0174-1 WP 0034-1 WP 0165-1 WP 0222-1 WP 0226-1 WP 0224-1 WP 0227-1 WP 0221-1
T
THEORY OF OPERATION..................................................................................................... THERMOSTAT HOUSING REPLACEMENT (CB534B)......................................................... THERMOSTAT HOUSING REPLACEMENT (CB534C)......................................................... THERMOSTAT MAINTENANCE (CB534B)............................................................................ THERMOSTAT MAINTENANCE (CB534C)............................................................................ THROTTLE CABLE REPLACEMENT/ADJUSTMENT (CB534B)........................................... THROTTLE CONTROL REPLACEMENT (CB534C).............................................................. THROTTLE CONTROL WILL NOT CHANGE ENGINE SPEED (CB534B)............................ TIMING GEAR CASE COVER REPLACEMENT.................................................................... TOO MUCH FORCE IS NEEDED TO TURN STEERING WHEEL......................................... TOOL IDENTIFICATION LIST................................................................................................. TOOLBOX REPLACEMENT................................................................................................... TROUBLESHOOTING INTRODUCTION................................................................................ TROUBLESHOOTING SYMPTOM INDEX............................................................................. TURBOCHARGER OIL LINES, HOSES, AND FITTINGS REPLACEMENT.......................... TURBOCHARGER REPAIR.................................................................................................... TURBOCHARGER REPLACEMENT...................................................................................... WP 0003-1 WP 0142-1 WP 0143-1 WP 0140-1 WP 0141-1 WP 0131-1 WP 0133-1 WP 0022-1 WP 0092-1 WP 0043-1 WP 0289-1 WP 0245-1 WP 0004-1 WP 0005-1 WP 0123-1 WP 0122-1 WP 0121-1
U
UNIVERSAL JOINT AND SHAFT MAINTENANCE................................................................ WP 0215-1
Index-6
TM 5-3895-379-23-2
INDEX - Continued
V
VALVE COVER AND BREATHER TUBE REPLACEMENT................................................... VALVE LASH (CLEARANCE) ADJUSTMENT........................................................................ VANDAL GUARD REPLACEMENT........................................................................................ VEHICLE CLASSIFICATION SIGN KIT REPLACEMENT...................................................... VIBRATION CONTROL SWITCH REPLACEMENT............................................................... VIBRATION DOES NOT OCCUR WHILE AMPLITUDE SELECT SWITCH IS SET TO HIGH PITCH...................................................................................................................................... VIBRATION DOES NOT OCCUR WHILE AMPLITUDE SELECT SWITCH IS SET TO LOW PITCH...................................................................................................................................... VIBRATION DOES NOT STOP WHEN TRAVEL STOPS...................................................... VIBRATION DOES NOT WORK IN FORWARD OR REVERSE TRAVEL............................. VIBRATION FREQUENCY START-UP IS SLOW, TIME LAG AFTER TRAVEL STARTS IS EXCESSIVE............................................................................................................................ VIBRATION OCCURS IN ONLY ONE DRUM......................................................................... VIBRATION ONLY OCCURS WHILE VIBRATION CONTROL SWITCH IS SET TO AUTOMATIC MODE................................................................................................................ VIBRATION ONLY OCCURS WHILE VIBRATION CONTROL SWITCH IS SET TO MANUAL MODE...................................................................................................................................... VIBRATION PUSH SWITCH REPLACEMENT....................................................................... VIBRATION SENSOR MAINTENANCE.................................................................................. VIBRATION STOPS TOO SOON BEFORE TRAVEL STOPS................................................ VIBRATIONS PER MINUTE (VPM) TACHOMETER AND FEET PER MINUTE (FPM) METER REPLACEMENT........................................................................................................ VIBRATIONS PER MINUTE (VPM) TACHOMETER DOES NOT WORK.............................. VIBRATORY AND PROPEL PUMPS REPLACEMENT.......................................................... VIBRATORY BEARING RESERVOIR SERVICE.................................................................... VIBRATORY CONTROL SOLENOID REPLACEMENT.......................................................... VIBRATORY COOLING/CONTROL VALVE REPAIR............................................................. VIBRATORY COOLING/CONTROL VALVE REPLACEMENT............................................... VIBRATORY MOTOR REPLACEMENT................................................................................. VIBRATORY SYSTEM ENGAGES HARSHLY....................................................................... WP 0101-1 WP 0088-1 WP 0239-1 WP 0248-1 WP 0159-1 WP 0055-1 WP 0056-1 WP 0057-1 WP 0058-1 WP 0059-1 WP 0060-1 WP 0061-1 WP 0062-1 WP 0167-1 WP 0184-1 WP 0063-1 WP 0170-1 WP 0035-1 WP 0203-1 WP 0262-1 WP 0251-1 WP 0253-1 WP 0254-1 WP 0252-1 WP 0064-1
W
WARNING AND INDICATOR LIGHTS DO NOT OPERATE................................................... WARNING HORN ASSEMBLY REPLACEMENT................................................................... WARNING LIGHTS ASSEMBLY REPLACEMENT................................................................. WATER CONSUMPTION UNEQUAL BETWEEN TANKS..................................................... WATER LEVEL GAUGE REPLACEMENT............................................................................. WATER PUMP REPLACEMENT............................................................................................ WATER SPRAY CHECK VALVE REPLACEMENT................................................................ WATER SPRAY OCCURS ON ONE DRUM ONLY................................................................ WATER SPRAY PIPE ASSEMBLY MAINTENANCE.............................................................. WATER SPRAY PRESSURE IS LOW.................................................................................... WATER SPRAY PUMP REPLACEMENT............................................................................... WATER SPRAY SCREEN ASSEMBLY MAINTENANCE (CB534C)...................................... WATER SPRAY STRAINER ASSEMBLY REPAIR................................................................ WATER SPRAY STRAINER ASSEMBLY REPLACEMENT................................................... WATER SPRAY SWITCH REPLACEMENT........................................................................... WATER SPRAY TUBES AND FITTINGS REPLACEMENT................................................... WP 0036-1 WP 0186-1 WP 0180-1 WP 0068-1 WP 0268-1 WP 0144-1 WP 0274-1 WP 0069-1 WP 0267-1 WP 0070-1 WP 0270-1 WP 0275-1 WP 0271-1 WP 0272-1 WP 0157-1 WP 0273-1
Index-7
TM 5-3895-379-23-2
INDEX - Continued
W
WATER TANK REPLACEMENT............................................................................................. WATER TANK STRAINER ASSEMBLY REPLACEMENT..................................................... WATER TEMPERATURE SENDING UNIT REPLACEMENT................................................. WORK LIGHT ASSEMBLY MAINTENANCE.......................................................................... WORK LIGHT BULB REPLACEMENT................................................................................... WORK LIGHT CONTROL SWITCH REPLACEMENT............................................................ WORK LIGHTS AND GAUGE LIGHTS DO NOT OPERATE.................................................. WP 0269-1 WP 0276-1 WP 0182-1 WP 0178-1 WP 0179-1 WP 0162-1 WP 0037-1
Y
YOKE REPLACEMENT........................................................................................................... WP 0228-1
Index-8
RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS

For use of this form, see AR 25-30; the proponent agency is OAASA.
Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).
DATE Date you filled out this form.
TO (Forward to proponent of publication or form) (Include ZIP Code) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS
FROM (Activity and location) (Include ZIP Code)
Your mailing address
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE TITLE
TM Number
ITEM PAGE PARAGRAPH LINE FIGURE TABLE NO.
Date of the TM
Title of the TM
RECOMMENDED CHANGES AND REASON (Exact wording of recommended change must be given)
0007-3
Figure 2, Item 9 should show a lockwasher. Currently shows a flat washer. Cleaning and inspection, Step 6, reference to governor support pin (14) is wrong reference. Reference should be change to (12).
0018-2
SAMPLE
TYPED NAME, GRADE OR TITLE
TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION
SIGNATURE
Your Name
DA FORM 2028, FEB 74
Your Phone Number
Your Signature
APD V4.00
REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.
TO (Forward direct to addressee listed in publication) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS
DATE Date you filled out this form
Your Address
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION NUMBER DATE TITLE
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PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER
Date of the TM
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RECOMMENDED ACTION
TOTAL NO. REFERENCE FIGURE ITEM OF MAJOR NO. NO. NO. ITEMS SUPPORTED
SAMPLE
PART III REMARKS (Any general remarks, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)
Your Name
TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION
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APD V4.00

For use of this form, see AR 25-30; the proponent agency is OAASA
DATE
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS TITLE Field Maintenance Manual for Roller, Motorized, PUBLICATION/FORM NUMBER DATE Vibrating Tandem Steel Drums Caterpiller Model CB534B, and 04 September 2012 TM 5-3895-379-23-2 Caterpiller Model CB534C PAGE PARAGRAPH LINE FIGURE TABLE NO. RECOMMENDED CHANGES AND REASON
SIGNATURE
APD V4.00
DATE
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE Field Maintenance Manual for Roller, Motorized, PUBLICATION/FORM NUMBER DATE Vibrating Tandem Steel Drums Caterpiller Model CB534B, 04 September 2012 TM 5-3895-379-23-2 and Caterpiller Model CB534C PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER REFERENCE FIGURE ITEM NO. NO. NO. TOTAL NO. OF MAJOR ITEMS SUPPORTED
RECOMMENDED ACTION
PART III REMARKS (Any general remarks, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)
APD V4.00

DATE
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS TITLE Field Maintenance Manual for Roller, Motorized, PUBLICATION/FORM NUMBER DATE Vibrating Tandem Steel Drums Caterpiller Model CB534B, and 04 September 2012 TM 5-3895-379-23-2 Caterpiller Model CB534C ITEM PAGE PARAGRAPH LINE FIGURE TABLE NO. RECOMMENDED CHANGES AND REASON
SIGNATURE
APD V4.00
DATE
RECOMMENDED ACTION
PART III REMARKS (Any general remark, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)
APD V4.00

DATE
SIGNATURE
APD V4.00
DATE
RECOMMENDED ACTION
PART III REMARKS (Any general remarks, recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)
APD V4.00

DATE
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APD V4.00
DATE
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE Field Maintenance Manual for Roller, Motorized, PUBLICATION/FORM NUMBER DATE Vibrating Tandem Steel Drums Caterpiller Model CB534B, 04 September 2012 TM 5-3895-379-23-2 and Caterpiller Model CB534C PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER REFERENCE FIGURE ITEM NO. NO. NO. TOTAL NO. OF MAJOR ITEMS SUPPORTED RECOMMENDED ACTION
PART III REMARKS (Any general remarks, recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)
APD V4.00
By Order of the Secretary of the Army:
Official: JOYCE E. MORROW Administrative Assistant to the Secretary of the Army

1220602
RAYMOND T. ODIERNO General, United States Army Chief of Staff
Distribution: To be distributed in accordance with the initial distribution number (IDN) 256609 requirements for TM 5-3895-379-23-2.
THE METRIC SYSTEM AND EQUIVALENTS

Linear Measure 1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches 1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches 1 Kilometer = 1000 Meters = 0.621 Miles Weights 1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces 1 Kilogram = 1000 Grams = 2.2 Pounds 1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons Liquid Measure 1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 1 Liter = 1000 Milliliters = 33.82 Fluid Ounces 9/5 C +32 = F 5/9 (F - 32) = C 212 Fahrenheit is equivalent to 100 Celsius 90 Fahrenheit is equivalent to 32.2 Celsius 32 Fahrenheit is equivalent to 0 Celsius Square Measure 1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches 1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet 1 Sq Kilometer = 1,000,000 Sq Meters = 0.0386 Sq Miles Cubic Measure 1 Cu Centimeter = 1,000 Cu Millimeters = 0.06 Cu Inches 1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet Temperature
APPROXIMATE CONVERSION FACTORS

To Change Inches Feet Yards Miles Sq Inches Sq Feet Sq Yards Sq Miles Acres Cubic Feet Cubic Yards Fluid Ounces Pints Quarts Gallons Ounces Pounds Short Tons Pound-Feet Pounds per Sq Inch Miles per Gallon Miles per Hour To Centimeters Meters Meters Kilometers Sq Centimeters Sq Meters Sq Meters Sq Kilometers Sq Hectometers Cubic Meters Cubic Meters Milliliters Liters Liters Liters Grams Kilograms Metric Tons Newton-Meters Kilopascals Multiply By 2.540 0.305 0.914 1.609 6.451 0.093 0.836 2.590 0.405 0.028 0.765 29.573 0.473 0.946 3.785 28.349 0.454 0.907 1.356 6.895 To Change Centimeters Meters Meters Kilometers Sq Centimeters Sq Meters Sq Meters Sq Kilometers Sq Hectometers Cubic Meters Cubic Meters Milliliters Liters Liters Liters Grams Kilograms Metric Tons Newton-Meters Kilopascals To Inches Feet Yards Miles Sq Inches Sq Feet Sq Yards Sq Miles Acres Cubic Feet Cubic Yards Fluid Ounces Pints Quarts Gallons Ounces Pounds Short Tons Pound-Feet Pounds per Sq Inch Miles per Gallon Miles per Hour Multiply By 0.394 3.280 1.094 0.621 0.155 10.764 1.196 0.386 2.471 35.315 1.308 0.034 2.113 1.057 0.264 0.035 2.205 1.102 0.738 0.145
Kilometers per Liter Kilometers per Hour
0.425 1.609
Kilometers per Liter Kilometers per Hour
2.354 0.621
PIN: 087181-000

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TECHNICAL MANUAL FIELD MAINTENANCE FOR

HEADQUARTERS, DEPARTMENT OF THE ARMY 04 SEPTEMBER 2012

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HYDRAULIC OIL SAMPLING...................................................................................................................... WP 0256 Figure 1. Hydraulic Oil Sampling......................................................................................................... 0256-3

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TOOL IDENTIFICATION LIST..................................................................................................................... WP 0289 Table 1. Tool Identification List........................................................................................................... 0289-1

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