087180

*TM 5-3895-379-23-1
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 4 September 2012

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TM 5-3895-379-23-1
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.
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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.
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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.
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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!
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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.
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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 manual 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 4 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 1 Front Cover (2 pages) a - i/j blank (10 pages) i - lxxiii/lxxiv blank (74 pages) Chapter 1 Title Page (2 pages) WP 0001 (6 pages) WP 0002 (6 pages) WP 0003 (20 pages) Chapter 2 Title Page (2 pages) WP 0004 (8 pages) WP 0005 (4 pages) WP 0006 (4 pages) WP 0007 (14 pages) WP 0008 (6 pages) WP 0009 (8 pages) WP 0010 (6 pages) WP 0011 (6 pages) WP 0012 (4 pages) WP 0013 (2 pages) WP 0014 (6 pages) WP 0015 (8 pages) WP 0016 (10 pages) WP 0017 (6 pages) WP 0018 (4 pages) WP 0019 (4 pages) WP 0020 (2 pages) WP 0021 (4 pages) WP 0022 (4 pages) WP 0023 (8 pages) WP 0024 (4 pages) WP 0025 (6 pages) WP 0026 (4 pages) WP 0027 (6 pages) WP 0028 (6 pages) WP 0029 (6 pages) WP 0030 (12 pages) WP 0031 (4 pages) WP 0032 (18 pages) WP 0033 (2 pages) WP 0034 (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 0035 (6 pages) WP 0036 (16 pages) WP 0037 (6 pages) WP 0038 (2 pages) WP 0039 (4 pages) WP 0040 (2 pages) WP 0041 (2 pages) WP 0042 (2 pages) WP 0043 (2 pages) WP 0044 (10 pages) WP 0045 (4 pages) WP 0046 (2 pages) WP 0047 (2 pages) WP 0048 (6 pages) WP 0049 (2 pages) WP 0050 (2 pages) WP 0051 (2 pages) WP 0052 (2 pages) WP 0053 (2 pages) WP 0054 (2 pages) WP 0055 (6 pages) WP 0056 (6 pages) WP 0057 (2 pages) WP 0058 (12 pages) WP 0059 (2 pages) WP 0060 (6 pages) WP 0061 (4 pages) WP 0062 (6 pages) WP 0063 (2 pages) WP 0064 (2 pages) WP 0065 (6 pages) WP 0066 (2 pages) WP 0067 (4 pages) WP 0068 (4 pages) WP 0069 (4 pages) WP 0070 (4 pages) Chapter 3 Title Page (2 pages) WP 0071 (12 pages) WP 0072 (6 pages) WP 0073 (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
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Page/WP No. WP 0175 (4 pages) WP 0176 (6 pages) WP 0177 (6 pages) WP 0178 (6 pages) WP 0179 (4 pages) WP 0180 (6 pages) WP 0181 (4 pages) WP 0182 (4 pages) WP 0183 (4 pages) WP 0184 (4 pages) WP 0185 (4 pages) WP 0186 (4 pages) WP 0187 (6 pages) WP 0188 (4 pages) WP 0189 (6 pages) WP 0190 (8 pages) WP 0191 (6 pages) WP 0192 (14 pages) WP 0193 (6 pages) WP 0194 (4 pages) WP 0195 (16 pages) WP 0196 (22 pages) WP 0197 (14 pages) WP 0198 (16 pages) WP 0199 (18 pages) WP 0200 (4 pages) WP 0201 (6 pages) WP 0202 (4 pages) WP 0203 (6 pages) WP 0204 (4 pages) WP 0205 (8 pages) WP 0206 (10 pages) WP 0207 (4 pages) WP 0208 (2 pages) WP 0209 (20 pages) WP 0210 (2 pages) WP 0211 (4 pages) WP 0212 (4 pages) WP 0213 (6 pages) WP 0214 (4 pages) WP 0215 (6 pages) WP 0216 (12 pages) WP 0217 (4 pages) WP 0218 (42 pages) WP 0219 (12 pages) WP 0220 (4 pages) WP 0221 (6 pages) Index-1 - Index-6 (6 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 0 0 0 0 0 0 0 0 0 0 0 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) 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) 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 0 0 0 0 0 0 0 0 0 0 0
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Page/WP No. 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) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Page/WP No. 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
*TM 5-3895-379-23-1 HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON, D.C., 4 September 2012 TECHNICAL MANUAL FIELD MAINTENANCE
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.
FOR
*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 1 HOW TO USE THIS MANUAL ........................................................................................................................ lxxiii Chapter 1 - GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION FOR CB534B or CB534C ROLLER, MOTORIZED, VIBRATING TANDEM STEEL DRUMS NSN 3895-01-396-2822 AND 3895-01-502-4005 GENERAL INFORMATION.......................................................................................................................... WP 0001 Table 1. List of Abbreviations/Acronyms............................................................................................ 0001-4
EQUIPMENT DESCRIPTION AND DATA................................................................................................... WP 0002 Figure 1. Table 1. Table 2. Table 3. Table 4. Table 5. Table 6. Table 7. Table 8. Location and Description of Major Components.................................................................. 0002-2 Location and Description of Major Components.................................................................. 0002-2 Differences Between Models................................................................................................ 0002-4 General................................................................................................................................. 0002-4 Functional............................................................................................................................. 0002-5 Refill Capacities.................................................................................................................... 0002-5 Power Train.......................................................................................................................... 0002-6 Vibratory System.................................................................................................................. 0002-6 Water Spray System............................................................................................................ 0002-6
THEORY OF OPERATION.......................................................................................................................... WP 0003 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Engine System..................................................................................................................... 0003-3 Fuel System......................................................................................................................... 0003-5 Cooling System.................................................................................................................... 0003-7 Electrical System.................................................................................................................. 0003-9 Electrical System................................................................................................................ 0003-11 Propel System.................................................................................................................... 0003-13 Hydraulic Steering System................................................................................................. 0003-15 Vibratory System................................................................................................................ 0003-17 Water Spray System.......................................................................................................... 0003-19
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TABLE OF CONTENTS - Continued

Page No. WP Sequence No. Chapter 2 - TROUBLESHOOTING PROCEDURES FOR CB534B or CB534C ROLLER, MOTORIZED, VIBRATING TANDEM STEEL DRUMS NSN 3895-01-396-2822 AND 3895-01-502-4005 TROUBLESHOOTING INTRODUCTION.................................................................................................... WP 0004 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Electrical Schematic. (Page 1 of 6)...................................................................................... 0004-3 Electrical Schematic. (Page 2 of 6)...................................................................................... 0004-4 Electrical Schematic. (Page 3 of 6)...................................................................................... 0004-5 Electrical Schematic. (Page 4 of 6)...................................................................................... 0004-6 Electrical Schematic. (Page 5 of 6)...................................................................................... 0004-7 Electrical Schematic. (Page 6 of 6)...................................................................................... 0004-8
TROUBLESHOOTING SYMPTOM INDEX.................................................................................................. WP 0005 COOLANT IN ENGINE OIL/ENGINE OIL IN COOLANT............................................................................. WP 0006 Figure 1. Water Pump......................................................................................................................... 0006-2
ENGINE CRANKS BUT WILL NOT START OR IS HARD TO START....................................................... WP 0007 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Fuel Shutoff Valves.............................................................................................................. 0007-3 Fuel Filter Drain Valve.......................................................................................................... 0007-5 Fuel Lines............................................................................................................................. 0007-6 Fuel Lift Pump...................................................................................................................... 0007-7 Engine Cold Start Heater..................................................................................................... 0007-9 Engine Cold Start Heater................................................................................................... 0007-11 Engine Cold Start Heater................................................................................................... 0007-12 Engine Cold Start Heater................................................................................................... 0007-13
ENGINE EXHAUST SMOKES EXCESSIVELY (BLACK OR GRAY SMOKE)............................................ WP 0008 Figure 1. Figure 2. Engine Cold Start Heater..................................................................................................... 0008-3 Engine Cold Start Heater..................................................................................................... 0008-4
ENGINE EXHAUST SMOKES EXCESSIVELY (WHITE OR BLUE SMOKE)............................................. WP 0009 Figure 1. Figure 2. Fuel Lines............................................................................................................................. 0009-2 Engine Cold Start Heater..................................................................................................... 0009-3
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Page No. WP Sequence No. Figure 3. Figure 4. Engine Cold Start Heater..................................................................................................... 0009-5 Engine Cold Start Heater..................................................................................................... 0009-6
ENGINE IS SLUGGISH............................................................................................................................... WP 0010 Figure 1. Figure 2. Figure 3. Figure 4. Fuel Filter Drain Valve.......................................................................................................... 0010-3 Fuel Lift Pump...................................................................................................................... 0010-4 Throttle Cable....................................................................................................................... 0010-5 Turbocharger........................................................................................................................ 0010-6
ENGINE IS UNUSUALLY NOISY................................................................................................................ WP 0011 Figure 1. Figure 2. Figure 3. Engine Fan Assembly.......................................................................................................... 0011-2 Turbocharger........................................................................................................................ 0011-3 Fuel Lines............................................................................................................................. 0011-5
ENGINE IS USING MORE FUEL THAN USUAL......................................................................................... WP 0012 Figure 1. Figure 2. Figure 3. Engine Air Intake System..................................................................................................... 0012-2 Turbocharger........................................................................................................................ 0012-3 Turbocharger........................................................................................................................ 0012-4
ENGINE IS USING MORE OIL THAN USUAL............................................................................................ WP 0013 ENGINE MISFIRES OR IDLES ROUGH..................................................................................................... WP 0014 Figure 1. Figure 2. Figure 3. Fuel Filter Drain Valve.......................................................................................................... 0014-3 Fuel Lines............................................................................................................................. 0014-4 Fuel Lift Pump...................................................................................................................... 0014-6
ENGINE OIL PRESSURE IS LOW (WARNING LIGHT AND WARNING HORN ON)................................. WP 0015 Figure 1. Figure 2. Figure 3. Figure 4. Engine Oil Level Check........................................................................................................ 0015-3 Oil Pressure Switch.............................................................................................................. 0015-5 Engine Oil Level Check........................................................................................................ 0015-6 Fuel Lift Pump...................................................................................................................... 0015-7
ENGINE OPERATING TEMPERATURE IS TOO HIGH (WARNING LIGHT AND WARNING HORN ON)................................................................................................................................................... WP 0016 Figure 1. Radiator Cap Assembly........................................................................................................ 0016-3
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Page No. WP Sequence No. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Radiator Cap Assembly........................................................................................................ 0016-4 Engine Fan Assembly.......................................................................................................... 0016-5 Engine Fan Assembly.......................................................................................................... 0016-6 Water Pump......................................................................................................................... 0016-7 Engine Oil Cooler Lines........................................................................................................ 0016-9
ENGINE STARTS BUT WILL NOT KEEP RUNNING................................................................................. WP 0017 Figure 1. Figure 2. Figure 3. Fuel Filter Drain Valve.......................................................................................................... 0017-2 Fuel Lines............................................................................................................................. 0017-3 Fuel Lift Pump...................................................................................................................... 0017-5
ENGINE SURGES (SPEED CHANGES)..................................................................................................... WP 0018 Figure 1. Fuel Lines............................................................................................................................. 0018-3
ENGINE VIBRATES EXCESSIVELY........................................................................................................... WP 0019 Figure 1. Figure 2. Engine Mounts..................................................................................................................... 0019-2 Fuel Lines............................................................................................................................. 0019-3
ENGINE WILL NOT STOP RUNNING......................................................................................................... WP 0020 Figure 1. Engine Start Switch.............................................................................................................. 0020-2
OIL LEAKING FROM EXHAUST................................................................................................................. WP 0021 Figure 1. Turbocharger........................................................................................................................ 0021-3
THROTTLE CONTROL WILL NOT CHANGE ENGINE SPEED (CB534B)................................................ WP 0022 Figure 1. Throttle Control Cable.......................................................................................................... 0022-3
ALTERNATOR INDICATOR IS ON............................................................................................................. WP 0023 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Engine Fan Assembly.......................................................................................................... 0023-3 Engine Fan Assembly.......................................................................................................... 0023-4 Alternator Wiring................................................................................................................... 0023-5 Batteries and Battery Cables................................................................................................ 0023-6 Batteries and Battery Cables................................................................................................ 0023-7 Battery Disconnect Switch Wiring........................................................................................ 0023-8
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Page No. WP Sequence No. ALTERNATOR IS NOISY............................................................................................................................ WP 0024 Figure 1. Figure 2. Engine Fan Assembly.......................................................................................................... 0024-2 Engine Fan Assembly.......................................................................................................... 0024-3
BACKUP ALARM DOES NOT WORK......................................................................................................... WP 0025 Figure 1. Figure 2. Figure 3. Backup Alarm Sending Unit Wiring...................................................................................... 0025-3 Backup Alarm Wiring............................................................................................................ 0025-4 Backup Alarm Wiring............................................................................................................ 0025-5
FEET PER MINUTE (FPM) METER DOES NOT WORK (CB534C)........................................................... WP 0026 Figure 1. Feet Per Minute (FPM) Meter Wiring................................................................................... 0026-3
FUEL GAUGE DOES NOT WORK.............................................................................................................. WP 0027 Figure 1. Figure 2. Fuel Level Sending Unit Wiring............................................................................................ 0027-2 Fuel Gauge Wiring............................................................................................................... 0027-5
HORN DOES NOT WORK.......................................................................................................................... WP 0028 Figure 1. Figure 2. Figure 3. Horn Wiring.......................................................................................................................... 0028-3 Horn Switch Wiring............................................................................................................... 0028-4 Horn Switch Wiring............................................................................................................... 0028-5
NO POWER TO ACCESSORIES WITH THE ENGINE RUNNING............................................................. WP 0029 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Main Relay Wiring................................................................................................................ 0029-2 Main Relay Wiring................................................................................................................ 0029-3 Main Relay Wiring................................................................................................................ 0029-4 Engine Start Switch Wiring................................................................................................... 0029-5 Engine Start Switch Wiring................................................................................................... 0029-6
ROLLER HAS NO ELECTRICAL POWER.................................................................................................. WP 0030 Figure 1. Figure 2. Figure 3. Figure 4. Batteries............................................................................................................................... 0030-3 Battery Cable Connections at Starter................................................................................... 0030-4 Battery Disconnect Switch Wiring........................................................................................ 0030-5 Alternator Circuit Breaker Wiring.......................................................................................... 0030-6
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Page No. WP Sequence No. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Alternator Circuit Breaker Wiring.......................................................................................... 0030-7 Main Relay Wiring................................................................................................................ 0030-8 Main Relay Wiring................................................................................................................ 0030-9 Main Relay Wiring.............................................................................................................. 0030-10 Engine Start Switch Wiring................................................................................................. 0030-11 Engine Start Switch Wiring................................................................................................. 0030-12
STARTER CONTINUES TO RUN AFTER ENGINE START SWITCH KEY IS RELEASED....................... WP 0031 Figure 1. Figure 2. Starter Relay Wiring............................................................................................................. 0031-3 Starter Relay Wiring............................................................................................................. 0031-4
STARTER DOES NOT TURN OR TURNS SLOWLY.................................................................................. WP 0032 Figure 1. Figure 2. Figure 3. Table 1. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Battery Cable Connections at Starter................................................................................... 0032-3 Batteries and Battery Cables................................................................................................ 0032-4 Battery Cable Connections at Starter................................................................................... 0032-5 Maximum Acceptable System Voltage Drops During Cranking........................................... 0032-7 Battery Cable Connections at Starter................................................................................... 0032-7 Starter Relay Wiring............................................................................................................. 0032-9 Starter Relay Wiring........................................................................................................... 0032-10 Starter Relay Wiring........................................................................................................... 0032-11 Neutral Start Relay No. 1 Wiring........................................................................................ 0032-13 Starter Relay Wiring........................................................................................................... 0032-14 Neutral Start Relay No. 1 Wiring........................................................................................ 0032-15 Neutral Start Relay No. 1 Wiring........................................................................................ 0032-16 Engine Start Switch Wiring................................................................................................. 0032-17 Engine Start Switch Wiring................................................................................................. 0032-18
STARTER TURNS, BUT DOES NOT CRANK ENGINE............................................................................. WP 0033 STARTING AID SWITCH DOES NOT WORK............................................................................................. WP 0034 Figure 1. Starting Aid Switch Wiring.................................................................................................... 0034-3
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Page No. WP Sequence No. Figure 2. Starting Aid Switch Wiring.................................................................................................... 0034-4
VIBRATIONS PER MINUTE (VPM) TACHOMETER DOES NOT WORK................................................... WP 0035 Figure 1. Figure 2. Figure 3. Vibration Sensor Wiring........................................................................................................ 0035-2 Vibrator Sensor Wiring......................................................................................................... 0035-3 Vibration Per Minute (VPM) Meter Wiring............................................................................ 0035-5
WARNING AND INDICATOR LIGHTS DO NOT OPERATE....................................................................... WP 0036 Figure 1. Table 1. Figure 2. Table 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. Functional Indicator and Warning Light Assemblies............................................................ 0036-2 Diode Checks....................................................................................................................... 0036-3 Functional Indicator and Warning Light Assemblies............................................................ 0036-3 Continuity Checks................................................................................................................ 0036-4 Functional Indicator and Warning Light Assemblies............................................................ 0036-5 Functional Indicator and Warning Light Assembly Wiring.................................................... 0036-6 Functional Light Relay Wiring............................................................................................... 0036-7 Functional Light Relay Wiring............................................................................................... 0036-8 Functional Light Relay Wiring............................................................................................... 0036-9 Warning Light Relay Wiring................................................................................................ 0036-10 Warning Light Relay Wiring................................................................................................ 0036-11 Warning Light Relay Wiring................................................................................................ 0036-12 Hourmeter Wiring............................................................................................................... 0036-13 Hourmeter Wiring............................................................................................................... 0036-14 Warning Alarm Diodes....................................................................................................... 0036-15 Warning Alarm Diodes....................................................................................................... 0036-16
WORK LIGHTS AND GAUGE LIGHTS DO NOT OPERATE...................................................................... WP 0037 Figure 1. Figure 2. Figure 3. Light Circuit Breaker Wiring.................................................................................................. 0037-3 Light Circuit Breaker Wiring.................................................................................................. 0037-4 Work Light Control Switch Wiring......................................................................................... 0037-5
HYDRAULIC OIL PRESSURE IS LOW (WARNING LIGHT AND WARNING HORN ON).......................... WP 0038
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Page No. WP Sequence No. Figure 1. Hydraulic Oil Filter Indicator................................................................................................. 0038-2
HYDRAULIC OIL TEMPERATURE IS HIGH (WARNING LIGHT AND WARNING HORN ON).............................................................................................................................................................. WP 0039 Figure 1. Figure 2. Hydraulic Oil Filter Indicator................................................................................................. 0039-2 Engine Fan Assembly.......................................................................................................... 0039-3
POWER STEERING PUMP MAKES NOISE AND STEERING CYLINDER RODS DO NOT MOVE SMOOTHLY..................................................................................................................................... WP 0040 Figure 1. Power Steering Pump.......................................................................................................... 0040-2
ROLLER DOES NOT TURN WHEN STEERING WHEEL IS TURNED...................................................... WP 0041 Figure 1. Power Steering Pump.......................................................................................................... 0041-2
ROLLER TURNS SLOWLY IN BOTH DIRECTIONS.................................................................................. WP 0042 Figure 1. Power Steering Pump.......................................................................................................... 0042-2
TOO MUCH FORCE IS NEEDED TO TURN STEERING WHEEL............................................................. WP 0043 Figure 1. Power Steering Pump.......................................................................................................... 0043-2
PARKING BRAKE DOES NOT DISENGAGE WHEN PARKING BRAKE SWITCH IS PULLED UP................................................................................................................................................................ WP 0044 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Parking Brake Solenoid Wiring............................................................................................. 0044-3 Parking Brake Solenoid Wiring............................................................................................. 0044-4 Parking Brake Switch Wiring................................................................................................ 0044-5 Parking Brake Switch Wiring................................................................................................ 0044-6 Brake Relay No. 1 Wiring..................................................................................................... 0044-7 Brake Relay 1 Wiring............................................................................................................ 0044-8 Brake Relay No. 1 Wiring..................................................................................................... 0044-9
PARKING BRAKE DOES NOT ENGAGE WHEN PARKING BRAKE SWITCH IS PUSHED DOWN.......................................................................................................................................................... WP 0045 Figure 1. Parking Brake Switch Wiring................................................................................................ 0045-3
PROPEL MOTOR IS NOISY....................................................................................................................... WP 0046 PROPEL MOTOR LEAKS OIL..................................................................................................................... WP 0047
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Page No. WP Sequence No. PROPEL SYSTEM DOES NOT CHANGE SPEEDS WHEN PROPEL SPEED SWITCH IS MOVED........................................................................................................................................................ WP 0048 Figure 1. Figure 2. Figure 3. Figure 4. Shift Solenoid Wiring............................................................................................................ 0048-3 Shift Solenoid Wiring............................................................................................................ 0048-4 Propel Speed Switch Wiring................................................................................................. 0048-5 Propel Speed Switch Wiring................................................................................................. 0048-6
PROPEL SYSTEM ENGAGES VERY QUICKLY WHEN MAKING A SHIFT.............................................. WP 0049 Figure 1. Hydraulic Oil Filter Indicator................................................................................................. 0049-2
PROPEL SYSTEM ENGAGES VERY SLOWLY WHEN MAKING A SHIFT............................................... WP 0050 Figure 1. Hydraulic Oil Filter Indicator................................................................................................. 0050-2
PROPEL SYSTEM OPERATES IN FORWARD SPEEDS ONLY............................................................... WP 0051 PROPEL SYSTEM OPERATES IN REVERSE SPEEDS ONLY................................................................. WP 0052 ROLLER WILL NOT MOVE WHEN PROPEL CONTROL LEVER IS OPERATED..................................... WP 0053 Figure 1. Hydraulic Oil Filter Indicator................................................................................................. 0053-2
NOISY VIBRATORY MOTOR...................................................................................................................... WP 0054 VIBRATION DOES NOT OCCUR WHILE AMPLITUDE SELECT SWITCH IS SET TO HIGH PITCH.......................................................................................................................................................... WP 0055 Figure 1. Figure 2. Figure 3. High Amplitude Solenoid Wiring........................................................................................... 0055-3 Amplitude Select Switch Wiring............................................................................................ 0055-4 Amplitude Select Switch Wiring............................................................................................ 0055-5
VIBRATION DOES NOT OCCUR WHILE AMPLITUDE SELECT SWITCH IS SET TO LOW PITCH.......................................................................................................................................................... WP 0056 Figure 1. Figure 2. Figure 3. Low Amplitude Solenoid Wiring............................................................................................ 0056-3 Amplitude Select Switch Wiring............................................................................................ 0056-4 Amplitude Select Switch Wiring............................................................................................ 0056-5
VIBRATION DOES NOT STOP WHEN TRAVEL STOPS........................................................................... WP 0057 VIBRATION DOES NOT WORK IN FORWARD OR REVERSE TRAVEL.................................................. WP 0058 Figure 1. Rear Drum Solenoid Wiring.................................................................................................. 0058-3
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Page No. WP Sequence No. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Vibration Push Switch Wiring............................................................................................... 0058-4 Vibration Push Switch Wiring............................................................................................... 0058-5 Drum Select Switch Wiring................................................................................................... 0058-6 Vibration Control Switch Wiring............................................................................................ 0058-8 Vibration Control Switch Wiring............................................................................................ 0058-9 Amplitude Select Switch Wiring.......................................................................................... 0058-10 Amplitude Select Switch Wiring.......................................................................................... 0058-11
VIBRATION FREQUENCY START-UP IS SLOW, TIME LAG AFTER TRAVEL STARTS IS EXCESSIVE................................................................................................................................................. WP 0059 VIBRATION OCCURS IN ONLY ONE DRUM............................................................................................. WP 0060 Figure 1. Figure 2. Figure 3. Drum Solenoid Wiring.......................................................................................................... 0060-3 Drum Select Switch Wiring................................................................................................... 0060-4 Drum Select Switch Wiring................................................................................................... 0060-5
VIBRATION ONLY OCCURS WHILE VIBRATION CONTROL SWITCH IS SET TO AUTOMATIC MODE.......................................................................................................................................................... WP 0061 Figure 1. Figure 2. Vibration Control Switch Wiring............................................................................................ 0061-3 Vibration Control Switch Wiring............................................................................................ 0061-4
VIBRATION ONLY OCCURS WHILE VIBRATION CONTROL SWITCH IS SET TO MANUAL MODE.......................................................................................................................................................... WP 0062 Figure 1. Figure 2. Figure 3. Figure 4. Vibration Control Switch Wiring............................................................................................ 0062-2 Vibration Control Switch Wiring............................................................................................ 0062-3 Amplitude Select Switch Wiring............................................................................................ 0062-4 Amplitude Select Switch Wiring............................................................................................ 0062-5
VIBRATION STOPS TOO SOON BEFORE TRAVEL STOPS.................................................................... WP 0063 VIBRATORY SYSTEM ENGAGES HARSHLY............................................................................................ WP 0064 NO SPRAY AT EITHER DRUM WHEN WATER SPRAY SWITCH IS IN INTERMITTENT SPRAY POSITION.................................................................................................................................................... WP 0065 Figure 1. Figure 2. Water Spray Switch Wiring................................................................................................... 0065-2 Water Spray Switch Wiring................................................................................................... 0065-3
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Page No. WP Sequence No. Figure 3. Figure 4. Figure 5. Intermittent Water Spray Timer Wiring................................................................................. 0065-4 Front And Rear Intermittent Relay Wiring............................................................................ 0065-5 Water Spray Pump Connector Wiring.................................................................................. 0065-6
NOZZLE SPRAY PATTERN IS INCONSISTENT........................................................................................ WP 0066 SPRAY DOES NOT OCCUR IN EITHER DRUM WHEN WATER SPRAY SWITCH IS IN CONTINUOUS SPRAY POSITION............................................................................................................. WP 0067 Figure 1. Figure 2. Figure 3. Water Spray Switch Wiring................................................................................................... 0067-2 Water Spray Switch Wiring................................................................................................... 0067-3 Water Spray Pump Connector Wiring.................................................................................. 0067-4
WATER CONSUMPTION UNEQUAL BETWEEN TANKS.......................................................................... WP 0068 Figure 1. Figure 2. Water Spray System Water Lines........................................................................................ 0068-2 Water Spray Pump Test....................................................................................................... 0068-3
WATER SPRAY OCCURS ON ONE DRUM ONLY.................................................................................... WP 0069 Figure 1. Figure 2. Water Spray Pump Connector Wiring.................................................................................. 0069-3 Water Spray System Waterlines.......................................................................................... 0069-4
WATER SPRAY PRESSURE IS LOW........................................................................................................ WP 0070 Figure 1. Figure 2. Water Spray System Water Lines........................................................................................ 0070-2 Water Spray Pump Test....................................................................................................... 0070-3
Chapter 3 - PREVENTIVE MAINTENANCE INSTRUCTIONS FOR CB534B or CB534C ROLLER, MOTORIZED, VIBRATING TANDEM STEEL DRUMS NSN 3895-01-396-2822 AND 3895-01-502-4005 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION............................. WP 0071 Table 1. Table 2. Figure 1. Figure 2. Figure 3. Figure 4. Leakage Definitions for PMCS............................................................................................. 0071-2 -Key-..................................................................................................................................... 0071-3 Lubrication Chart.................................................................................................................. 0071-5 Item A................................................................................................................................... 0071-6 Item B................................................................................................................................... 0071-6 Item C................................................................................................................................... 0071-7
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Page No. WP Sequence No. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Item D................................................................................................................................... 0071-7 Item E................................................................................................................................... 0071-8 Item F................................................................................................................................... 0071-8 Item G................................................................................................................................... 0071-9 Item H................................................................................................................................... 0071-9 Item J.................................................................................................................................. 0071-10 Item K................................................................................................................................. 0071-10 Item L................................................................................................................................. 0071-11 Item M................................................................................................................................ 0071-11 Item N................................................................................................................................. 0071-12 Item O................................................................................................................................. 0071-12
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (QUARTERLY)................................ WP 0072 Table 1. Figure 1. Preventive Maintenance Checks and Services (PMCS) (Quarterly) for CB534 Roller.................................................................................................................................... 0072-2 Fan Belts.............................................................................................................................. 0072-4
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (ANNUAL) ...................................... WP 0073 Table 1. Figure 1. Preventive Maintenance Checks and Services (PMCS) (Annual) for CB534 Roller............ 0073-1 Platform................................................................................................................................ 0073-2
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (BIENNIAL)...................................... WP 0074 Table 1. Preventive Maintenance Checks and Services (PMCS) (Biennial) for CB534 Roller.......... 0074-1
Chapter 4 - MAINTENANCE INSTRUCTIONS FOR CB534B or CB534C ROLLER, MOTORIZED, VIBRATING TANDEM STEEL DRUMS NSN 3895-01-396-2822 AND 3895-01-502-4005 SERVICE UPON RECEIPT......................................................................................................................... WP 0075 ENGINE, TURBO, DIESEL TESTS............................................................................................................. WP 0076 Figure 1. Cylinder Compression Test.................................................................................................. 0076-1
ENGINE OIL SERVICE................................................................................................................................ WP 0077 Figure 1. Engine Oil Drain................................................................................................................... 0077-3
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Page No. WP Sequence No. Figure 2. Figure 3. Figure 4. Engine Oil Filter Removal..................................................................................................... 0077-4 Engine Oil Filter Installation.................................................................................................. 0077-5 Engine Oil Fill....................................................................................................................... 0077-6
ENGINE ASSEMBLY REPLACEMENT....................................................................................................... WP 0078 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. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Engine Assembly Removal.................................................................................................. 0078-2 Engine Assembly Removal.................................................................................................. 0078-3 Engine Assembly Removal.................................................................................................. 0078-4 Engine Assembly Removal.................................................................................................. 0078-5 Engine Assembly Removal.................................................................................................. 0078-5 Engine Assembly Removal.................................................................................................. 0078-6 Engine Assembly Removal.................................................................................................. 0078-6 Engine Assembly Removal.................................................................................................. 0078-7 Engine Assembly Removal.................................................................................................. 0078-7 Engine Assembly Removal.................................................................................................. 0078-8 Engine Assembly Removal.................................................................................................. 0078-8 Engine Assembly Removal.................................................................................................. 0078-9 Engine Assembly Removal................................................................................................ 0078-10 Engine Assembly Removal................................................................................................ 0078-11 Engine Assembly Removal................................................................................................ 0078-11 Engine Assembly Removal................................................................................................ 0078-12 Engine Assembly Removal................................................................................................ 0078-13 Engine Assembly Removal................................................................................................ 0078-13 Engine Assembly Removal................................................................................................ 0078-14 Engine Assembly Removal................................................................................................ 0078-15 Engine Assembly Removal................................................................................................ 0078-15 Engine Assembly Removal................................................................................................ 0078-16 Engine Assembly Removal................................................................................................ 0078-17
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Page No. WP Sequence No. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Figure 35. Figure 36. Figure 37. Figure 38. Figure 39. Figure 40. Figure 41. Figure 42. Figure 43. Figure 44. Figure 45. Figure 46. Engine Assembly Installation............................................................................................. 0078-18 Engine Assembly Installation............................................................................................. 0078-19 Engine Assembly Installation............................................................................................. 0078-19 Engine Assembly Installation............................................................................................. 0078-20 Engine Assembly Installation............................................................................................. 0078-21 Engine Assembly Installation............................................................................................. 0078-22 Engine Assembly Installation............................................................................................. 0078-22 Engine Assembly Installation............................................................................................. 0078-23 Engine Assembly Installation............................................................................................. 0078-23 Engine Assembly Installation............................................................................................. 0078-24 Engine Assembly Installation............................................................................................. 0078-25 Engine Assembly Installation............................................................................................. 0078-25 Engine Assembly Installation............................................................................................. 0078-26 Engine Assembly Installation............................................................................................. 0078-26 Engine Assembly Installation............................................................................................. 0078-27 Engine Assembly Installation............................................................................................. 0078-27 Engine Assembly Installation............................................................................................. 0078-28 Engine Assembly Installation............................................................................................. 0078-28 Engine Assembly Installation............................................................................................. 0078-29 Engine Assembly Installation............................................................................................. 0078-29 Engine Assembly Installation............................................................................................. 0078-30 Engine Assembly Installation............................................................................................. 0078-31 Engine Assembly Installation............................................................................................. 0078-31
ENGINE LIFTING PLATES REPLACEMENT.............................................................................................. WP 0079 Figure 1. Figure 2. Figure 3. Engine Lifting Plates Removal............................................................................................. 0079-2 Engine Lifting Plates Removal............................................................................................. 0079-3 Engine Lifting Plates Installation.......................................................................................... 0079-4
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Page No. WP Sequence No. Figure 4. Engine Lifting Plates Installation.......................................................................................... 0079-5
FRONT ENGINE MOUNT REPLACEMENT................................................................................................ WP 0080 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Front Engine Mount Removal............................................................................................... 0080-2 Front Engine Mount Removal............................................................................................... 0080-3 Front Engine Mount Removal............................................................................................... 0080-5 Front Engine Mount Installation............................................................................................ 0080-7 Front Engine Mount Installation............................................................................................ 0080-7 Front Engine Mount Installation............................................................................................ 0080-8
REAR ENGINE MOUNT REPLACEMENT.................................................................................................. WP 0081 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Rear Engine Mount Removal............................................................................................... 0081-2 Rear Engine Mount Removal............................................................................................... 0081-3 Rear Engine Mount Removal............................................................................................... 0081-4 Rear Engine Mount Removal............................................................................................... 0081-4 Rear Engine Mount Removal............................................................................................... 0081-5 Rear Engine Mount Installation............................................................................................ 0081-6 Rear Engine Mount Installation............................................................................................ 0081-7 Rear Engine Mount Installation............................................................................................ 0081-7 Rear Engine Mount Installation............................................................................................ 0081-8 Rear Engine Mount Installation............................................................................................ 0081-8
CYLINDER HEAD REPLACEMENT............................................................................................................ WP 0082 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Cylinder Head Removal....................................................................................................... 0082-2 Cylinder Head Removal....................................................................................................... 0082-3 Cylinder Head Removal....................................................................................................... 0082-3 Cylinder Head Cleaning and Inspection............................................................................... 0082-4 Cylinder Head Installation.................................................................................................... 0082-5 Cylinder Head Installation.................................................................................................... 0082-5 Cylinder Head Installation.................................................................................................... 0082-6
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Page No. WP Sequence No. CRANKSHAFT PULLEY REPLACEMENT.................................................................................................. WP 0083 Figure 1. Figure 2. Crankshaft Pulley Removal.................................................................................................. 0083-2 Crankshaft Pulley Installation............................................................................................... 0083-3
CRANKSHAFT FRONT OIL SEAL REPLACEMENT.................................................................................. WP 0084 Figure 1. Figure 2. Crankshaft Front Oil Seal Removal...................................................................................... 0084-1 Crankshaft Front Oil Seal Installation................................................................................... 0084-2
CRANKSHAFT REAR OIL SEAL REPLACEMENT..................................................................................... WP 0085 Figure 1. Figure 2. Figure 3. Figure 4. Crankshaft Rear Oil Seal Removal...................................................................................... 0085-2 Crankshaft Rear Oil Seal Installation................................................................................... 0085-3 Crankshaft Rear Oil Seal Installation................................................................................... 0085-3 Crankshaft Rear Oil Seal Installation................................................................................... 0085-4
FLYWHEEL ASSEMBLY REPLACEMENT................................................................................................. WP 0086 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Flywheel Assembly Removal............................................................................................... 0086-2 Flywheel Assembly Removal............................................................................................... 0086-3 Flywheel Assembly Removal............................................................................................... 0086-3 Flywheel Assembly Installation............................................................................................ 0086-4 Flywheel Assembly Installation............................................................................................ 0086-5 Flywheel Assembly Installation............................................................................................ 0086-5
FLYWHEEL HOUSING REPLACEMENT.................................................................................................... WP 0087 Figure 1. Figure 2. Figure 3. Figure 4. Flywheel Housing Removal.................................................................................................. 0087-2 Flywheel Housing Removal.................................................................................................. 0087-3 Flywheel Housing Installation............................................................................................... 0087-4 Flywheel Housing Installation............................................................................................... 0087-5
VALVE LASH (CLEARANCE) ADJUSTMENT............................................................................................ WP 0088 ROCKER SHAFT ASSEMBLY REPLACEMENT........................................................................................ WP 0089 Figure 1. Figure 2. Rocker Shaft Assembly Removal......................................................................................... 0089-2 Rocker Shaft Assembly Installation...................................................................................... 0089-3
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Page No. WP Sequence No. ROCKER ARM ASSEMBLY REPAIR.......................................................................................................... WP 0090 Figure 1. Figure 2. Rocker Arm Disassembly..................................................................................................... 0090-2 Rocker Arm Assembly.......................................................................................................... 0090-3
IDLER GEAR AND HUB REPLACEMENT.................................................................................................. WP 0091 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Idler Gear and Hub Removal................................................................................................ 0091-2 Idler Gear and Hub Removal................................................................................................ 0091-3 Idler Gear and Hub Removal................................................................................................ 0091-3 Idler Gear and Hub Installation............................................................................................. 0091-4 Idler Gear and Hub Installation............................................................................................. 0091-5 Idler Gear and Hub Installation............................................................................................. 0091-6
TIMING GEAR CASE COVER REPLACEMENT......................................................................................... WP 0092 Figure 1. Figure 2. Figure 3. Figure 4. Timing Gear Case Cover Removal...................................................................................... 0092-1 Timing Gear Case Cover Installation................................................................................... 0092-2 Timing Gear Case Cover Installation................................................................................... 0092-2 Timing Gear Cover Installation............................................................................................. 0092-3
OIL PAN REPLACEMENT........................................................................................................................... WP 0093 Figure 1. Figure 2. Figure 3. Figure 4. Oil Pan Removal.................................................................................................................. 0093-2 Oil Pan Removal.................................................................................................................. 0093-3 Oil Pan Installation............................................................................................................... 0093-4 Oil Pan Installation............................................................................................................... 0093-5
ENGINE OIL PUMP REPLACEMENT......................................................................................................... WP 0094 Figure 1. Figure 2. Engine Oil Pump Removal................................................................................................... 0094-2 Engine Oil Pump Installation................................................................................................ 0094-3
ENGINE OIL COOLER REPLACEMENT.................................................................................................... WP 0095 Figure 1. Figure 2. Engine Oil Cooler Removal.................................................................................................. 0095-2 Engine Oil Cooler Installation............................................................................................... 0095-4
ENGINE OIL COOLER LINES AND FITTINGS REPLACEMENT (CB534B).............................................. WP 0096
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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. Engine Oil Cooler Lines and Fittings Removal..................................................................... 0096-1 Engine Oil Cooler Lines and Fittings Removal..................................................................... 0096-2 Engine Oil Cooler Lines and Fittings Removal..................................................................... 0096-3 Engine Oil Cooler Lines and Fittings Installation.................................................................. 0096-4 Engine Oil Cooler Lines and Fittings Installation.................................................................. 0096-5 Engine Oil Cooler Lines and Fittings Installation.................................................................. 0096-5 Engine Oil Cooler Lines and Fittings Installation.................................................................. 0096-6 Engine Oil Cooler Lines and Fittings Installation.................................................................. 0096-6
ENGINE OIL COOLER LINES AND FITTINGS REPLACEMENT (CB534C).............................................. WP 0097 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Engine Oil Cooler Lines and Fittings Removal..................................................................... 0097-2 Engine Oil Cooler Lines and Fittings Removal..................................................................... 0097-3 Engine Oil Cooler Lines and Fittings Removal..................................................................... 0097-3 Engine Oil Cooler Lines and Fittings Removal..................................................................... 0097-4 Engine Oil Cooler Lines and Fittings Installation.................................................................. 0097-4 Engine Oil Cooler Lines and Fittings Installation.................................................................. 0097-5 Engine Oil Cooler Lines and Fittings Installation.................................................................. 0097-5 Engine Oil Cooler Lines and Fittings Installation.................................................................. 0097-6
ENGINE OIL SAMPLING VALVE AND FITTINGS REPLACEMENT.......................................................... WP 0098 Figure 1. Figure 2. Figure 3. Figure 4. Engine Oil Sampling Valve and Fittings Removal................................................................ 0098-2 Engine Oil Sampling Valve and Fittings Removal................................................................ 0098-3 Engine Oil Sampling Valve and Fittings Installation............................................................. 0098-3 Engine Oil Sampling Valve and Fittings Installation............................................................. 0098-4
GAUGE ROD (DIPSTICK) TUBE ASSEMBLY REPLACEMENT................................................................ WP 0099 Figure 1. Figure 2. Gauge Rod (Dipstick) Tube Assembly Removal.................................................................. 0099-2 Gauge Rod (Dipstick) Tube Assembly Installation............................................................... 0099-3
ENGINE OIL FILLER REPLACEMENT....................................................................................................... WP 0100 Figure 1. Engine Oil Filler Removal..................................................................................................... 0100-1
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Page No. WP Sequence No. Figure 2. Figure 3. Figure 4. Engine Oil Filler Removal..................................................................................................... 0100-2 Engine Oil Filler Installation.................................................................................................. 0100-3 Engine Oil Filler Installation.................................................................................................. 0100-3
VALVE COVER AND BREATHER TUBE REPLACEMENT........................................................................ WP 0101 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Valve Cover and Breather Tube Removal............................................................................ 0101-2 Valve Cover and Breather Tube Removal............................................................................ 0101-3 Valve Cover and Breather Tube Removal............................................................................ 0101-4 Valve Cover and Breather Tube Installation......................................................................... 0101-5 Valve Cover and Breather Tube Installation......................................................................... 0101-6 Valve Cover and Breather Tube Installation......................................................................... 0101-7
OIL FILTER HEAD ASSEMBLY REPLACEMENT (CB534B)...................................................................... WP 0102 Figure 1. Figure 2. Oil Filter Head Assembly Removal....................................................................................... 0102-2 Oil Filter Head Assembly Installation.................................................................................... 0102-3
OIL FILTER HEAD ASSEMBLY REPLACEMENT (CB534C)..................................................................... WP 0103 Figure 1. Figure 2. Oil Filter Head Assembly Removal....................................................................................... 0103-2 Oil Filter Head Assembly Installation.................................................................................... 0103-3
OIL STRAINER AND SUCTION TUBE REPLACEMENT............................................................................ WP 0104 Figure 1. Figure 2. Figure 3. Figure 4. Oil Strainer and Suction Tube Removal............................................................................... 0104-1 Oil Strainer and Suction Tube Removal............................................................................... 0104-2 Oil Strainer and Suction Tube Installation............................................................................ 0104-3 Push Rod Cover Installation................................................................................................. 0104-3
INTAKE MANIFOLD REPLACEMENT........................................................................................................ WP 0105 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Intake Manifold Removal...................................................................................................... 0105-1 Intake Manifold Removal...................................................................................................... 0105-2 Intake Manifold Removal...................................................................................................... 0105-3 Intake Manifold Installation................................................................................................... 0105-4 Intake Manifold Installation................................................................................................... 0105-5
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Page No. WP Sequence No. Figure 6. Intake Manifold Installation................................................................................................... 0105-5
EXHAUST MANIFOLD REPLACEMENT (CB534B).................................................................................... WP 0106 Figure 1. Figure 2. Exhaust Manifold Removal................................................................................................... 0106-1 Exhaust Manifold Installation................................................................................................ 0106-2
EXHAUST MANIFOLD REPLACEMENT (CB534C)................................................................................... WP 0107 Figure 1. Figure 2. Exhaust Manifold Removal................................................................................................... 0107-1 Exhaust Manifold Installation................................................................................................ 0107-2
FUEL INJECTOR AND NOZZLE TEST....................................................................................................... WP 0108 Figure 1. Fuel Injector and Nozzle Test............................................................................................... 0108-2
FUEL INJECTOR AND NOZZLE REPLACEMENT (CB534B).................................................................... WP 0109 Figure 1. Figure 2. Figure 3. Figure 4. Fuel Injector and Nozzle Removal....................................................................................... 0109-1 Fuel Injector and Nozzle Removal....................................................................................... 0109-2 Fuel Injector and Nozzle Installation.................................................................................... 0109-3 Fuel Injector and Nozzle Installation.................................................................................... 0109-3
FUEL INJECTOR AND NOZZLE REPLACEMENT (CB534C).................................................................... WP 0110 Figure 1. Figure 2. Figure 3. Fuel Injector and Nozzle Removal....................................................................................... 0110-2 Fuel Injector and Nozzle Installation.................................................................................... 0110-3 Fuel Injector and Nozzle Installation.................................................................................... 0110-4
FUEL INJECTION PUMP GEAR REPLACEMENT..................................................................................... WP 0111 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Fuel Injection Pump Gear Removal..................................................................................... 0111-2 Fuel Injection Pump Gear Installation.................................................................................. 0111-3 Fuel Injection Pump Gear Removal..................................................................................... 0111-4 Fuel Injection Pump Gear Removal..................................................................................... 0111-4 Fuel Injection Pump Gear Installation.................................................................................. 0111-5 Fuel Injection Pump Gear Installation.................................................................................. 0111-5
FUEL INJECTION PUMP REPLACEMENT................................................................................................ WP 0112 Figure 1. Fuel Injection Pump Removal.............................................................................................. 0112-2
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Page No. WP Sequence No. Figure 2. Fuel Injection Pump Installation........................................................................................... 0112-3
FUEL INJECTION PUMP TEST AND ADJUSTMENT (CB534B)................................................................ WP 0113 FUEL INJECTOR LINES AND FITTINGS REPLACEMENT (CB534B)....................................................... WP 0114 Figure 1. Figure 2. Figure 3. Figure 4. Fuel Lines and Fittings Removal.......................................................................................... 0114-3 Fuel Lines and Fittings Installation....................................................................................... 0114-5 Fuel Injector Lines and Fittings Removal............................................................................. 0114-6 Fuel Injector Lines and Fittings Installation.......................................................................... 0114-7
FUEL INJECTOR LINES AND FITTINGS REPLACEMENT (CB534C)...................................................... WP 0115 Figure 1. Figure 2. Figure 3. Figure 4. Fuel Lines and Fittings Removal.......................................................................................... 0115-3 Fuel Lines and Fittings Installation....................................................................................... 0115-5 Fuel Injector Lines and Fittings Removal............................................................................. 0115-7 Fuel Injector Lines and Fittings Installation.......................................................................... 0115-8
FUEL LIFT PUMP REPLACEMENT............................................................................................................ WP 0116 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Fuel Lift Pump Removal....................................................................................................... 0116-2 Fuel Lift Pump Removal....................................................................................................... 0116-3 Fuel Lift Pump Removal....................................................................................................... 0116-5 Fuel Lift Pump Installation.................................................................................................... 0116-7 Fuel Lift Pump Installation.................................................................................................... 0116-7 Fuel Lift Pump Installation.................................................................................................... 0116-8
AIR CLEANER CAP REPLACEMENT......................................................................................................... WP 0117 Figure 1. Figure 2. Air Cleaner Removal............................................................................................................ 0117-2 Air Cleaner Installation......................................................................................................... 0117-3
AIR CLEANER ELEMENTS AND AIR CLEANER ASSEMBLY REPLACEMENT....................................... WP 0118 Figure 1. Figure 2. Figure 3. Figure 4. Air Cleaner Elements and Air Cleaner Assembly Removal.................................................. 0118-2 Air Cleaner Elements and Air Cleaner Assembly Removal.................................................. 0118-3 Air Cleaner Elements and Air Cleaner Assembly Removal.................................................. 0118-3 Air Cleaner Elements and Air Cleaner Assembly Removal.................................................. 0118-4
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Page No. WP Sequence No. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Air Cleaner Elements and Air Cleaner Assembly Removal.................................................. 0118-5 Air Cleaner and Air Cleaner Assembly Installation............................................................... 0118-6 Air Cleaner Elements and Air Cleaner Assembly Installation............................................... 0118-7 Air Cleaner Elements and Air Cleaner Assembly Installation............................................... 0118-7 Air Cleaner Elements and Air Cleaner Assembly Installation............................................... 0118-8 Air Cleaner Elements and Air Cleaner Assembly Installation............................................... 0118-8
AIR CLEANER SUPPORT ASSEMBLY REPLACEMENT.......................................................................... WP 0119 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Air Cleaner Support Assembly Removal.............................................................................. 0119-1 Air Cleaner Support Assembly Removal.............................................................................. 0119-2 Air Cleaner Support Assembly Removal.............................................................................. 0119-3 Air Cleaner Support Assembly Removal.............................................................................. 0119-3 Air Cleaner Support Assembly Removal.............................................................................. 0119-4 Air Cleaner Support Assembly Installation........................................................................... 0119-4 Air Cleaner Support Assembly Installation........................................................................... 0119-5 Air Cleaner Support Assembly Installation........................................................................... 0119-5 Air Cleaner Support Assembly Installation........................................................................... 0119-6 Air Cleaner Support Assembly Installation........................................................................... 0119-7
AIR CLEANER SERVICE INDICATOR REPLACEMENT........................................................................... WP 0120 Figure 1. Figure 2. Figure 3. Figure 4. Air Cleaner Service Indicator Removal................................................................................ 0120-1 Air Cleaner Service Indicator Removal................................................................................ 0120-2 Air Cleaner Service Indicator Installation............................................................................. 0120-2 Air Cleaner Service Indicator Installation............................................................................. 0120-3
TURBOCHARGER REPLACEMENT.......................................................................................................... WP 0121 Figure 1. Figure 2. Figure 3. Figure 4. Turbocharger Removal......................................................................................................... 0121-2 Turbocharger Removal......................................................................................................... 0121-3 Turbocharger Removal......................................................................................................... 0121-3 Turbocharger Removal......................................................................................................... 0121-4
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Page No. WP Sequence No. Figure 5. Figure 6. Figure 7. Figure 8. Turbocharger Installation...................................................................................................... 0121-5 Turbocharger Installation...................................................................................................... 0121-6 Turbocharger Installation...................................................................................................... 0121-7 Turbocharger Installation...................................................................................................... 0121-7
TURBOCHARGER REPAIR........................................................................................................................ WP 0122 Figure 1. Figure 2. Figure 3. Figure 4. Turbocharger Disassembly.................................................................................................. 0122-1 Turbocharger Disassembly.................................................................................................. 0122-2 Turbocharger Assembly....................................................................................................... 0122-3 Turbocharger Assembly....................................................................................................... 0122-3
TURBOCHARGER OIL LINES, HOSES, AND FITTINGS REPLACEMENT............................................... WP 0123 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Turbocharger Oil Lines, Hoses, and Fittings Removal......................................................... 0123-2 Turbocharger Oil Lines, Hoses, and Fittings Removal......................................................... 0123-3 Turbocharger Oil Lines, Hoses, and Fittings Removal......................................................... 0123-3 Turbocharger Oil Lines, Hoses, and Fittings Installation...................................................... 0123-4 Turbocharger Oil Lines, Hoses, and Fittings Installation...................................................... 0123-5 Turbocharger Oil Lines, Hoses, and Fittings Installation...................................................... 0123-5
FUEL/HYDRAULIC OIL TANK DRAIN/FILL................................................................................................ WP 0124 Figure 1. Figure 2. Figure 3. Figure 4. Fuel Tank Drain.................................................................................................................... 0124-2 Hydraulic Oil Tank Drain...................................................................................................... 0124-3 Hydraulic Oil Tank Fill.......................................................................................................... 0124-4 Fuel Tank Fill........................................................................................................................ 0124-5
FUEL/HYDRAULIC OIL TANK AND DRAIN LINES REPLACEMENT........................................................ WP 0125 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Drain Lines Removal............................................................................................................ 0125-2 Drain Lines Removal............................................................................................................ 0125-3 Drain Lines Removal............................................................................................................ 0125-4 Fuel/Hydraulic Oil Tank Removal......................................................................................... 0125-5 Fuel/Hydraulic Oil Tank Removal......................................................................................... 0125-5
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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. Figure 29. Figure 30. Figure 31. Figure 32. Fuel/Hydraulic Oil Tank Removal......................................................................................... 0125-6 Fuel/Hydraulic Oil Tank Removal......................................................................................... 0125-6 Fuel/Hydraulic Oil Tank Removal......................................................................................... 0125-7 Fuel/Hydraulic Oil Tank Removal......................................................................................... 0125-8 Fuel/Hydraulic Oil Tank Removal......................................................................................... 0125-9 Fuel/Hydraulic Oil Tank Removal......................................................................................... 0125-9 Fuel/Hydraulic Oil Tank Removal....................................................................................... 0125-10 Fuel/Hydraulic Oil Tank Removal....................................................................................... 0125-10 Fuel/Hydraulic Oil Tank Removal....................................................................................... 0125-11 Fuel/Hydraulic Oil Tank Removal....................................................................................... 0125-11 Fuel/Hydraulic Oil Tank Removal....................................................................................... 0125-12 Fuel/Hydraulic Oil Tank Removal....................................................................................... 0125-13 Fuel/Hydraulic Oil Tank Removal....................................................................................... 0125-13 Fuel/Hydraulic Oil Tank Removal....................................................................................... 0125-14 Fuel/Hydraulic Oil Tank Installation.................................................................................... 0125-15 Fuel/Hydraulic Oil Tank Installation.................................................................................... 0125-15 Fuel/Hydraulic Oil Tank Installation.................................................................................... 0125-16 Fuel/Hydraulic Oil Tank Installation.................................................................................... 0125-17 Fuel/Hydraulic Oil Tank Installation.................................................................................... 0125-17 Fuel/Hydraulic Oil Tank Installation.................................................................................... 0125-18 Fuel/Hydraulic Oil Tank Installation.................................................................................... 0125-19 Fuel/Hydraulic Oil Tank Installation.................................................................................... 0125-19 Fuel/Hydraulic Oil Tank Installation.................................................................................... 0125-20 Fuel/Hydraulic Oil Tank Installation.................................................................................... 0125-21 Fuel/Hydraulic Oil Tank Installation.................................................................................... 0125-22 Fuel/Hydraulic Oil Tank Installation.................................................................................... 0125-23 Fuel/Hydraulic Oil Tank Installation.................................................................................... 0125-23
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Page No. WP Sequence No. Figure 33. Figure 34. Figure 35. Figure 36. Figure 37. Figure 38. Fuel/Hydraulic Oil Tank Installation.................................................................................... 0125-24 Fuel/Hydraulic Oil Tank Installation.................................................................................... 0125-24 Fuel/Hydraulic Oil Tank Installation.................................................................................... 0125-25 Drain Lines Installation....................................................................................................... 0125-26 Drain Lines Installation....................................................................................................... 0125-27 Drain Lines Installation....................................................................................................... 0125-27
FUEL CAP ASSEMBLY REPAIR................................................................................................................. WP 0126 Figure 1. Figure 2. Figure 3. Figure 4. Fuel Cap Assembly Removal............................................................................................... 0126-2 Fuel Cap Disassembly......................................................................................................... 0126-3 Fuel Cap Assembly.............................................................................................................. 0126-5 Fuel Cap Assembly Installation............................................................................................ 0126-6
FUEL FILTER ASSEMBLY REPLACEMENT.............................................................................................. WP 0127 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. Fuel Filter Assembly Removal.............................................................................................. 0127-3 Fuel Filter Assembly Installation........................................................................................... 0127-4 Fuel Filter Assembly Installation........................................................................................... 0127-5 Fuel Filter Assembly Removal.............................................................................................. 0127-7 Fuel Filter Assembly Removal.............................................................................................. 0127-8 Fuel Filter Assembly Removal.............................................................................................. 0127-8 Fuel Filter Assembly Removal.............................................................................................. 0127-9 Fuel Filter Assembly Disassembly..................................................................................... 0127-10 Fuel Filter Assembly Inspection......................................................................................... 0127-11 Fuel Filter Assembly Assembly.......................................................................................... 0127-12 Fuel Filter Assembly Installation......................................................................................... 0127-13 Fuel Filter Assembly Installation......................................................................................... 0127-13 Fuel Filter Assembly Installation......................................................................................... 0127-14 Fuel Filter Assembly Installation......................................................................................... 0127-15
PRIMING FUEL SYSTEM............................................................................................................................ WP 0128
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Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Priming Fuel System............................................................................................................ 0128-3 Priming Fuel System............................................................................................................ 0128-4 Priming Fuel System............................................................................................................ 0128-5
FUEL/WATER SEPARATOR ASSEMBLY SERVICE................................................................................. WP 0129 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. Fuel/Water Separator Element Removal.............................................................................. 0129-2 Fuel/Water Separator Element Removal.............................................................................. 0129-3 Fuel/Water Separator Element Installation........................................................................... 0129-4 Fuel/Water Separator Element Installation........................................................................... 0129-5 Fuel/Water Separator Element Installation........................................................................... 0129-6 Fuel/Water Separator Assembly Removal........................................................................... 0129-7 Fuel/Water Separator Assembly Removal........................................................................... 0129-8 Fuel/Water Separator Assembly Removal........................................................................... 0129-9 Fuel/Water Separator Disassembly...................................................................................... 0129-9 Fuel/Water Separator Disassembly.................................................................................... 0129-10 Fuel/Water Separator Disassembly.................................................................................... 0129-11 Fuel/Water Separator Assembly........................................................................................ 0129-12 Fuel/Water Separator Assembly........................................................................................ 0129-13 Fuel/Water Separator Assembly........................................................................................ 0129-14 Fuel/Water Separator Assembly Installation...................................................................... 0129-14 Fuel/Water Separator Assembly Installation...................................................................... 0129-15 Fuel/Water Separator Assembly Installation...................................................................... 0129-15
COLD START HEATER REPLACEMENT................................................................................................... WP 0130 Figure 1. Figure 2. Figure 3. Figure 4. Cold Start Heater Removal.................................................................................................. 0130-2 Cold Start Heater Removal.................................................................................................. 0130-3 Cold Start Heater Installation............................................................................................... 0130-3 Cold Start Heater Installation............................................................................................... 0130-4
THROTTLE CABLE REPLACEMENT/ADJUSTMENT (CB534B)............................................................... WP 0131
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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. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Throttle Cable Removal........................................................................................................ 0131-2 Throttle Cable Removal........................................................................................................ 0131-3 Throttle Cable Removal........................................................................................................ 0131-3 Throttle Cable Removal........................................................................................................ 0131-4 Throttle Cable Removal........................................................................................................ 0131-4 Throttle Cable Removal........................................................................................................ 0131-5 Throttle Cable Removal........................................................................................................ 0131-6 Throttle Cable Removal........................................................................................................ 0131-6 Throttle Cable Removal........................................................................................................ 0131-7 Throttle Cable Installation..................................................................................................... 0131-8 Throttle Cable Installation..................................................................................................... 0131-9 Throttle Cable Installation................................................................................................... 0131-10 Throttle Cable Installation................................................................................................... 0131-11 Throttle Cable Installation................................................................................................... 0131-11 Throttle Cable Installation................................................................................................... 0131-12 Throttle Cable Installation................................................................................................... 0131-12 Throttle Cable Installation................................................................................................... 0131-13 Throttle Cable Adjustment.................................................................................................. 0131-15 Throttle Cable Adjustment.................................................................................................. 0131-15 Throttle Cable Adjustment.................................................................................................. 0131-16
LOW IDLE SPEED ADJUSTMENT............................................................................................................. WP 0132 Figure 1. Figure 2. Figure 3. Low Idle Speed Adjustment.................................................................................................. 0132-2 Low Idle Speed Adjustment.................................................................................................. 0132-3 Low Idle Speed Adjustment.................................................................................................. 0132-3
THROTTLE CONTROL REPLACEMENT (CB534C).................................................................................. WP 0133 Figure 1. Figure 2. Throttle Control Removal..................................................................................................... 0133-2 Throttle Control Installation.................................................................................................. 0133-3
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Page No. WP Sequence No. Figure 3. Throttle Control Adjustment.................................................................................................. 0133-4
MUFFLER AND TAILPIPE REPLACEMENT............................................................................................... WP 0134 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Muffler and Tailpipe Removal............................................................................................... 0134-2 Muffler and Tailpipe Removal............................................................................................... 0134-3 Muffler and Tailpipe Removal............................................................................................... 0134-3 Muffler and Tailpipe Removal............................................................................................... 0134-4 Muffler and Tailpipe Installation............................................................................................ 0134-4 Muffler and Tailpipe Installation............................................................................................ 0134-5 Muffler and Tailpipe Installation............................................................................................ 0134-6 Muffler and Tailpipe Installation............................................................................................ 0134-7
COOLANT SYSTEM PRESSURE TEST..................................................................................................... WP 0135 Figure 1. Coolant System Pressure Test............................................................................................. 0135-3
RADIATOR ASSEMBLY REPLACEMENT.................................................................................................. WP 0136 Figure 1. Figure 2. Figure 3. Figure 4. Radiator Assembly Removal................................................................................................ 0136-2 Radiator Assembly Removal................................................................................................ 0136-3 Radiator Assembly Installation............................................................................................. 0136-5 Radiator Assembly Installation............................................................................................. 0136-6
RADIATOR ASSEMBLY REPAIR................................................................................................................ WP 0137 RADIATOR HOSES REPLACEMENT......................................................................................................... WP 0138 Figure 1. Figure 2. Radiator Hoses Removal..................................................................................................... 0138-2 Radiator Hoses Installation.................................................................................................. 0138-3
COOLANT SYSTEM SERVICE................................................................................................................... WP 0139 Figure 1. Figure 2. Figure 3. Figure 4. Coolant System Check......................................................................................................... 0139-3 Coolant System Drain.......................................................................................................... 0139-4 Coolant System Drain.......................................................................................................... 0139-5 Coolant System Fill.............................................................................................................. 0139-6
THERMOSTAT MAINTENANCE (CB534B)................................................................................................ WP 0140
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Page No. WP Sequence No. Figure 1. Figure 2. Thermostat Removal............................................................................................................ 0140-2 Thermostat Installation......................................................................................................... 0140-3
THERMOSTAT MAINTENANCE (CB534C)................................................................................................ WP 0141 Figure 1. Figure 2. Thermostat Removal............................................................................................................ 0141-2 Thermostat Installation......................................................................................................... 0141-3
THERMOSTAT HOUSING REPLACEMENT (CB534B).............................................................................. WP 0142 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Thermostat Housing Removal.............................................................................................. 0142-2 Thermostat Housing Removal.............................................................................................. 0142-3 Thermostat Housing Removal.............................................................................................. 0142-4 Thermostat Housing Installation........................................................................................... 0142-5 Thermostat Housing Installation........................................................................................... 0142-6 Thermostat Housing Installation........................................................................................... 0142-7
THERMOSTAT HOUSING REPLACEMENT (CB534C)............................................................................. WP 0143 Figure 1. Figure 2. Thermostat Housing Removal.............................................................................................. 0143-2 Thermostat Housing Installation........................................................................................... 0143-3
WATER PUMP REPLACEMENT................................................................................................................. WP 0144 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Water Pump Removal.......................................................................................................... 0144-2 Water Pump Removal.......................................................................................................... 0144-2 Water Pump Removal.......................................................................................................... 0144-3 Water Pump Removal.......................................................................................................... 0144-3 Water Pump Removal.......................................................................................................... 0144-4 Water Pump Installation....................................................................................................... 0144-5 Water Pump Installation....................................................................................................... 0144-6 Water Pump Installation....................................................................................................... 0144-6 Water Pump Installation....................................................................................................... 0144-7 Water Pump Installation....................................................................................................... 0144-7
FAN DRIVE HOUSING ASSEMBLY REPLACEMENT................................................................................ WP 0145
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Page No. WP Sequence No. Figure 1. Figure 2. Fan Drive Housing Assembly Removal................................................................................ 0145-1 Fan Drive Housing Assembly Installation............................................................................. 0145-2
FAN ASSEMBLY AND GUARD REPLACEMENT....................................................................................... WP 0146 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Fan Assembly and Guard Removal..................................................................................... 0146-2 Fan Assembly and Guard Removal..................................................................................... 0146-3 Fan Assembly and Guard Removal..................................................................................... 0146-4 Fan Assembly and Guard Installation.................................................................................. 0146-5 Fan Assembly and Guard Installation.................................................................................. 0146-5 Fan Assembly and Guard Installation.................................................................................. 0146-6
FAN V-BELTS MAINTENANCE................................................................................................................... WP 0147 Figure 1. Figure 2. Figure 3. Figure 4. Fan V-Belts Removal........................................................................................................... 0147-2 Fan V-Belts Installation........................................................................................................ 0147-3 Fan V-Belts Adjustment........................................................................................................ 0147-4 Fan V-Belts Adjustment........................................................................................................ 0147-4
ALTERNATOR REPLACEMENT................................................................................................................. WP 0148 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Alternator Removal............................................................................................................... 0148-1 Alternator Removal............................................................................................................... 0148-2 Alternator Removal............................................................................................................... 0148-3 Alternator Installation............................................................................................................ 0148-4 Alternator Installation............................................................................................................ 0148-5 Alternator Installation............................................................................................................ 0148-5
ALTERNATOR TEST................................................................................................................................... WP 0149 ALTERNATOR BRACKET REPLACEMENT............................................................................................... WP 0150 Figure 1. Figure 2. Figure 3. Figure 4. Alternator Bracket Removal................................................................................................. 0150-1 Alternator Bracket Removal................................................................................................. 0150-2 Alternator Bracket Installation.............................................................................................. 0150-2 Alternator Bracket Installation.............................................................................................. 0150-3
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Page No. WP Sequence No. ALTERNATOR CIRCUIT BREAKER REPLACEMENT............................................................................... WP 0151 Figure 1. Figure 2. Alternator Circuit Breaker Removal...................................................................................... 0151-2 Alternator Circuit Breaker Installation................................................................................... 0151-3
STARTER REPLACEMENT........................................................................................................................ WP 0152 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Starter Removal................................................................................................................... 0152-2 Starter Removal................................................................................................................... 0152-3 Starter Removal................................................................................................................... 0152-4 Starter Removal................................................................................................................... 0152-5 Starter Installation................................................................................................................ 0152-6 Starter Installation................................................................................................................ 0152-7 Starter Installation................................................................................................................ 0152-8 Starter Installation................................................................................................................ 0152-9
STARTER RELAY SWITCH ASSEMBLY REPLACEMENT........................................................................ WP 0153 Figure 1. Figure 2. Figure 3. Figure 4. Starter Relay Switch Removal.............................................................................................. 0153-2 Starter Relay Switch Removal.............................................................................................. 0153-2 Starter Relay Switch Installation........................................................................................... 0153-3 Starter Relay Switch Installation........................................................................................... 0153-4
MAIN RELAY REPLACEMENT................................................................................................................... WP 0154 Figure 1. Figure 2. Figure 3. Figure 4. Main Relay Removal............................................................................................................ 0154-2 Main Relay Removal............................................................................................................ 0154-3 Main Relay Installation......................................................................................................... 0154-3 Main Relay Installation......................................................................................................... 0154-4
RELAY REPLACEMENT............................................................................................................................. WP 0155 Figure 1. Table 1. Figure 2. Table 2. Relay Removal..................................................................................................................... 0155-2 Wire and Relay Connections (CB534B)............................................................................... 0155-3 Relay Removal..................................................................................................................... 0155-4 Wire and Relay Connections (CB534C)............................................................................... 0155-5
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Page No. WP Sequence No. Figure 3. Figure 4. Figure 5. Figure 6. Relay Removal..................................................................................................................... 0155-6 Relay Removal..................................................................................................................... 0155-7 Relay Installation.................................................................................................................. 0155-8 Relay Installation.................................................................................................................. 0155-9
PARKING BRAKE SWITCH REPLACEMENT............................................................................................ WP 0156 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Parking Brake Switch Removal............................................................................................ 0156-2 Parking Brake Switch Removal............................................................................................ 0156-3 Parking Brake Switch Removal............................................................................................ 0156-4 Parking Brake Switch Installation......................................................................................... 0156-5 Parking Brake Switch Installation......................................................................................... 0156-5 Parking Brake Switch Installation......................................................................................... 0156-6
WATER SPRAY SWITCH REPLACEMENT................................................................................................ WP 0157 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Water Spray Switch Removal............................................................................................... 0157-1 Water Spray Switch Removal............................................................................................... 0157-2 Water Spray Switch Removal............................................................................................... 0157-3 Water Spray Switch Installation............................................................................................ 0157-3 Water Spray Switch Installation............................................................................................ 0157-4 Water Spray Switch Installation............................................................................................ 0157-5
DRUM SELECT SWITCH REPLACEMENT................................................................................................ WP 0158 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Drum Select Switch Removal............................................................................................... 0158-1 Drum Select Switch Removal............................................................................................... 0158-2 Drum Select Switch Removal............................................................................................... 0158-3 Drum Select Switch Installation............................................................................................ 0158-3 Drum Select Switch Installation............................................................................................ 0158-4 Drum Select Switch Installation............................................................................................ 0158-5
VIBRATION CONTROL SWITCH REPLACEMENT.................................................................................... WP 0159 Figure 1. Vibration Control Switch Removal........................................................................................ 0159-2
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Page No. WP Sequence No. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Vibration Control Switch Removal........................................................................................ 0159-3 Vibration Control Switch Removal........................................................................................ 0159-3 Vibration Control Switch Installation..................................................................................... 0159-4 Vibration Control Switch Installation..................................................................................... 0159-4 Vibration Control Switch Installation..................................................................................... 0159-5
AMPLITUDE SELECT SWITCH REPLACEMENT...................................................................................... WP 0160 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Amplitude Select Switch Removal........................................................................................ 0160-2 Amplitude Select Switch Removal........................................................................................ 0160-3 Amplitude Select Switch Removal........................................................................................ 0160-3 Amplitude Select Switch Installation..................................................................................... 0160-4 Amplitude Select Switch Installation..................................................................................... 0160-4 Amplitude Select Switch Installation..................................................................................... 0160-5
PROPEL SPEED RANGE SWITCH REPLACEMENT................................................................................ WP 0161 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Propel Speed Range Switch Removal................................................................................. 0161-2 Propel Speed Range Switch Removal................................................................................. 0161-3 Propel Speed Range Switch Removal................................................................................. 0161-4 Propel Speed Range Switch Installation.............................................................................. 0161-4 Propel Speed Range Switch Installation.............................................................................. 0161-5 Propel Speed Range Switch Installation.............................................................................. 0161-6
WORK LIGHT CONTROL SWITCH REPLACEMENT................................................................................ WP 0162 Figure 1. Figure 2. Figure 3. Figure 4. Work Light Control Switch Removal..................................................................................... 0162-1 Work Light Control Switch Removal..................................................................................... 0162-2 Work Light Control Switch Installation.................................................................................. 0162-3 Work Light Control Switch Installation.................................................................................. 0162-4
INTERMITTENT WATER SPRAY TIMER REPLACEMENT....................................................................... WP 0163 Figure 1. Figure 2. Intermittent Water Spray Timer Removal............................................................................. 0163-2 Intermittent Water Spray Timer Removal............................................................................. 0163-3
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Page No. WP Sequence No. Figure 3. Figure 4. Intermittent Water Spray Timer Installation.......................................................................... 0163-4 Intermittent Water Spray Timer Installation.......................................................................... 0163-4
FUSE AND FUSE HOLDER REPLACEMENT............................................................................................ WP 0164 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Fuse and Fuse Holder Removal........................................................................................... 0164-1 Fuse and Fuse Holder Removal........................................................................................... 0164-2 Fuse and Fuse Holder Removal........................................................................................... 0164-3 Fuse and Fuse Holder Installation........................................................................................ 0164-3 Fuse and Fuse Holder Installation........................................................................................ 0164-4 Fuse and Fuse Holder Installation........................................................................................ 0164-5
STARTING AID SWITCH REPLACEMENT................................................................................................. WP 0165 Figure 1. Figure 2. Figure 3. Figure 4. Starting Aid Switch Removal................................................................................................ 0165-2 Starting Aid Switch Removal................................................................................................ 0165-3 Starting Aid Switch Installation............................................................................................. 0165-4 Starting Aid Switch Installation............................................................................................. 0165-5
ENGINE START SWITCH REPLACEMENT............................................................................................... WP 0166 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Engine Start Switch Removal............................................................................................... 0166-2 Engine Start Switch Removal............................................................................................... 0166-3 Engine Start Switch Removal............................................................................................... 0166-3 Engine Start Switch Installation............................................................................................ 0166-4 Engine Start Switch Installation............................................................................................ 0166-5 Engine Start Switch Installation............................................................................................ 0166-5
VIBRATION PUSH SWITCH REPLACEMENT........................................................................................... WP 0167 Figure 1. Figure 2. Figure 3. Figure 4. Vibration Push Switch Removal........................................................................................... 0167-2 Vibration Push Switch Removal........................................................................................... 0167-3 Vibration Push Switch Installation........................................................................................ 0167-4 Vibration Push Switch Installation........................................................................................ 0167-5
FUEL LEVEL GAUGE REPLACEMENT...................................................................................................... WP 0168
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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. Fuel Level Gauge Removal.................................................................................................. 0168-2 Fuel Level Gauge Removal.................................................................................................. 0168-3 Fuel Level Gauge Removal.................................................................................................. 0168-3 Fuel Level Gauge Removal.................................................................................................. 0168-4 Fuel Level Gauge Removal.................................................................................................. 0168-5 Fuel Level Gauge Installation............................................................................................... 0168-5 Fuel Level Gauge Installation............................................................................................... 0168-6 Fuel Level Gauge Installation............................................................................................... 0168-6 Fuel Level Gauge Installation............................................................................................... 0168-7 Fuel Level Gauge Installation............................................................................................... 0168-8
SERVICE METER REPLACEMENT............................................................................................................ WP 0169 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Service Meter Removal........................................................................................................ 0169-2 Service Meter Removal........................................................................................................ 0169-3 Service Meter Removal........................................................................................................ 0169-3 Service Meter Installation..................................................................................................... 0169-4 Service Meter Installation..................................................................................................... 0169-4 Service Meter Installation..................................................................................................... 0169-5
VIBRATIONS PER MINUTE (VPM) TACHOMETER AND FEET PER MINUTE (FPM) METER REPLACEMENT.......................................................................................................................................... WP 0170 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. VPM Tachometer and FPM Meter Removal........................................................................ 0170-2 VPM Tachometer and FPM Meter Removal........................................................................ 0170-3 VPM Tachometer and FPM Meter Removal........................................................................ 0170-3 VPM Tachometer and FPM Meter Removal........................................................................ 0170-4 VPM Tachometer and FPM Meter Removal........................................................................ 0170-5 VPM Tachometer and FPM Meter Removal........................................................................ 0170-6 VPM Tachometer and FPM Meter Installation..................................................................... 0170-7 VPM Tachometer and FPM Meter Installation..................................................................... 0170-8 VPM Tachometer and FPM Meter Installation..................................................................... 0170-9
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Page No. WP Sequence No. Figure 10. Figure 11. VPM Tachometer and FPM Meter Installation..................................................................... 0170-9 VPM Tachometer and FPM Meter Installation................................................................... 0170-10
HOURMETER PRESSURE SWITCH REPLACEMENT.............................................................................. WP 0171 Figure 1. Figure 2. Hourmeter Pressure Switch Removal.................................................................................. 0171-2 Hourmeter Pressure Switch Installation............................................................................... 0171-3
ENGINE OIL PRESSURE SWITCH REPLACEMENT................................................................................ WP 0172 Figure 1. Figure 2. Oil Pressure Switch Removal............................................................................................... 0172-2 Oil Pressure Switch Installation............................................................................................ 0172-3
LIGHTS CIRCUIT BREAKER REPLACEMENT.......................................................................................... WP 0173 Figure 1. Figure 2. Figure 3. Figure 4. Lights Circuit Breaker Removal............................................................................................ 0173-1 Lights Circuit Breaker Removal............................................................................................ 0173-2 Lights Circuit Breaker Installation......................................................................................... 0173-3 Lights Circuit Breaker Installation......................................................................................... 0173-3
STARTING AID RESISTOR REPLACEMENT............................................................................................ WP 0174 Figure 1. Figure 2. Figure 3. Figure 4. Starting Aid Resistor Removal............................................................................................. 0174-1 Starting Aid Resistor Removal............................................................................................. 0174-2 Starting Aid Resistor Installation.......................................................................................... 0174-3 Starting Aid Resistor Installation.......................................................................................... 0174-3
FUEL SOLENOID RESISTOR REPLACEMENT......................................................................................... WP 0175 Figure 1. Figure 2. Figure 3. Figure 4. Fuel Solenoid Resistor Removal.......................................................................................... 0175-1 Fuel Solenoid Resistor Removal.......................................................................................... 0175-2 Fuel Solenoid Resistor Installation....................................................................................... 0175-3 Fuel Solenoid Resistor Installation....................................................................................... 0175-3
ALTERNATOR LIGHT REPLACEMENT..................................................................................................... WP 0176 Figure 1. Figure 2. Figure 3. Alternator Light Removal...................................................................................................... 0176-1 Alternator Light Removal...................................................................................................... 0176-2 Alternator Light Removal...................................................................................................... 0176-3
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Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Alternator Light Removal...................................................................................................... 0176-3 Alternator Light Installation................................................................................................... 0176-4 Alternator Light Installation................................................................................................... 0176-5 Alternator Light Installation................................................................................................... 0176-5 Alternator Light Installation................................................................................................... 0176-6
FUNCTIONAL INDICATOR LIGHT ASSEMBLY REPLACEMENT............................................................. WP 0177 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Functional Indicator Light Removal...................................................................................... 0177-2 Functional Indicator Light Removal...................................................................................... 0177-3 Functional Indicator Light Removal...................................................................................... 0177-3 Functional Indicator Light Installation................................................................................... 0177-4 Functional Indicator Light Installation................................................................................... 0177-5 Functional Indicator Light Installation................................................................................... 0177-6
WORK LIGHT ASSEMBLY MAINTENANCE............................................................................................... WP 0178 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Work Light Removal............................................................................................................. 0178-1 Work Light Removal............................................................................................................. 0178-2 Work Light Removal............................................................................................................. 0178-3 Work Light Installation.......................................................................................................... 0178-3 Work Light Installation.......................................................................................................... 0178-4 Work Light Installation.......................................................................................................... 0178-5 Work Light Adjustment......................................................................................................... 0178-5 Work Light Adjustment......................................................................................................... 0178-6
WORK LIGHT BULB REPLACEMENT........................................................................................................ WP 0179 Figure 1. Figure 2. Figure 3. Figure 4. Work Light Bulb Removal..................................................................................................... 0179-1 Work Light Bulb Removal..................................................................................................... 0179-2 Work Light Bulb Installation.................................................................................................. 0179-3 Work Light Bulb Installation.................................................................................................. 0179-3
WARNING LIGHTS ASSEMBLY REPLACEMENT..................................................................................... WP 0180
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Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Warning Light Removal........................................................................................................ 0180-2 Warning Light Removal........................................................................................................ 0180-3 Warning Light Removal........................................................................................................ 0180-3 Warning Light Installation..................................................................................................... 0180-4 Warning Light Installation..................................................................................................... 0180-5 Warning Light Installation..................................................................................................... 0180-6
BACKUP ALARM SENDING UNIT REPLACEMENT.................................................................................. WP 0181 Figure 1. Figure 2. Figure 3. Figure 4. Backup Alarm Sending Unit Removal.................................................................................. 0181-1 Backup Alarm Sending Unit Removal.................................................................................. 0181-2 Backup Alarm Sending Unit Installation............................................................................... 0181-2 Backup Alarm Sending Unit Installation............................................................................... 0181-3
WATER TEMPERATURE SENDING UNIT REPLACEMENT..................................................................... WP 0182 Figure 1. Figure 2. Water Temperature Sending Unit Removal......................................................................... 0182-2 Water Temperature Sending Unit Installation...................................................................... 0182-3
FUEL LEVEL SENDING UNIT REPLACEMENT......................................................................................... WP 0183 Figure 1. Figure 2. Fuel Level Sending Unit Removal........................................................................................ 0183-2 Fuel Level Sending Unit Installation..................................................................................... 0183-3
VIBRATION SENSOR MAINTENANCE...................................................................................................... WP 0184 Figure 1. Figure 2. Figure 3. Vibration Sensor Removal.................................................................................................... 0184-2 Vibration Sensor Installation................................................................................................. 0184-3 Vibration Sensor Adjustment................................................................................................ 0184-4
HYDRAULIC OIL TEMPERATURE SENSOR REPLACEMENT................................................................. WP 0185 Figure 1. Figure 2. Temperature Sensor Removal............................................................................................. 0185-2 Temperature Sensor Installation.......................................................................................... 0185-3
WARNING HORN ASSEMBLY REPLACEMENT........................................................................................ WP 0186 Figure 1. Figure 2. Warning Horn Removal........................................................................................................ 0186-1 Warning Horn Removal........................................................................................................ 0186-2
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Page No. WP Sequence No. Figure 3. Figure 4. Warning Horn Installation..................................................................................................... 0186-3 Warning Horn Installation..................................................................................................... 0186-3
BACKUP ALARM REPLACEMENT............................................................................................................. WP 0187 Figure 1. Figure 2. Figure 3. Figure 4. Backup Alarm Removal........................................................................................................ 0187-2 Backup Alarm Removal........................................................................................................ 0187-3 Backup Alarm Installation..................................................................................................... 0187-4 Backup Alarm Installation..................................................................................................... 0187-5
HORN SWITCH REPLACEMENT............................................................................................................... WP 0188 Figure 1. Figure 2. Figure 3. Figure 4. Horn Switch Removal........................................................................................................... 0188-1 Horn Switch Removal........................................................................................................... 0188-2 Horn Switch Installation........................................................................................................ 0188-3 Horn Switch Installation........................................................................................................ 0188-3
HORN ASSEMBLY REPLACEMENT.......................................................................................................... WP 0189 Figure 1. Figure 2. Figure 3. Figure 4. Horn Removal...................................................................................................................... 0189-2 Horn Removal...................................................................................................................... 0189-3 Horn Installation................................................................................................................... 0189-4 Horn Installation................................................................................................................... 0189-5
BATTERY MAINTENANCE......................................................................................................................... WP 0190 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Battery Inspection................................................................................................................. 0190-3 Battery Removal................................................................................................................... 0190-4 Battery Removal................................................................................................................... 0190-5 Battery Installation................................................................................................................ 0190-6 Battery Installation................................................................................................................ 0190-7
BATTERY DISCONNECT SWITCH REPLACEMENT................................................................................ WP 0191 Figure 1. Figure 2. Figure 3. Battery Disconnect Switch Removal.................................................................................... 0191-2 Battery Disconnect Switch Removal.................................................................................... 0191-3 Battery Disconnect Switch Installation................................................................................. 0191-4
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Page No. WP Sequence No. Figure 4. Battery Disconnect Switch Installation................................................................................. 0191-5
BATTERY CABLE REPLACEMENT............................................................................................................ WP 0192 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. Battery Cable Removal........................................................................................................ 0192-3 Battery Cable Removal........................................................................................................ 0192-3 Battery Cable Removal........................................................................................................ 0192-4 Battery Cable Removal........................................................................................................ 0192-5 Battery Cable Removal........................................................................................................ 0192-6 Battery Cable Removal........................................................................................................ 0192-7 Battery Cable Installation..................................................................................................... 0192-8 Battery Cable Installation..................................................................................................... 0192-8 Battery Cable Installation..................................................................................................... 0192-9 Battery Cable Installation................................................................................................... 0192-10 Battery Cable Installation................................................................................................... 0192-11 Battery Cable Installation................................................................................................... 0192-12 Battery Cable Installation................................................................................................... 0192-13 Battery Cable Installation................................................................................................... 0192-13
NATO CONNECTOR REPLACEMENT....................................................................................................... WP 0193 Figure 1. Figure 2. Figure 3. Figure 4. NATO Connector Removal................................................................................................... 0193-3 NATO Connector Removal................................................................................................... 0193-4 NATO Connector Installation................................................................................................ 0193-5 NATO Connector Installation................................................................................................ 0193-6
GROUND CABLE REPLACEMENT............................................................................................................ WP 0194 Figure 1. Figure 2. Ground Cable Removal........................................................................................................ 0194-2 Ground Cable Installation..................................................................................................... 0194-4
GENERAL WIRING REPAIR....................................................................................................................... WP 0195 Figure 1. Figure 2. Solderless Terminal Replacement....................................................................................... 0195-2 Wire Splicing Using Butt Connectors................................................................................... 0195-3
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Page No. WP Sequence No. 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. Wire Splicing Using Solder Method...................................................................................... 0195-5 Wire Splicing Using Solder Method...................................................................................... 0195-6 Male Cable Connector Replacement................................................................................... 0195-7 Female Cable Connector Replacement............................................................................... 0195-8 Wiring Repair........................................................................................................................ 0195-9 Wiring Repair...................................................................................................................... 0195-10 Wiring Repair...................................................................................................................... 0195-10 Wiring Repair...................................................................................................................... 0195-11 Wiring Repair...................................................................................................................... 0195-12 Wiring Repair...................................................................................................................... 0195-13 Wiring Repair...................................................................................................................... 0195-13 Wiring Repair...................................................................................................................... 0195-14 Wiring Repair...................................................................................................................... 0195-14 Wiring Repair...................................................................................................................... 0195-15 Wiring Repair...................................................................................................................... 0195-15
ENGINE WIRING HARNESS REPLACEMENT.......................................................................................... WP 0196 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Engine Wiring Harness Removal......................................................................................... 0196-3 Engine Wiring Harness Removal......................................................................................... 0196-4 Engine Wiring Harness Removal......................................................................................... 0196-4 Engine Wiring Harness Removal......................................................................................... 0196-5 Engine Wiring Harness Removal......................................................................................... 0196-5 Engine Wiring Harness Removal......................................................................................... 0196-6 Engine Wiring Harness Removal......................................................................................... 0196-6 Engine Wiring Harness Removal......................................................................................... 0196-7 Engine Wiring Harness Removal......................................................................................... 0196-7 Engine Wiring Harness Removal......................................................................................... 0196-8 Engine Wiring Harness Removal......................................................................................... 0196-8
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Page No. WP Sequence No. 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. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Engine Wiring Harness Removal......................................................................................... 0196-9 Engine Wiring Harness Removal......................................................................................... 0196-9 Engine Wiring Harness Removal....................................................................................... 0196-10 Engine Wiring Harness Removal....................................................................................... 0196-10 Engine Wiring Harness Removal....................................................................................... 0196-11 Engine Wiring Harness Removal....................................................................................... 0196-11 Engine Wiring Harness Installation.................................................................................... 0196-12 Engine Wiring Harness Installation.................................................................................... 0196-12 Engine Wiring Harness Installation.................................................................................... 0196-13 Engine Wiring Harness Installation.................................................................................... 0196-13 Engine Wiring Harness Installation.................................................................................... 0196-13 Engine Wiring Harness Installation.................................................................................... 0196-14 Engine Wiring Harness Installation.................................................................................... 0196-14 Engine Wiring Harness Installation.................................................................................... 0196-15 Engine Wiring Harness Installation.................................................................................... 0196-15 Engine Wiring Harness Installation.................................................................................... 0196-16 Engine Wiring Harness Installation.................................................................................... 0196-16 Engine Wiring Harness Installation.................................................................................... 0196-17 Engine Wiring Harness Installation.................................................................................... 0196-17 Engine Wiring Harness Installation.................................................................................... 0196-18 Engine Wiring Harness Installation.................................................................................... 0196-18 Engine Wiring Harness Installation.................................................................................... 0196-19 Engine Wiring Harness Installation.................................................................................... 0196-20
FRONT WIRING HARNESS REPLACEMENT............................................................................................ WP 0197 Figure 1. Figure 2. Figure 3. Front Wiring Harness Removal............................................................................................ 0197-2 Front Wiring Harness Removal............................................................................................ 0197-3 Front Wiring Harness Removal............................................................................................ 0197-3
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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. Figure 22. Front Wiring Harness Removal............................................................................................ 0197-4 Front Wiring Harness Removal............................................................................................ 0197-4 Front Wiring Harness Removal............................................................................................ 0197-5 Front Wiring Harness Removal............................................................................................ 0197-5 Front Wiring Harness Removal............................................................................................ 0197-6 Front Wiring Harness Removal............................................................................................ 0197-6 Front Wiring Harness Removal............................................................................................ 0197-7 Front Wiring Harness Removal............................................................................................ 0197-8 Front Wiring Harness Installation......................................................................................... 0197-9 Front Wiring Harness Installation......................................................................................... 0197-9 Front Wiring Harness Installation....................................................................................... 0197-10 Front Wiring Harness Installation....................................................................................... 0197-10 Front Wiring Harness Installation....................................................................................... 0197-11 Front Wiring Harness Installation....................................................................................... 0197-11 Front Wiring Harness Installation....................................................................................... 0197-12 Front Wiring Harness Installation....................................................................................... 0197-12 Front Wiring Harness Installation....................................................................................... 0197-13 Front Wiring Harness Installation....................................................................................... 0197-13 Front Wiring Harness Installation....................................................................................... 0197-14
REAR WIRING HARNESS REPLACEMENT.............................................................................................. WP 0198 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Rear Wiring Harness Removal............................................................................................. 0198-2 Rear Wiring Harness Removal............................................................................................. 0198-3 Rear Wiring Harness Removal............................................................................................. 0198-3 Rear Wiring Harness Removal............................................................................................. 0198-4 Rear Wiring Harness Removal............................................................................................. 0198-4 Rear Wiring Harness Removal............................................................................................. 0198-5 Rear Wiring Harness Removal............................................................................................. 0198-6
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Page No. WP Sequence No. 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. Rear Wiring Harness Removal............................................................................................. 0198-7 Rear Wiring Harness Removal............................................................................................. 0198-7 Rear Wiring Harness Removal............................................................................................. 0198-8 Rear Wiring Harness Removal............................................................................................. 0198-9 Rear Wiring Harness Installation........................................................................................ 0198-10 Rear Wiring Harness Installation........................................................................................ 0198-11 Rear Wiring Harness Installation........................................................................................ 0198-11 Rear Wiring Harness Installation........................................................................................ 0198-12 Rear Wiring Harness Installation........................................................................................ 0198-13 Rear Wiring Harness Installation........................................................................................ 0198-13 Rear Wiring Harness Installation........................................................................................ 0198-14 Rear Wiring Harness Installation........................................................................................ 0198-14 Rear Wiring Harness Installation........................................................................................ 0198-15 Rear Wiring Harness Installation........................................................................................ 0198-15 Rear Wiring Harness Installation........................................................................................ 0198-16
INSTRUMENT WIRING HARNESS REPLACEMENT................................................................................. WP 0199 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Instrument Wiring Harness Removal.................................................................................... 0199-2 Instrument Wiring Harness Removal.................................................................................... 0199-3 Instrument Wiring Harness Removal.................................................................................... 0199-4 Instrument Wiring Harness Removal.................................................................................... 0199-5 Instrument Wiring Harness Removal.................................................................................... 0199-5 Instrument Wiring Harness Removal.................................................................................... 0199-6 Instrument Wiring Harness Removal.................................................................................... 0199-6 Instrument Wiring Harness Removal.................................................................................... 0199-7 Instrument Wiring Harness Removal.................................................................................... 0199-7 Instrument Wiring Harness Removal.................................................................................... 0199-8 Instrument Wiring Harness Removal.................................................................................... 0199-8
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Page No. WP Sequence No. 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. Instrument Wiring Harness Removal.................................................................................... 0199-9 Instrument Wiring Harness Removal.................................................................................. 0199-10 Instrument Wiring Harness Installation............................................................................... 0199-11 Instrument Wiring Harness Installation............................................................................... 0199-12 Instrument Wiring Harness Installation............................................................................... 0199-12 Instrument Wiring Harness Installation............................................................................... 0199-13 Instrument Wiring Harness Installation............................................................................... 0199-13 Instrument Wiring Harness Installation............................................................................... 0199-14 Instrument Wiring Harness Installation............................................................................... 0199-14 Instrument Wiring Harness Installation............................................................................... 0199-15 Instrument Wiring Harness Installation............................................................................... 0199-15 Instrument Wiring Harness Installation............................................................................... 0199-16 Instrument Wiring Harness Installation............................................................................... 0199-17 Instrument Wiring Harness Installation............................................................................... 0199-17 Instrument Wiring Harness Installation............................................................................... 0199-18
MAIN WIRING HARNESS REPLACEMENT (CB534B).............................................................................. WP 0200 MAIN WIRING HARNESS REPLACEMENT (CB534C).............................................................................. WP 0201 SEPARATE AND CONNECT VIBRATORY AND PROPEL PUMPS........................................................... WP 0202 Figure 1. Figure 2. Figure 3. Figure 4. Vibratory and Propel Pumps Separate................................................................................. 0202-2 Vibratory and Propel Pumps Separate................................................................................. 0202-3 Vibratory and Propel Pumps Connect.................................................................................. 0202-3 Vibratory and Propel Pumps Connect.................................................................................. 0202-4
VIBRATORY AND PROPEL PUMPS REPLACEMENT.............................................................................. WP 0203 Figure 1. Figure 2. Vibratory and Propel Pumps Removal................................................................................. 0203-3 Vibratory and Propel Pumps Installation.............................................................................. 0203-5
REAR PROPEL MOTOR REPLACEMENT................................................................................................. WP 0204 Figure 1. Rear Propel Motor Removal................................................................................................. 0204-3
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Page No. WP Sequence No. Figure 2. Rear Propel Motor Installation.............................................................................................. 0204-4
PROPEL MOTOR AND TORQUE HUB REPLACEMENT.......................................................................... WP 0205 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Propel Motor and Torque Hub Removal............................................................................... 0205-2 Propel Motor and Torque Hub Removal............................................................................... 0205-3 Propel Motor and Torque Hub Removal............................................................................... 0205-4 Propel Motor and Torque Hub Installation............................................................................ 0205-5 Propel Motor and Torque Hub Installation............................................................................ 0205-6 Propel Motor and Torque Hub Installation............................................................................ 0205-7
PROPEL CONTROL LEVER ASSEMBLY MAINTENANCE....................................................................... WP 0206 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Propel Control Lever Removal............................................................................................. 0206-2 Propel Control Lever Removal............................................................................................. 0206-3 Propel Control Lever Disassembly....................................................................................... 0206-5 Propel Control Lever Assembly............................................................................................ 0206-7 Propel Control Lever Installation.......................................................................................... 0206-8 Propel Control Lever Installation.......................................................................................... 0206-9
PROPEL CONTROL LEVER VIBRATORY SYSTEM ENGAGEMENT STOPS ADJUSTMENT............................................................................................................................................. WP 0207 Figure 1. Figure 2. Figure 3. Engagement Stops Adjustment............................................................................................ 0207-2 Engagement Stops Adjustment............................................................................................ 0207-3 Engagement Stops Adjustment............................................................................................ 0207-4
PROPEL CONTROL LEVER TENSION ADJUSTMENT............................................................................. WP 0208 Figure 1. Propel Control Lever Tension Adjustment............................................................................ 0208-1
PROPEL AND VIBRATORY VALVE TESTS AND ADJUSTMENTS........................................................... WP 0209 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Valve Tests and Adjustments............................................................................................... 0209-2 Valve Tests and Adjustments............................................................................................... 0209-3 Valve Tests and Adjustments............................................................................................... 0209-5 Valve Tests and Adjustments............................................................................................... 0209-6 Valve Tests and Adjustments............................................................................................... 0209-7
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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. Valve Tests and Adjustments............................................................................................... 0209-8 Valve Tests and Adjustments............................................................................................... 0209-9 Valve Tests and Adjustments............................................................................................. 0209-10 Valve Tests and Adjustments............................................................................................. 0209-11 Valve Tests and Adjustments............................................................................................. 0209-12 Valve Tests and Adjustments............................................................................................. 0209-12 Valve Tests and Adjustments............................................................................................. 0209-13 Valve Tests and Adjustments............................................................................................. 0209-14 Valve Tests and Adjustments............................................................................................. 0209-15 Valve Tests and Adjustments............................................................................................. 0209-16 Valve Tests and Adjustments............................................................................................. 0209-16 Valve Tests and Adjustments............................................................................................. 0209-17 Valve Tests and Adjustments............................................................................................. 0209-18 Valve Tests and Adjustments............................................................................................. 0209-19
PRESSURE OVERRIDE RELIEF (POR) VALVE PRESSURE TEST (CB534C)........................................ WP 0210 Figure 1. Figure 2. Pressure Override Relief Valve Pressure Test..................................................................... 0210-1 Pressure Override Relief Valve Pressure Test..................................................................... 0210-2
PROPEL AND SPEED CONTROL VALVE REPAIR................................................................................... WP 0211 Figure 1. Figure 2. Propel and Speed Control Valve Disassembly..................................................................... 0211-2 Propel and Speed Control Valve Assembly......................................................................... 0211-3
HYDRAULIC PUMP DRIVE REPLACEMENT............................................................................................. WP 0212 Figure 1. Figure 2. Hydraulic Pump Drive Removal........................................................................................... 0212-2 Hydraulic Pump Drive Installation........................................................................................ 0212-3
FRONT AND REAR PROPEL GEARBOX SERVICE.................................................................................. WP 0213 Figure 1. Figure 2. Figure 3. Propel Gearbox Service....................................................................................................... 0213-2 Propel Gear Service............................................................................................................. 0213-3 Propel Gearbox Service....................................................................................................... 0213-4
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Page No. WP Sequence No. SEPARATE AND CONNECT PROPEL MOTOR AND TORQUE HUB....................................................... WP 0214 Figure 1. Figure 2. Figure 3. Figure 4. Propel Motor and Torque Hub Separate.............................................................................. 0214-1 Propel Motor and Torque Hub Separate.............................................................................. 0214-2 Propel Motor and Start Hub Connect................................................................................... 0214-3 Propel Motor and Start Hub Connect................................................................................... 0214-4
UNIVERSAL JOINT AND SHAFT MAINTENANCE..................................................................................... WP 0215 Figure 1. Figure 2. Universal Joint and Shaft Disassembly................................................................................ 0215-3 Universal Joint and Shaft Assembly..................................................................................... 0215-5
BRAKE CONTROL VALVE REPLACEMENT.............................................................................................. WP 0216 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. Brake Control Valve Removal.............................................................................................. 0216-2 Brake Control Valve Removal.............................................................................................. 0216-3 Brake Control Valve Removal.............................................................................................. 0216-3 Brake Control Valve Removal.............................................................................................. 0216-4 Brake Control Valve Removal.............................................................................................. 0216-4 Brake Control Valve Removal.............................................................................................. 0216-5 Brake Control Valve Removal.............................................................................................. 0216-5 Brake Control Valve Removal.............................................................................................. 0216-6 Brake Control Valve Installation........................................................................................... 0216-7 Brake Control Valve Installation........................................................................................... 0216-7 Brake Control Valve Installation........................................................................................... 0216-8 Brake Control Valve Installation........................................................................................... 0216-8 Brake Control Valve Installation........................................................................................... 0216-9 Brake Control Valve Installation........................................................................................... 0216-9 Brake Control Valve Installation......................................................................................... 0216-10 Brake Control Valve Installation......................................................................................... 0216-10
BRAKE CONTROL VALVE REPAIR........................................................................................................... WP 0217 Figure 1. Brake Control Valve Disassembly........................................................................................ 0217-2
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Page No. WP Sequence No. Figure 2. Brake Control Valve Assembly............................................................................................. 0217-3
BRAKE HOSES, LINES, AND FITTINGS REPLACEMENT........................................................................ WP 0218 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. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Brake Hoses, Lines, and Fittings Inspection........................................................................ 0218-2 Brake Hoses, Lines, and Fittings Replacement................................................................... 0218-3 Brake Hoses, Lines, and Fittings Replacement................................................................... 0218-4 Brake Hoses, Lines, and Fittings Replacement................................................................... 0218-4 Brake Hoses, Lines, and Fittings Replacement................................................................... 0218-5 Brake Hoses, Lines, and Fittings Replacement................................................................... 0218-5 Brake Hoses, Lines, and Fittings Replacement................................................................... 0218-6 Brake Hoses, Lines, and Fittings Replacement................................................................... 0218-7 Brake Hoses, Lines, and Fittings Replacement................................................................... 0218-8 Brake Hoses, Lines and Fitting Replacement...................................................................... 0218-8 Brake Hoses, Lines, and Fittings Replacement................................................................... 0218-9 Brake Hoses, Lines, and Fittings Replacement................................................................... 0218-9 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-10 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-10 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-11 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-11 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-12 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-12 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-13 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-13 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-14 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-15 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-16 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-17 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-18
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Page No. WP Sequence No. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Figure 35. Figure 36. Figure 37. Figure 38. Figure 39. Figure 40. Figure 41. Figure 42. Figure 43. Figure 44. Figure 45. Figure 46. Figure 47. Figure 48. Figure 49. Figure 50. Figure 51. Figure 52. Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-19 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-20 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-20 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-21 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-21 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-22 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-23 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-23 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-24 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-25 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-26 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-26 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-27 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-27 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-28 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-28 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-29 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-30 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-31 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-32 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-32 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-33 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-34 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-35 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-35 Brake Hoses, Lines, and Replacement.............................................................................. 0218-36 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-36
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Page No. WP Sequence No. Figure 53. Figure 54. Figure 55. Figure 56. Figure 57. Figure 58. Figure 59. Figure 60. Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-37 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-37 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-38 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-38 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-39 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-39 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-40 Brake Hoses, Lines, and Fittings Replacement................................................................. 0218-41
MANUAL BRAKE RELEASE PUMP MAINTENANCE................................................................................. WP 0219 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Manual Brake Release Pump Removal............................................................................... 0219-2 Manual Brake Release Pump Removal............................................................................... 0219-3 Manual Brake Release Pump Removal............................................................................... 0219-3 Manual Brake Release Pump Removal............................................................................... 0219-4 Manual Brake Release Pump Disassembly......................................................................... 0219-5 Manual Brake Release Pump Assembly.............................................................................. 0219-7 Manual Brake Release Pump Installation............................................................................ 0219-8 Manual Brake Release Pump Installation............................................................................ 0219-9 Manual Brake Release Pump Installation.......................................................................... 0219-10 Manual Brake Release Pump Installation.......................................................................... 0219-10
BRAKE CONTROL VALVE COIL REPLACEMENT.................................................................................... WP 0220 Figure 1. Figure 2. Brake Control Valve Coil Removal....................................................................................... 0220-2 Brake Control Valve Coil Installation.................................................................................... 0220-3
STEERING WHEEL AND COLUMN REPLACEMENT................................................................................ WP 0221 Figure 1. Figure 2. Figure 3. Figure 4. Index Steering Wheel and Column Removal................................................................................. 0221-2 Steering Wheel and Column Removal................................................................................. 0221-3 Steering Wheel and Column Installation.............................................................................. 0221-4 Steering Wheel and Column Installation.............................................................................. 0221-5
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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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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 1 The TABLE OF CONTENTS lists the titles of each Chapter and Work Package. CHAPTER 1 provides general information, equipment description, and theory of operation. CHAPTER 2 provides troubleshooting procedures. CHAPTER 3 provides PMCS maintenance instructions. CHAPTER 4 provides maintenance instructions.
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.
Troubleshooting section is setup by either how a physical problem is occurring or how an active or stored trouble code is read from a diagnostic tool. A prescribed flow path through decision-making will lead you to a solution to the problem. 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 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.
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HOW TO USE THIS MANUAL - Continued

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 1 GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION FOR CB534B or CB534C ROLLER, MOTORIZED, VIBRATING TANDEM STEEL DRUMS NSN 3895-01-396-2822 AND 3895-01-502-4005
TM 5-3895-379-23-1 FIELD MAINTENANCE GENERAL INFORMATION
0001
SCOPE 1. Type of Manual. This manual is for use in performing Field Maintenance on the CB534B and CB534C Rollers, Motorized, Vibrating Tandem Steel Drums. 2. Equipment Name and Model Number. Models CB534B and CB534C. Roller, Motorized, Vibrating Tandem Steel Drums: Caterpillar
3. Purpose of Equipment. The CB534B and CB534C Rollers are self-propelled and designed to compact asphalt and gravel bases for parking lots, streets, roads, and highways. MAINTENANCE FORMS, RECORDS, AND REPORTS Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR) If your Steel Wheel Roller needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you do not like about your equipment. Let us know why you do not like the design or performance.
All non-Aviation/Missile EIRs and PQDRs must be submitted through the Product Data Reporting and Evaluation Program (PDREP) Web site. The PDREP site is: https://www.pdrep.csd.disa.mil/. If you do not have Internet access, you may submit your information using an SF 368 (Product Quality Deficiency Report). You can send your SF 368 using email, regular mail, or fax using the addresses/fax numbers specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual. We will send you a reply.
CORROSION PREVENTION AND CONTROL (CPC) Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items. Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals. It is commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron. Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or cracking. Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation (oxygen), solvation (solvents), or photolytic (light, typically UV) processes. The most common exposures are excessive heat or light. Damage from these processes will appear as cracking, softening, swelling, and/or breaking. SF Form 368, Product Quality Deficiency Report (PDQR) should be submitted to the address specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual. DESTRUCTION OF MILITARY EQUIPMENT TO PREVENT ENEMY USE Procedures for Destruction of Tank-Automotive Equipment To Prevent Enemy Use (U.S. Army TACOM Life Cycle Management Command) can be found in TM 750-244-6.
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0001
PREPARATION FOR STORAGE OR SHIPMENT For procedures for preparation for storage or shipment, refer to PREPARATION FOR TRANSPORT (TM 5-3895-379-10) and PREPARATION FOR STORAGE AND SHIPMENT (Volume 2, WP 0281). WARRANTY INFORMATION 1. Caterpillar warrants the following products sold by it and operating within the area specified under "Limitations" to be free from defects in material and workmanship: a. New earthmoving, construction materials handling, and paving product machines designated by Caterpillar as having a 6 month/unlimited hour warranty. See your Caterpillar dealer for a complete listing of covered models. b. New engines used as replacements in such Caterpillar machines. c. Attachments installed on such machines prior to delivery.
2. An additional warranty against breakage is applicable to certain Caterpillar Ground Engaging Tools. An additional warranty against wear is also applicable to certain weld-on landfill compactor plus tips. Refer to the appropriate warranty statement for coverage details. This warranty does not apply to Caterpillar brand batteries which are covered by a different Caterpillar warranty. 3. The warranty is subject to the following: a. Warranty Period. For the CB534B Roller, the warranty period is 6 months, starting from date of delivery to the first user. For the CB534C Roller, the warranty period is 12 months, starting from the date of delivery to the first user.
b. Manufacturer Responsibilities. If a defect in material or workmanship is found during the warranty period, the manufacturer will, during normal working hours and at a place of business of a manufacturer or other authorized source: Provide (at manufacturer's expense) new, Major Component Exchange (MCE), Remanufactured, or Caterpillar approved repaired parts or assembled components needed to correct the defect.
NOTE
Items replaced under this warranty become the property of manufacturer. Replace lubricating oil, filters, antifreeze, and other service items made unusable by the defect. Provide labor needed to correct the defect except in the case of a new replacement engine originally installed by other than a manufacturer's dealer or other authorized source. In that case, labor is limited to repair only, and removal and installation is the user's responsibility.
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0001
WARRANTY INFORMATION - Continued c. User Responsibilities. The user is responsible for: The costs associated with transporting the roller. Labor costs, except as stated under "Manufacturer Responsibilities." Local taxes, if applicable. Parts shipping charges in excess of those which are usual and customary. Costs to investigate complaints unless the problem is caused by a defect in manufacturer material or workmanship. Giving timely notice of a warrantable failure and promptly making the product available for repair. Performance of the required maintenance and use of proper fuel, oil, lubricants, and coolant.
d. Limitations. Manufacturer is not responsible for failures resulting from: Any use or installation which manufacturer judges improper. Attachments, accessory items, and parts not sold by Caterpillar. Abuse, neglect, and/or improper repair. User's unreasonable delay in making the product available after being notified of a potential product problem. NEITHER THE FOREGOING EXPRESS WARRANTY NOR ANY OTHER WARRANTY BY CATERPILLAR, EXPRESS OR IMPLIED, IS APPLICABLE TO ANY ITEM CATERPILLAR SELLS WHICH IS WARRANTED TO THE USER BY ITS MANUFACTURER. THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. REMEDIES UNDER THIS WARRANTY ARE LIMITED TO THE PROVISION OF MATERIAL AND SERVICES, AS SPECIFIED HEREIN. CATERPILLAR IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. 4. This warranty applies to all the geographic areas covered by the U.S.A. and Canadian dealers only. In other areas, different warranties may apply. Copies of applicable warranties may be obtained by writing Caterpillar Inc., 100 N.E. Adams Street, Peoria, IL 61829-3345. 5. As used in this warranty, the term "Caterpillar" means Caterpillar Inc., or one of its subsidiaries, except Caterpillar Overseas S.A., Caterpillar France S.A., Caterpillar (U.K.) Limited, or Caterpillar Belgium S.A., whichever last sold the product involved. NOMENCLATURE CROSS-REFERENCE COMMON NAME Roller OFFICIAL NOMENCLATURE Roller, Motorized, Vibrating Tandem Steel Drums Caterpillar Model CB534B and Model CB534C
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0001
LIST OF ABBREVIATIONS/ACRONYMS
NOTE
Refer to MIL-STD-12 for standard abbreviations. Table 1. List of Abbreviations/Acronyms. Abbreviation AAL AC BII CAGEC CCW COEI CPC CW daN DC EIR FPM gal hp IAW in. kg kPa kph lb MAC mm Definition Additional Authorization List Alternating Current Basic Issue Items Commercial and Government Entity Code Counterclockwise Components of End Items Corrosion Prevention and Control Clockwise Deka Newton Direct Current Equipment Improvement Recommendations Feet Per Minute Gallons Horsepower In Accordance With Inches Kilograms Kilopascal Kilometers Per Hour Pounds Maintenance Allocation Chart Millimeters
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0001
LIST OF ABBREVIATIONS/ACRONYMS - Continued Table 1. Abbreviation mph NBC Nm No NSN PDQR pli PMCS P/N ROPS rpm RPSTL SCU TAMMS TB TM TMDE TULSA U/I UOC VAC VDC VPM List of Abbreviations/Acronyms - Continued. Definition Miles Per Hour Nuclear-Biological-Chemical Newton Meter Number National Stock Number Product Quality Deficiency Report Pounds per Linear Inch Preventive Maintenance Checks and Services Part Number Rollover Protective Structure Revolutions Per Minute Repair Parts and Special Tools Lists Steering Control Unit The Army Maintenance Management System Technical Booklet Technical Manual Test, Measurement, and Diagnostic Equipment TACOM Unique Logistics Support Applications Unit of Issue Usable On Code Volts of Alternating Current Volts of Direct Current Vibrations Per Minute
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0001
LIST OF ABBREVIATIONS/ACRONYMS - Continued Table 1. Abbreviation WP List of Abbreviations/Acronyms - Continued. Definition Work Package
END OF WORK PACKAGE
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0002
FIELD MAINTENANCE EQUIPMENT DESCRIPTION AND DATA
EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES Characteristics
NOTE
Characteristics, capabilities, and features are the same for the CB534B and CB534C Rollers, Motorized, Vibrating Tandem Steel Drums, except as noted. 1. The roller is designed to be operated by one operator. 2. The motion of the roller is controlled by the operator using a steering wheel and propel control lever (joystick). 3. The roller is propelled by a hydrostatic transmission driven by a four-cylinder, turbocharged engine. 4. Compaction is achieved with two cylindrical drums. Hydraulic motor-driven eccentric weights produce vibration in the drums which enhances compaction. Capabilities and Features 1. The roller has a static tip angle range of 40 to 50 degrees. The static angle is the slope angle where a stationary roller will begin to tip over to the side when it is parallel to the slope, in straight-ahead travel position. a. Roller operating stability depends upon many factors including operating speed, steering, braking, terrain conditions, fluid levels, and most of all, operator's skill and judgment. b. The best operating roller stability indicator is the human operator with the ability to comprehend working conditions based on the relevant environmental situation and the operator's feel for the roller to predetermined situations potential hazards and determine the proper operating decisions to keep the roller in a safe operating mode. 2. Vibration selection allows independent vibratory or static operation of either drum. 3. Two amplitudes of vibration (high and low) are always available to the operator to accommodate the needs of a variety of operations. 4. A water spray system wets the drum to help prevent hot asphalt from sticking to the drum surfaces during the compacting operation. Water spray can be constant or intermittent to accommodate the needs of a variety of environments. Two identical but separate tanks, each with their own pump and filter, are located on the front and rear of the roller and allow for extended operation between fill-ups. A tie line is provided allowing the operator to use one pump and tank to supply water to spray both drums in the event of failure of the other pump. 5. 60/40 articulation simplifies maneuvering of the roller. Sixty percent of the roller is behind the pivot, while forty percent is head of the pivot. This allows the operator to concentrate on only one drum when entering or leaving a curve, and decreases the risk of damage when moving roller away from curbs or other stationary objects. 6. The operator station pivots 90 degrees in either direction to allow the operator to view drum surfaces and edges during back-and-forth rolling operation. The gauges and controls move with the operator station.
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0002
7. The Rollover Protective Structure (ROPS) canopy helps protect the operator from potential hazards resulting from equipment rollover and falling objects. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
NOTE
Location and description of major components are the same for the CB534B and CB534C Rollers. CB534B Roller is shown.
1 2 14 3 12 13
4 11 5 6 10 9 8 6
G0001SWR
Figure 1. Table 1. KEY 1
Location and Description of Major Components. Location and Description of Major Components. COMPONENT Rollover Protective Structure (ROPS) DESCRIPTION The ROPS canopy helps protect operator from potential hazards resulting from equipment rollover and falling objects. The fuel and hydraulic tanks are connected, yet separate. Fuel is stored in the right-side. The left-side stores hydraulic oil. The water spray bars spray the drum surfaces with water to help prevent hot asphalt from sticking to drums. There is a water spray bar located above front and rear drum. The frame assembly provides a means of support for roller components.
Hydraulic/Fuel Tank
Water Spray Bars
Frame Assembly
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0002
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued Table 1. KEY 5 Location and Description of Major Components - Continued. COMPONENT Vibratory Motors DESCRIPTION The vibratory motors turn eccentric weights inside drums which create vibrating force that aids in surface material compaction. They are located on left-side of the rear drum and right-side of the front drum. The scrapers keep drums clean to provide a smooth compacted surface. The engine and hydraulic pumps are located in this compartment. The engine and pumps power the steering, propulsion, and vibratory systems. The drums provide a smooth surface for surface material compaction. The propel motors provide power to drums to move roller. They are located on right-side of rear drum and left-side of front drum. The yoke assembly provides support for front drum and pivots on frame assembly for steering. The work lights provide light for use in poor visibility situations. They are located at front and rear of roller. The water spray tanks hold water for delivery to drums via water spray nozzles on spray bars. A water spray tank is mounted above each drum. The toolbox holds tools the operator needs to do all authorized maintenance. The pivoting console may be moved 90 degrees left or right to increase visibility. The gauges and controls move with console for easy operation.
Scrapers
Engine Compartment
Drums
Propel Motors
10
Yoke Assembly
11
Work Lights
12
Water Spray Tanks
13
Toolbox
14
Operator Station
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0002
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued
Table 2. ITEM Throttle Speedometer Starting Aid Handrails
Differences Between Models. CB534C Electronic toggle switch (high/low) Yes Air inlet heater Design differences; same function, different look
CB534B Mechanically controlled by cable No Water heater jacket Design differences; same function, different look
EQUIPMENT DATA Table 3. Type Model Length (CB534B Roller) Length (CB534C Roller) Height Width Height at Steering Wheel Operating Weight (CB534B Roller) Operating Weight (CB534C Roller) Static Tip Angle General. Roller, Motorized, Vibrating Tandem Steel Drums Caterpillar, CB534B and CB534C Rollers 203 in. (5,156 mm) 195 in. (4,953 mm) 118 in. (2,997 mm) 73 in. (1,854 mm) 95 in. (2,413 mm) 21,232 lb (9,639 kg) 21,832 lb (9,912 kg) 40-50 degrees
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0002
EQUIPMENT DATA - Continued
Table 4. Drum Width Drum Diameter Drum Shell Thickness Curb Clearance Side Clearance Wheelbase Steering Angle-Left/Right Minimum Turning Angle: Inside Drum Edge Outside Drum Edge Weight at Front Drum Weight at Rear Drum
Functional. 67 in. (1,702 mm) 51 in. (1,295 mm) 0.71 in. (18 mm) 16 in. (406 mm) 3 in. (76 mm) 124 in. (3,150 mm) 35 degrees
164 in. (4,166 mm) 231 in. (5,867 mm) 10,330 lb (4,690 kg) 11,530 lb (5,235 kg)
Table 5. Engine Oil Fuel Tank Hydraulic Tank (CB534B Roller) Hydraulic Tank (CB534C Roller) Front and Rear Vibratory Bearing Reservoirs Water Spray Tank Cooling System Front Propel Gearbox Rear Propel Gearbox
Refill Capacities. 2.3 gal (9 Liters) 55 gal (208 Liters) 15.5 gal (59 Liters) 24 gal (91 Liters) 3.1 gal (12 Liters) 132 gal (500 Liters) each 7.3 gal (28 Liters) 0.5 gal (2 Liters) 0.6 gal (2.4 Liters)
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0002
EQUIPMENT DATA - Continued
Table 6. Engine Horsepower Displacement Transmission Speed in Low Range Speed in High Range
Power Train. Caterpillar 3045T, Turbocharged, Four-cylinder, diesel 107 hp (80 kw) @ 2,200 rpm 243 cu in. (4.0 Liters) Hydrostatic 4.5 mph (7.2 kph) 7.0 mph (11.2 kph)
Table 7. Electrical System Frequency Nominal Amplitude: Low High Centrifugal Force per Drum: Low High Pli: Static Centrifugal (max)
Vibratory System. 24 Volt 2,520 VPM (42 Hz)
0.022 in. (0.56 mm) 0.043 in. (1.092 mm)
13,480 lb (6,000 daN) 26,550 lb (11,810 daN)
161 in-lb (28.8 kg/cm) 396 in-lb (70.7 kg/cm)
Table 8. Water Spray System. Tank Material Number of Pumps Number of Nozzles per Drum Number of draincocks Number of Screens Polyethylene 2 7 3 2
END OF WORK PACKAGE
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FIELD MAINTENANCE THEORY OF OPERATION
INTRODUCTION 1. This work package explains how components of the Roller, Motorized, Vibrating Tandem Steel Drums work together. A functional description is given for the engine system, fuel system, electrical system, propel system, steering system, vibratory system, and water spray system. 2. Theory of operation is the same for the CB534B and CB534C Rollers. CB534B Roller is shown unless otherwise indicated. BASIC OPERATION 1. The roller is designed to compact asphalt and gravel bases for constructing parking lots, roads, landing strips, and other asphalt-paved areas. 2. The roller is controlled by a single operator. 3. An on-board water spray system is provided to prevent hot asphalt from sticking to the drum surfaces. 4. The roller operates in vibratory mode, using twin vibrating drums, as the means for compacting surface material. 5. The roller operates in static-mode in order to smooth surface material.
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ENGINE SYSTEM 1. General. a. The engine system provides power for the roller. The engine combines fuel and pressurized air together and compresses it until ignition occurs, creating mechanical energy. The internal explosion from the ignited air/fuel mixture pushes the pistons down, turning the crankshaft. The crankshaft is connected to a pulley and gear on the front of the engine and an output shaft on the rear of the engine. The pulley forces belts to turn the alternator which keeps the electrical system fully charged with electricity. The front gear also turns both the power steering hydraulic pump and the fuel injection pump. The output shaft turns both of the main hydraulic pumps. A cam lobe operates the fuel lift pump. b. The engine is turbocharged. When the ignited air is pushed out of the engine, it is routed to the turbocharger. The exhausted from the engine turns the turbocharger which forces high pressure air into the engine intake manifold. 2. Turbocharger. The turbocharger forces air into the intake manifold. Exhaust gases coming out of the combustion chamber force a rotor inside the turbocharger to spin at a very high rate of speed. This rotor is attached to the intake impeller. The impeller pulls air in from the air filter and forces it into the intake manifold at a high pressure. The faster the engine runs, the faster the turbocharger spins and the higher the air pressure it produces. 3. Cylinder Head. The fuel/air mixture is ignited in the combustion chambers of the cylinder head, located directly over each piston. The intake ports of the cylinder head route air into the combustion chamber while the injectors supply the fuel to the mixture. The exhaust ports route burned gases out of the engine. 4. Cylinder Head Valves. The cylinder head valves open or close the passages in the cylinder head that allow flow from the intake manifold or to the exhaust manifold. Valve lash must be adjusted periodically. 5. Combustion Chamber. The combustion chamber is where combustion and ignition occur. Ignition occurs when diesel fuel or JP-8 is injected into air heated by being compressed by the piston. When the air/fuel is ignited, it pushes down the piston, turning the crankshaft. 6. Crankshaft. The crankshaft is an eccentric shaft that changes the up-and-down piston motion. The crankshaft uses this motion at the front of the engine to power the alternator, cooling system, and steering and fuel pumps. 7. Exhaust System. The exhaust system allows the exhaust gases to be drawn out of the combustion chamber. The exhaust is pushed out of the cylinder by the piston. It then goes into the turbocharger and makes it spin. The exhaust is then vented into the air out of an exhaust pipe. 8. Air Filter. The air filter cleans the air entering the engine. The filter consists of a primary element and a secondary element. Air is pulled through both elements to remove particulates that could damage the engine.
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ENGINE SYSTEM - Continued
INTAKE MANIFOLD CYLINDER HEAD VALVES AIR FILTER TURBOCHARGER CYLINDER HEAD
COMBUSTION CHAMBER EXHAUST SYSTEM MUFFLER

G0002SWR
CRANKSHAFT
Figure 1.
Engine System.
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FUEL SYSTEM 1. General. a. When the engine is turning, fuel is pulled from the fuel tank through the fuel/water separator by the fuel lift pump. The fuel lift pump sends the fuel at low pressure to the fuel filter. From the filter, the fuel is sent to the fuel injection pump. The fuel injection pump sends high pressure fuel through the high pressure fuel lines to the fuel injector nozzles. The four fuel injector nozzles spray fuel into the cylinders of the engine. Any fuel not used by the fuel injector pump is returned to the inlet side of the fuel filter. b. The engine is equipped with a cold start heater to warm fuel for starting the engine in cold weather. 2. Fuel Tank. The fuel tank is part of the fuel, hydraulic tank assembly. The fuel tank is located on the right side of the assembly. The fuel and hydraulic tanks are welded together, but are separate containers. The capacity of the fuel tank is 55 gal (208 Liters) of diesel fuel or JP-8. 3. High Pressure Fuel Lines. The high pressure fuel lines deliver fuel from the fuel injection pump to the fuel injector nozzles. 4. Fuel/Water Separator. The fuel/water separator separates any water from the fuel before reaching the fuel filter and the engine. The water that is separate from the fuel collects at the bottom of a glass bowl located on the bottom of the separator. The drain valve is located at the bottom of the bowl and can be used to drain the water from the fuel/water separator. 5. Fuel Lift Pump. The fuel lift pump delivers fuel to the fuel injection pump. The manually-operated lever primes the pump by removing air and introducing fuel. Priming is needed after the fuel system has been opened or air is in the system. 6. Fuel Filter. The fuel filter removes foreign matter from the fuel before fuel into the fuel enters the fuel injector pump. 7. Fuel Injection Pump. The fuel injection pump forces high pressure fuel into the fuel injector nozzles. The fuel injection pump is gear-driven from the crankshaft. The fuel injection pump needs fuel for lubrication. The precision parts are easily damaged. For this reason, the engine must NOT be started until the fuel injector pump is full of fuel that is free of air. 8. Fuel Injectors. The fuel injectors spray fuel into the cylinders of the engine. 9. Cold Start Heater. The cold start heater is installed in the inlet manifold to heat inlet air in cold weather. When activated by operator controls, the current from the electrical wire causes the coil inside the heater to become very hot. A small amount of fuel will flow through the heater as the engine is cranking.
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FUEL SYSTEM - Continued
FUEL GAGE
FUEL INJECTOR NOZZLE FUEL TANK FUEL INJECTOR NOZZLE FUEL SHUT-OFF SOLENOID FUEL INJECTION PUMP
FUEL LIFT PUMP
FUEL FILTER
COLD START HEATER
ENGINE START SWITCH
STARTING AID SWITCH
FUEL/ WATER SEPARATOR

G0003SWR
Figure 2.
Fuel System.
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COOLING SYSTEM 1. General. Coolant from the bottom of the radiator passes through the centrifugal water pump which is installed on the front of the engine timing case. The pump is gear-driven from the gear of the fuel injection pump and assists the flow of coolant through the system. From the pump, coolant goes through a passage in the timing case to the front of the cylinder block. The coolant passes through a passage in the left-side of the cylinder block. Some of the coolant passes through a lubricating oil cooler before going to the rear of the cylinder block. The coolant then passes around the cylinder and up to the cylinder head. Coolant leaves the front of the cylinder head and passes to the thermostat housing. If the thermostat is closed, the coolant goes directly through a by-pass to the inlet side of the water pump. If the thermostat is open, the coolant passes to the top of the radiator. A push-type fan forces air through the radiator, relieving the coolant of heat. 2. Radiator. The radiator acts as a coolant reservoir. The radiator cools the heater coolant from the engine while it is being stored. 3. Water Pump. The centrifugal water pump draws coolant from the radiator and forces it into the coolant passages in the engine. After the coolant has flowed through the entire engine, pressure from the water pump pushes it back into the radiator. The water pump is gear driven from the engine. 4. Radiator Hose (Two Hoses). The radiator hoses connect the radiator to the water pump and engine. These hoses provide a passage for coolant transfer between the radiator and the engine. 5. Fan. The cooling fan pushes air through the radiator to aid in helping lower the temperature of the coolant by relieving heat from the coolant. 6. Temperature Sending Unit. The temperature sending unit sends a signal to the engine coolant temperature warning light when the engine coolant temperature is too high for safe operation. 7. Engine Coolant Temperature Warning Light. The engine coolant temperature warning light is connected to the temperature sending unit. When the sending unit signals high operating temperature, the warning light will illuminate to alert the operator. A warning horn is connected to the light for both a visual and audible warning. 8. Thermostat. The thermostat controls the temperature of the coolant and engine. The thermostat blocks the path of the coolant traveling back to the radiator. Until the engine reaches proper operating temperature, the thermostat will not allow the coolant to pass into the radiator.
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COOLING SYSTEM - Continued
RADIATOR HOSE
TEMPERATURE SENDING UNIT
THERMOSTAT HOUSING
ENGINE COOLANT TEMPERATURE WARNING LIGHT THERMOSTAT
LOCATED INSIDE THERMOSTAT HOUSING
WATER PUMP
COOLING FAN
RADIATOR
RADIATOR HOSE
G0004SWR
Figure 3.
Cooling System.
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ELECTRICAL SYSTEM 1. General. a. Two batteries wired in series provide the roller with a 24-volt electrical system. Battery cables connect the batteries to the starter and the alternator. From the starter, electricity is sent to the engine wiring harness and to the operator station. When the roller is running, the alternator produces 24 volts that are sent to the batteries to maintain a full charge. Control switches at the operator station allow the flow of electricity to power the roller systems through the wiring harness. There are four wiring harnesses on the roller: the instrument, engine, front, and rear harnesses. Electricity is sent through the harnesses to the electrical systems the returned to the harness, which ground the electricity to the roller chassis. Fuses are used to protect the electrical systems from an overload. The negative battery cable is attached to the chassis, completing the circuit. A NATO connector on the battery positive side allows the roller to be connected to another vehicle. This connector allows another roller's electrical system be connected to the roller if, for example, the roller does not have enough electrical energy to start the motor with its own batteries. b. The starting system is used to start the engine. When the start switch is tuned to the START position, electricity is sent from the battery to the fuses and then through the main relay, the neutral start relay and the starter relay. The starter relay engages the starter solenoid. The starter solenoid sends electricity to the electricity to the electric starter motor and forces it to turn the engine crankshaft. The engine will crank until the start switch is turned to the center or OFF position. 2. Batteries. Two 12-volt batteries provide stored electricity to the electrical system. Combined, the two batteries provide 24 volts. The batteries are negatively grounded. 3. Battery Cables. The positive battery cable is connected to the NATO connector and the starter. The negative cable is connected to the battery disconnect switch which is then connected to the roller chassis. 4. NATO Connector. The NATO connector is a standard receptacle with which NATO jumper cables can be used to "jump start" one roller in the event of battery failure. 5. Alternator. a. The alternator is an electrical and mechanical component driven by a belt from engine rotation. The alternator is used to charge the storage batteries during engine operation. The alternator is used to charge the storage batteries during engine operation. The alternator is cooled by an external fan mounted behind the pulley. The fan pulls air through holes in the back of the alternator and exits to the front, cooling the alternator. b. The alternator converts mechanical and magnetic energy to Alternating Current (AC) and voltage by rotating a Direct Current (DC) field inside a three-phase stator. The alternating current and voltage are changed to direct current by a three-phase, full wave rectifier system. Direct current flows to the alternator output terminal. The rectifier has three exciter diodes that rectify the current needed to start the charging process. c. A solid state regulator is installed in the back of the alternator. A capacitor protects the rectifier from high voltages.
d. The alternator is connected to the battery through the engine start switch for alternator turn-on. Therefore, alternator excitation occurs when the engine start switch is turned on. 6. Alternator Circuit Breaker. The alternator circuit breaker is a heat-triggered switch that opens the battery circuit when the current in the electrical system goes higher than the rating of the circuit breaker (60 amps). Push the reset button to close the circuit again.
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ELECTRICAL SYSTEM - Continued
GROUND TO FRAME NATO CONNECTOR BATTERIES BATTERY DISCONNECT SWITCH BATTERY CABLES
ENGINE START SWITCH FUSES
ALTERNATOR ENGINE BLOCK TO FRAME GROUND GROUND TO ENGINE BLOCK
MAIN RELAY 60 ALTERNATOR CIRCUIT BREAKER
LIGHTS CIRCUIT BREAKER
STARTER
STARTER RELAY NEUTRAL START RELAY
G0005SWR
Figure 4.
Electrical System.
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ELECTRICAL SYSTEM - Continued 7. Starter. a. The starter is used to turn the engine flywheel fast enough to start the compression/ignition process and make the engine run. When the engine start switch is activated, voltage from the electrical system causes a solenoid to move a pinion toward the flywheel ring gear of the engine. The electrical contacts in the solenoid close the circuit between the battery and the starter just before the pinion engages the ring gear causing the starter to rotate. A starter with this type of turn-on is known as a positive shift starting motor. b. When the engine begins to run, the overrunning clutch portion of the pinion drive prevents damage to the starter caused by excessive speeds by breaking the mechanical connection. The pinion will stay meshed with the ring gear until the engine start is released from the start position. A returned spring in the overrunning clutch returns the clutch to its rest position. 8. Fuses. Fuses are safety devices which open an electrical circuit in the event of a short or malfunction to protect the system from damage. A filament inside the fuse allows a measured amount of current to travel through the circuit. The filament disintegrates when too much current attempts to pass through the fuse. Once a fuse has "blown" it must be replaced. Fuses are provided for each of the major system circuits. 9. Engine Start Switch. The engine start switch is a rotary key-type switch that turns the electrical system on or off and activates the starter. When the start switch is turned to the START position (held to far right), electricity is sent through the neutral start and main relays. After these relays, the electricity then goes to the starter. 10. Starter Relay. The starter relay allows electricity to flow to the starter when the engine start switch is in the START position. 11. Neutral Start Relay. The neutral start relay is a safety device that stops the flow of electricity to the starter when the propel control lever is set in a position other than neutral. 12. Lights Circuit Breaker. The lights circuit breaker is a heat-triggered switch that opens the lights circuit when the current in the electrical system goes higher than the rating of the circuit breaker (20 amps). Push the reset button to close the circuit again. 13. Main Relay. The main relay allows electricity to flow to all circuits only when the engine start switch is in the ACCESSORY, RUN, or START positions.
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ELECTRICAL SYSTEM - Continued
GROUND TO FRAME NATO CONNECTOR BATTERIES BATTERY DISCONNECT SWITCH BATTERY CABLES
ENGINE START SWITCH FUSES
ALTERNATOR ENGINE BLOCK TO FRAME GROUND GROUND TO ENGINE BLOCK
MAIN RELAY 60 ALTERNATOR CIRCUIT BREAKER
STARTER
STARTER RELAY NEUTRAL START RELAY
G0006SWR
Figure 5.
Electrical System.
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PROPEL SYSTEM 1. General. The propel system allows the roller to move either forward or backward. When the engine is started, oil under pressure oil from the charge (control) circuit flows to the propel control valves. When the propel control lever (which is connected to the propel control valves) is in the forward or reverse position, oil is sent to the propel hydraulic pump. The further the lever is pushed, the higher the oil pressure sent to the hydraulic pump. The more pressure there is, the faster the roller will move. The hydraulic pump pushes oil through hydraulic lines until the oil enters the propel motors. The front and rear propel motors turn the propel gearboxes which turn the roller drums. Inside each propel gearbox is a brake. This brake is always engaged unless pressure from the brake/shift manifold is present. This pressure is controlled by the propel control valve. If the roller needs to move while the engine is not able to supply the pump with power, there is a manual brake release pump on the roller. This manual brake release pump pressurized the hydraulic lines releasing the brakes. Also, there are brake and neutral start relays in the system which prevent movement of the roller during the starting procedure. 2. Fuel/Hydraulic Pump. The fuel/hydraulic oil tank consists of the hydraulic tank (located on the right-side) and the fuel tank (located on the right-side). Although the tanks are welded together, they are separate in their function. The CB534B Roller hydraulic oil tank holds 15.5 gal (59 Liters) of hydraulic oil. The CB534C Roller hydraulic oil tank holds 24 gal (91 Liters) of hydraulic oil. 3. Propel Hydraulic Pump. The propel hydraulic pump is a variable displacement, piston-type pump mounted in tandem with the vibratory hydraulic pump to the engine. Both run at engine speed and rotate clockwise as seen from the drive end of the pump. 4. Propel Motors. The hydraulic propel motors are located on the left-side of the front drum and the right-side of the rear drum. The front motors is a fixed displacement axial piston-type motor. The rear motor is a variable displacement axial piston-type motor. 5. Propel Control Lever and Valve. The propel control lever controls the direction of the roller. If the lever is pushed forward, the control valve, which is connected to the lever, directs fluid to the propel hydraulic pump in such a way that the hydraulic pump sends oil to the propel motor to turn forward. This propel pump sends fluid the opposite direction if the control lever is pulled backward. The further the lever is pulled, the higher the oil pressure being sent from the control valve is. The more control valve pressure, the more volume of fluid the pump sends to the motors and the faster the roller travels. 6. Parking Brake Switch. The parking brake switch keeps the roller from moving by interrupting the inputs from the control valve. The hydraulic pump will not send oil to the motors that the brake will not disengage while the parking brake is on . The parking brake switch glows red when parking brake is engaged. 7. Brake and Neutral Start Relays. The brake and neutral start relays are safety devices that interrupt the electrical signal to the starter if the control lever is not in the neutral, or center position. This ensures that the roller will not move while the engine is being started. 8. Steering Pump. The steering pump provides a charge pressure to the propel system. This charge pressure sends source pressure to the brake/shift valves. The charge pressure is used to supply the propel control valve with signal oil, and to disengage the brakes. 9. Brake/Shift Valves. The brake/shift valves distribute the charge pressure to the propel control valve and the brakes. When pressure is sent from the control valve, the brake/shift valve sends pressure to release the brakes. The brakes/shift valves also control the speed range of the roller operates. The operator controls the speed range by an electrical switch that operates the valve solenoid. This solenoid either opens or closes the brake/shift valve changing the fluid pressure to propel control valve which effectively changes the speed range.
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PROPEL SYSTEM - Continued
10. Manual Brake Release Pump. The manual brake release pump is a manually operated plunger-type that forces hydraulic oil to the brakes. The manual brake release pump is used when normal means of brake disengagement are not possible. 11. Cooling Valve. The cooling valve is a two-position pilot-operated valve. Pilot oil from the high pressure side of the closed loop circuit opens the valve, allowing some of the hydraulic oil in the return side of the closed loop circuit to be directed to the oil cooler. 12. Propel Gearbox. The propel gearboxes are attached to the drums. The propel motors turn the gearboxes which turn the drums. There is a brake inside the gearbox that is always engaged until hydraulic pressure from the brake/shift valves is present.
FRONT PROPEL MOTOR
PROPEL GEARBOX
PROPEL CONTROL VALVE
PARKING BRAKE SWITCH BRAKE & NEUTRAL START SWITCH
BRAKE/ SHIFT MANIFOLD SOLENOID VIBRATORY HYDRAULIC PUMP PROPEL HYDRAULIC PUMP COOLING VALVE HYD OIL FILTER
STEERING PUMP
HYDRAULIC OIL COOLER
HYDRAULIC OIL TANK MANUAL BRAKE RELEASE PUMP PROPEL GEARBOX REAR PROPEL MOTOR
G0007SWR
Figure 6.
Propel System.
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HYDRAULIC STEERING SYSTEM 1. General. The hydraulic steering system has two functions. The primary purpose is for steering the roller. The steering pump receives oil from the hydraulic oil tank after it has been cleaned by a hydraulic filter. Oil from the steering pump flows through a priority valve and continues on in two directions. The primary path for the oil is to the steering control unit. The steering control unit sends hydraulic oil to the steering cylinders. When the steering wheel is turned, the steering control unit sends hydraulic oil through the steering hydraulic lines to force the steering cylinders to turn the roller. The secondary flow of oil and return oil from the steering control unit is combined with the parking brake and two-speed shift manifold by way of an oil line. This oil is used for the charge system. The charge system supplies the control circuit and replenished the main closed loop and cooling circuit of the vibratory system. 2. Steering Control Unit. The steering control unit is a spring-centered, non-load, reaction-type pump which sends pressurized hydraulic oil to the steering cylinders. The steering control unit has two sections: the control section and the metering section. Oil from the steering pumps goes into the control section. As the steering wheel is turned, the control sends oil out from the metering section. Metered oil from the metering section is directed by the control section to either the left turn port or right turn port. 3. Steering Pump. The steering pump is a gear-type mounted to the accessory drive on the engine and turns clockwise as the engine is running. The steering pump supplies pressurized hydraulic oil to the steering system and charge oil to the propel and vibratory systems. A priority valve gives the steering system priority over the propel charge circuits. A pressure compensator valve regulates a constant six gallons per minute flow to the steering system. 4. Priority Valve. Inside the steering is the priority valve which is a pressure compensated flow divider. The priority valve divides flow between the steering circuit and the propel charge circuits. The steering circuit has priority. 5. Brake/Shift Manifold Valve. The brake/shift manifold valve is part of the propel system, yet receives it charge from the steering pump. 6. Steering Cylinders. The steering cylinders are piston-type hydraulic cylinders mounted at the pivot joint of the frame and yoke assemblies. When the steering control unit sends pressurized oil to them, the steering cylinders force the yoke assembly to shift its relative placement on the frame assembly, causing the roller to steer either left or right. 7. Fuel/Hydraulic Oil Tank. The fuel/hydraulic oil tank consists of the hydraulic tank (located on the left-side) and the fuel tank (located on the right-side). Although the tanks are welded together, they are separate in their function. The CB534B Roller hydraulic oil tank holds 15.5 gal (59 Liters) of hydraulic oil. The CB534C Roller hydraulic oil tank holds 24 gal (91 Liters) of hydraulic oil. 8. Hydraulic Oil Filter. The hydraulic oil filter cleans all hydraulic oil used in the propel, vibratory and steering systems. When the filter element is clogged, or oil is cold, the bypass valve opens and oil flows past the element and a signal is sent to the warning light. On the CB534B roller, an indicator is mounted on the filter assembly to display the condition of the filter element.
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HYDRAULIC STEERING SYSTEM - Continued
STEERING CYLINDER
STEERING CYLINDER
BRAKE/SHIFT MANIFOLD VALVE
STEERING CONTROL UNIT PRIORITY VALVE STEERING PUMP
HYD OIL FILTER
VIBRATORY HYDRAULIC PUMP
HYDRAULIC OIL TANK

G0008SWR
Figure 7.
Hydraulic Steering System.
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VIBRATORY SYSTEM 1. General. a. The drum vibration is produced by the turning of an eccentric weight mounted inside each drum. Hydraulic motors, mounted on the left-side of the axis of the front drum and on the right-side of the axis of the rear drum, turn the eccentric weights. A hydraulic pump provides power to the motors. Controls are provided for the operator to implement the use of the vibratory system in high or low range. b. The vibratory system is a hydrostatic, closed loop system. Oil for the vibratory system is supplied by the steering change circuit pressure created by the steering pump. Charged pressure is used to supply the control circuit and replenish the main closed loop and cooling circuits of the vibratory system. 2. Vibratory Hydraulic Pump. The vibratory hydraulic pump is a variable displacement, piston-type pump mounted in tandem with the propel hydraulic pump to the engine. Both run at engine speed and rotate clockwise as seen from the drive end of the pump. 3. Vibratory Hydraulic Motor. The vibratory motors are located on the right-side of the front drum and the left-side of the rear drum. The front and rear motors are fixed displacement bidirectional motors that are identical. 4. Eccentric Weights. As the eccentric weight spins, kinetic energy creates forces that cause the drum to vibrate, which intensifies the roller compaction of surface material. The eccentric weight is a chamber filled with steel shot and has a weight attached to one side. Inside the chamber are baffles. As the weight is turned one direction, the baffle collects the steel shot on the same side as the weight to produce a severe imbalance in the rotation. The imbalance causes the entire drum to vibrate. This is the high amplitude range. As the weight is turned the other director, the baffle collects the steel shot on the opposite side as the weight to produce a mild imbalance in the rotation causing less vibration. This is the low amplitude range. 5. Vibratory Indicators. The vibratory indicators allows the operator to monitor the vibratory system. A vibratory sensor is located on each drum and measures how many Vibrations Per Minute (VPM) the drum produce. This sensor is connected to a VPM meter on the control panel. The VPM meter points to a number which shows the vibrations per minute reading. A system light is also illuminated whenever the vibratory system is engaged. 6. Brake/Shift Manifold Valve. The brake/shift manifold valve will not allow the vibratory system to engage when the system is in automatic mode until the propel lever is positioned for roller movement. 7. Cooling Valve. The cooling valve is a two-position pilot operated valve. Pilot oil from the high pressure side of the closed loop circuit opens the valve allowing some of the oil in the return side of the closed loop circuit to be directed to the oil cooler. 8. Hydraulic Oil Cooler. The hydraulic oil cooler is mounted between the fan shroud and the radiator and is a heat transfer device which cools the oil in the hydraulic system.
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VIBRATORY SYSTEM - Continued
VIBRATORY SENSOR VIBRATORY HYDRAULIC MOTOR
ECCENTRIC WEIGHT
VIBRATORY INDICATORS VIBRATORY HYDRAULIC SWITCHES
HYD OIL FILTER BRAKE/SHIFT MANIFOLD VALVE
SOLENOID VIBRATORY HYDRAULIC PUMP COOLING VALVE
SOLENOID PROPEL HYDRAULIC PUMP COOLING VALVE
HYDRAULIC OIL TANK
VIBRATORY HYDRAULIC MOTOR
ECCENTRIC WEIGHT
VIBRATORY SENSOR
Figure 8. Vibratory System.
G0009SWR
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WATER SPRAY SYSTEM 1. General. The water spray system is used to wet the front and rear drums to help prevent hot asphalt from sticking to the drum surfaces during compaction. The water spray system consists of two identical, but separate systems, one at each end of the roller. The water spray system uses pumps that provide pressurized water flow. Only one pump operates at a time. The pumps are controlled by a switch on the operator console. This switch has three positions: off, continuous spray, and intermittent spray. The continuous spray setting turns on the water spray system and water sprays on the drums continuously. The intermittent spray switch position uses fifteen-second on/off cycles of water spraying on the drums to reduce water consumption. There are three draincocks that allow the water to be drained from the system. The pumps pull water from two tanks and water spray screens which filter foreign material from the water. The water then enters the pump and is pumped to the spray bar. There are seven spray nozzles in each spray bar which distribute the water evenly over the surface of the drums. A check valve is located at the end of the spray bar to control the pressure of the water in the spray bars. Excess water is sent past the check valve and back into the water tank. On the CB534B Roller only, the front and rear water spray systems are connected by a tie-line valve, which allows one water spray system to supply pressurized water to the nozzles of the other water system, in the event of failure of one the pumps. 2. Water Spray Pumps. The water spray pumps are electrically activated positive displacement piston-type pumps that operate on 24 VDC. When activated, the pumps provide pressurized water flow to the water spray system. 3. Water Spray Screens. The water spray screens filter foreign matter from the water supply. There are two screens at the water tank fill port and two in the water spray system. 4. Water Spray Tanks. The water spray tanks store water to be used in the water spray system. There is a screen on top of the tank at the fill cap that acts as an initial filtering device at the tank. 5. Check Valves. A check valve is installed in each water tank at the end of each spray bar. The check valve regulates the water pressure in the spray bar and allows excess water to flow back into the water tank. 6. Water Spray Bars. The spray bars distribute water to the spray nozzles. There are seven outlets on each spray bar where the spray nozzles are attached. The spray bar is adjustable to change the coverage of water to the drums. 7. Water Spray Nozzles. The water spray nozzles spray water in a fan pattern onto the drums. The nozzles are made of polyethylene and brass and contain a wire mesh screen to filter foreign material. There are 14 nozzles and all are adjustable. 8. Draincocks. The draincocks are directional valves that allow the water spray system to be drained. There are three draincocks on the roller. One is located near each of the two water pumps and a third is located near the tie-line valve. 9. Tie-Line Valve. On the CB534B Roller, the tie-line valve is located in the center of the roller. The on/off valve allows the front and rear water spray systems to interact. When this valve is open, one pump can send water to both the front and rear spray bar and nozzles. 10. Drain Nipples. The drain nipples are located on the bottom of each water tank. Each tank can be completely drained by removing the cap assembly from the nipple. 11. Shut Off Valves. On the CB534B Roller, shut off valves interrupt the flow of water from the water spray tank to the water spray screen and spray pump. When turned off, water from the water tank cannot reach the rest of the system.
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WATER SPRAY SYSTEM - Continued 12. Water Spray Control Switches. On the CB534C Roller, the water spray control switches are toggle-type switches mounted on the operator station. The intermittent/continuous switch controls the time interval that the system sprays the water. Continuous mode sprays continuously, while the intermittent mode sprays water for 15 seconds and stops for 15 seconds. The drum select switch sets whether the front, rear, or both pumps are activated.
DRAINCOCK
* SHUT-OFF VALVE DRAIN NIPPLE WATER SPRAY SCREEN FRONT WATER SPRAY TANK
WATER SPRAY PUMP
CHECK VALVE SPRAY BAR AND SPRAY NOZZLES
DRAINCOCK * CB534B ONLY ** CB534C ONLY WATER SPRAY CONTROL SWITCHES** * TIE-LINE VALVE
SPRAY BAR AND SPRAY NOZZLES CHECK VALVE REAR WATER SPRAY TANK WATER SPRAY SCREEN WATER SPRAY PUMP * SHUT-OFF VALVE
DRAIN NIPPLE
DRAINCOCK
G0010SWR
Figure 9. END OF WORK PACKAGE
Water Spray System.
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CHAPTER 2 TROUBLESHOOTING PROCEDURES FOR CB534B or CB534C ROLLER, MOTORIZED, VIBRATING TANDEM STEEL DRUMS NSN 3895-01-396-2822 AND 3895-01-502-4005
TM 5-3895-379-23-1
0004
FIELD MAINTENANCE TROUBLESHOOTING INTRODUCTION
INTRODUCTION 1. Troubleshooting procedures in this chapter contain information you need to locate malfunctions on the CB534B and CB534C Rollers, Motorized, Vibrating Tandem Steel Drums and components. 2. Troubleshooting procedures listed in (WP 0005) are as follows: a. b. c. d. e. f. g. Engine Troubleshooting Electrical Troubleshooting Hydraulic Troubleshooting Steering Troubleshooting Propel Troubleshooting Vibratory System Troubleshooting Water Spray System Troubleshooting
3. A Troubleshooting Symptom Index in (WP 0005) is provided to aid in locating a malfunction or symptom and directs you to the appropriate troubleshooting procedure. 4. Troubleshooting procedures in this manual cannot provide all the answers or correct all malfunctions encountered. However, these procedures are an organized step-by-step approach to a problem, that direct tests and inspections toward the source of the problem and its successful resolution. 5. If a malfunction is not listed in the Troubleshooting Symptom Index in (WP 0005), or stated tests or inspections and corrective actions do not correct the problem, notify your supervisor. 6. Before performing troubleshooting, read and follow all safety instructions found in the Warning Summary at the front of this manual. PRELIMINARY TROUBLESHOOTING PROCEDURES 1. Before starting any specific troubleshooting procedures, perform the following:
NOTE
Fluid leaks are classified as Class I, Class II, or Class III. Class I: Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops. Class II: Leakage of fluid great enough to form drops, but not great enough to cause drops to drip from item being checked/inspected. Class III: Leakage of fluid great enough to form drops that fall from item being checked/inspected.
a. Visually check for ruptured fluid hoses or tubes and for Class II or Class III leaks. b. Check for mechanical jamming or binding caused by rocks or other foreign matter. c. Check fluid levels in subject area and service as required (TM 5-3895-379-10) or (WP 0071) in this manual.
2. Ensure all applicable Operator Troubleshooting has been performed before proceeding.
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0004
EXPLANATION OF TROUBLESHOOTING PROCEDURES Troubleshooting procedures are defined as follows: 1. SYMPTOM: Indicates fault that has occurred in system/equipment. 2. MALFUNCTION: Indicates possible malfunction that may cause the symptom. 3. CORRECTIVE ACTION: Indicates test or inspection to be performed to isolate problem and correct cause for the malfunction. ELECTRICAL TROUBLESHOOTING-GENERAL INFORMATION
NOTE
Refer to Electrical General Maintenance Instructions (Volume 2, WP 0280) for instructions on using a multimeter to check for continuity or shorts and to perform voltage checks. Analyze the symptoms and conditions and use common sense and logic to determine the most likely cause for the problem, the easier it will be to troubleshoot. 1. Isolate to the subsystem level (in cases where more than one subsystem is involved); next isolate the problem to a single circuit within the subsystem; then, isolate the problem to the faulty component using the troubleshooting symptom index (WP 0005). 2. Frayed, broken, loose, or corroded wiring is a common source of problems in any electrical circuit. Always make visual inspection before starting detailed troubleshooting. Pay particular attention to contacts to ground and components with case grounds. 3. Most of checks made are voltage checks. Pay particular attention to voltage being checked in procedures. This equipment is a 24 volt system. Instructions prior to the step instruct to disconnect at test point from the potential malfunctioning component. Once the check has been made, either repair the component or go to the referenced step. If going to another step, reconnect connection or do as otherwise instructed, such as install jumper wires using jumper wire kit. When ready to make the prescribed check, apply power to the circuit (if required). A helper may be required if the switch or power source is out of reach. Release the power function prior to going on, to avoid damage to equipment. 4. Refer to the following simplified electrical schematics when performing electrical troubleshooting.
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0004
ELECTRICAL TROUBLESHOOTING-GENERAL INFORMATION - Continued
T0034SWR
Figure 1.
Electrical Schematic. (Page 1 of 6) 0004-3

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0004
T0035SWR
Figure 2. Electrical Schematic. (Page 2 of 6)
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0004
T0036SWR
Figure 3.
Electrical Schematic. (Page 3 of 6) 0004-5

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0004
T0037SWR
Figure 4. Electrical Schematic. (Page 4 of 6)
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0004
T0038SWR
Figure 5.
Electrical Schematic. (Page 5 of 6)
0004-7
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0004
T0039SWR
Figure 6. Electrical Schematic. (Page 6 of 6) END OF WORK PACKAGE
0004-8
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0005
FIELD MAINTENANCE TROUBLESHOOTING SYMPTOM INDEX
TROUBLESHOOTING SYMPTOM INDEX Malfunction/Symptom Troubleshooting Procedure
ENGINE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Coolant In Engine Oil/Engine Oil In Coolant.......................................................................................WP 0006 Engine Cranks But Will Not Start or Is Hard To Start..........................................................................WP 0007 Engine Exhaust Smokes Excessively (Black or Gray Smoke)............................................................WP 0008 Engine Exhaust Smokes Excessively (White or Blue Smoke)............................................................WP 0009 Engine Is Sluggish..............................................................................................................................WP 0010 Engine Is Usually Noisy......................................................................................................................WP 0011 Engine Is Using More Fuel Than Usual...............................................................................................WP 0012 Engine Is Using More Oil Than Usual.................................................................................................WP 0013 Engine Misfires or Idles Rough...........................................................................................................WP 0014 Engine Oil Pressure Is Low (Warning Light and Warning Horn On)......................................................................................................................................................WP 0015 Engine Operating Temperature Is Too High (Warning Light and Warning Horn On)...............................................................................................................................WP 0016 Engine Starts But Will Not Keep Running...........................................................................................WP 0017 Engine Surges (Speed Changes).......................................................................................................WP 0018 Engine Vibrates Excessively...............................................................................................................WP 0019 Engine Will Not Stop Running.............................................................................................................WP 0020 Oil Leaking From Exhaust...................................................................................................................WP 0021 Throttle Control Will Not Change Engine Speed.................................................................................WP 0022
ELECTRICAL SYSTEM 1. 2. 3. 4. 5. 6. 7. 8. Alternator Indicator Is On....................................................................................................................WP 0023 Alternator Is Noisy...............................................................................................................................WP 0024 Backup Alarm Does Not Work.............................................................................................................WP 0025 Feet Per Minute (FPM) Meter Does Not Work....................................................................................WP 0026 Fuel Gauge Does Not Work................................................................................................................WP 0027 Horn Does Not Work...........................................................................................................................WP 0028 No Power To Accessories With The Engine Running.........................................................................WP 0029 Roller Has No Electrical Power...........................................................................................................WP 0030
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0005
TROUBLESHOOTING SYMPTOM INDEX - Continued Malfunction/Symptom 9. 10. 11. 12. 13. 14. 15. Troubleshooting Procedure
Starter Continues To Run After Engine Start Switch Key Is Released.............................................................................................................................................WP 0031 Starter Does Not Turn or Turns Slowly...............................................................................................WP 0032 Starter Turns, But Does Not Crank Engine.........................................................................................WP 0033 Starting Aid Switch Does Not Work.....................................................................................................WP 0034 Vibrations Per Min (VPM) Tachometer Does Not Work......................................................................WP 0035 Warning and Indicator Lights Do Not Operate....................................................................................WP 0036 Work Lights and Gauge Lights Do Not Operate..................................................................................WP 0037
HYDRAULIC SYSTEM 1. 2. Hydraulic Oil Pressure Is Low (Warning Light and Warning Horn On)......................................................................................................................................................WP 0038 Hydraulic Oil Temperature Is High (Warning Light and Warning Horn On).............................................................................................................................................WP 0039
STEERING SYSTEM 1. 2. 3. 4. Power Steering Pump Makes Noise and Steering Cylinder Rods Do Not Move Smoothly..............................................................................................................WP 0040 Roller Does Not Turn When Steering Wheel Is Turned......................................................................WP 0041 Roller Turns Slowly In Both Directions................................................................................................WP 0042 Too Much Force Is Needed To Turn Steering Wheel..........................................................................WP 0043
PROPEL SYSTEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Parking Brake Does Not Disengage When Parking Brake Switch Is Pulled Up.............................................................................................................................WP 0044 Parking Brake Does Not Engage When Parking Brake Switch Is Pushed Down..................................................................................................................................WP 0045 Propel Motor Is Noisy..........................................................................................................................WP 0046 Propel Motor Leaks Oil........................................................................................................................WP 0047 Propel System Does Not Change Speeds When Propel Speed Switch Is Moved..................................................................................................................................WP 0048 Propel System Engages Very Quickly When Making A Shift..............................................................WP 0049 Propel System Engages Very Slowly When Making A Shift...............................................................WP 0050 Propel System Operates In Forward Speeds Only.............................................................................WP 0051 Propel System Operates In Reverse Speeds Only.............................................................................WP 0052 Roller Will Not Move When Propel Control Lever Is Operated............................................................WP 0053
0005-2
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0005
TROUBLESHOOTING SYMPTOM INDEX - Continued Malfunction/Symptom Troubleshooting Procedure
VIBRATORY SYSTEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Noisy Vibrator Motor...........................................................................................................................WP 0054 Vibration Does Not Occur While Amplitude Select Switch Is Set To High Pitch.......................................................................................................................................WP 0055 Vibration Does Not Occur While Amplitude Select Switch Is Set To Low Pitch.......................................................................................................................................WP 0056 Vibration Does Not Stop When Travel Stops......................................................................................WP 0057 Vibration Does Not Work In Forward or Reverse Travel.....................................................................WP 0058 Vibration Frequency Start-up Is Slow, Time Lag After Travel Starts Is Excessive..............................................................................................................................WP 0059 Vibration Occurs In Only One Drum....................................................................................................WP 0060 Vibration Only Occurs While Vibration Control Switch Is Set To Automatic Mode..................................................................................................................................WP 0061 Vibration Only Occurs While Vibration Control Switch Is Set To Manual Mode......................................................................................................................................WP 0062 Vibration Stops Too Soon Before Travel Stops..................................................................................WP 0063 Vibratory System Engages Harshly.....................................................................................................WP 0064
WATER SPRAY SYSTEM 1. 2. 3. 4. 5. 6. No Spray At Either Drum When Water Spray Switch Is In Intermittent Spray Position..................................................................................................................WP 0065 Nozzle Spray Pattern Is Inconsistent..................................................................................................WP 0066 Spray Does Not Occur In Either Drum When Water Spray Switch Is In Continuous Spray Position...............................................................................................WP 0067 Water Consumption Unequal Between Tanks....................................................................................WP 0068 Water Spray Occurs On One Drum Only............................................................................................WP 0069 Water Spray Pressure Is Low..............................................................................................................WP 0070
END OF WORK PACKAGE
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0006
FIELD MAINTENANCE COOLANT IN ENGINE OIL/ENGINE OIL IN COOLANT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References WP 0077 References (cont.) WP 0095 WP 0139 WP 0144 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
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0006
TROUBLESHOOTING PROCEDURE SYMPTOM COOLANT IN ENGINE OIL/ENGINE OIL IN COOLANT MALFUNCTION Water Pump Leaks. CORRECTIVE ACTION
NOTE
Class I leakage at water pump bleed holes is normal. Any Class II or Class III leakage represents a problem with the water pump. 1. 2. Open right-side door assembly (TM 5-3895-379-10). Check water pump for signs of leakage (discoloration, corrosion, wetness).
NOTE
There are two failure bleed holes located on engine side of water pump. 3. Check failure bleed holes for Class II and Class III leakage of engine oil or coolant. If engine oil or coolant is leaking from either failure bleed hole or water pump shows signs of leakage, perform the following: (1) (2) (3) Replace water pump (WP 0144). Change engine oil and filter (WP 0077). Replace coolant system fluid (WP 0139).
WATER PUMP WATER PUMP
WATER PUMP SHOWN REMOVED FOR CLARITY
FAILURE BLEED HOLES

T0052SWR
Figure 1. Water Pump.
0006-2
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0006
MALFUNCTION Engine Oil Cooler Leaking. CORRECTIVE ACTION Remove and inspect engine oil cooler (WP 0095). a. If engine oil cooler or components are damaged, perform the following: (1) (2) (3) b. Replace oil cooler or components with new parts (WP 0095). Change engine oil and filter (WP 0077). Replace coolant system fluid (WP 0139).
If engine oil cooler and components are OK, notify supervisor that coolant is in engine oil, or engine oil is in coolant.
END OF WORK PACKAGE
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0007
FIELD MAINTENANCE ENGINE CRANKS BUT WILL NOT START OR IS HARD TO START
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Personnel Required Construction Equipment Repairer 91L (2) References WP 0034 WP 0105 WP 0109 WP 0110 WP 0114 References (cont.) WP 0115 WP 0116 WP 0124 WP 0127 WP 0128 WP 0129 WP 0130 WP 0174 Volume 2, WP 0235 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0007-1
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0007
TROUBLESHOOTING PROCEDURE SYMPTOM ENGINE CRANKS BUT WILL NOT START OR IS HARD TO START MALFUNCTION Fuel Shutoff Valves In Closed Position. CORRECTIVE ACTION
WARNING
Use caution when working under operator platform assembly. Falling platform may cause injury or death. 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 from crushing. Unlock steering frame before operation to prevent loss of steering. 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.
NOTE
Fuel shutoff valves may be seen without raising operator platform with use of a flashlight. 1. 2. Open right-side door for CB534B Roller and left-side door for CB534C Roller (TM 5-3895-379-10). Check that fuel shutoff valves are in open position. a. If valves are in closed position, perform the following: (1) (2) (3) b. c. Raise operator platform (Volume 2, WP 0235). Open fuel shutoff valves. Lower operator platform (Volume 2, WP 0235).
If fuel shutoff valves are in open position, prime fuel system (WP 0128). If symptom persists, go to next malfunction.
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0007
CORRECTIVE ACTION - Continued
VALVES SHOWN IN CLOSED POSITION
CB534C ROLLER CB534B ROLLER OPEN
CLOSE
T0040SWR
Figure 1. Fuel Shutoff Valves.
0007-3
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0007
MALFUNCTION Fuel Contaminated. CORRECTIVE ACTION
WARNING
DO NOT perform fuel system checks, inspections or maintenance while smoking or near fire, flames or sparks. Fuel may ignite, causing injury or death, or damage to machine. Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel, properly wash exposed skin and change fuel-soaked clothing. Fuel and oil are very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury.
NOTE
Use drain pan to catch any fuel that may drain from system. Dispose of fuel IAW local policy and ordinances. Ensure all spills are cleaned. 1. 2. 3. Place container under fuel filter element. Open drain valve on bottom of fuel filter and collect sample in container. Close drain valve. If fuel is contaminated, perform the following: (1) (2) (3) Drain and flush the fuel tank (WP 0124). Replace fuel filter element (WP 0127). Replace fuel/water separator element (WP 0129).
0007-4
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0007
DRAIN VALVE CLOSE OPEN
FUEL FILTER ELEMENT
T0041SWR
Figure 2. Fuel Filter Drain Valve.
0007-5
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0007
MALFUNCTION Fuel Lines and Fittings Leaking, Kinked, or Damaged. CORRECTIVE ACTION 1. 2. Open left-side door assembly (TM 5-3895-379-10). Check fuel lines and fitting for looseness or damage such as kinks, tears, or restrictions. a. b. If fuel lines or fittings are loose, tighten. If fuel lines or fittings are damaged, perform the following as needed: (1) (2) (3) (4) Replace fuel injector and nozzle (CB534B) (WP 0109). Replace fuel injector and nozzle (CB534C) (WP 0110). Replace fuel lines and fittings (CB534B) (WP 0114). Replace fuel lines and fittings (CB534C) (WP 0115).
FUEL LINES AND FITTINGS
T0042SWR
Figure 3. Fuel Lines.
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0007
MALFUNCTION Fuel Lift Pump Filter Plugged or Damaged. CORRECTIVE ACTION Check fuel lift pump filter on inlet side of fuel injection pump for obstruction and damage. Replace filter if obstructed or damaged (WP 0116).
FUEL LINE FUEL LIFT PUMP
OUTPUT PORT
T0043SWR
Figure 4. Fuel Lift Pump.
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0007
MALFUNCTION Fuel Lift Pump Pressure Low. CORRECTIVE ACTION 1. 2. 3. 4. 5. Remove fuel line from output port of fuel lift pump (WP 0116). Attach pressure gauge to output port of fuel lift pump. Lock steering frame (TM 5-3895-379-10). Turn battery disconnect switch to ON position (TM 5-3895-379-10). Have assistant crank engine for 10 seconds.
NOTE
Normal pressure is 6-10 psi (40-70 kPa). Minimum pressure is 4.5 psi (30 kPa). 6. 7. 8. Observe pressure gauge. Note highest indication on pressure gauge. Turn engine start switch to OFF position (TM 5-3895-379-10).
NOTE
Time should be greater than 30 seconds. 9. 10. 11. Observe amount of time for maximum pressure noted during cranking to drop by one half. Remove pressure gauge from fuel lift pump. Install fuel line to fuel lift pump (WP 0116). a. b. If fuel lift pump outlet pressure is below 4.5 psi (30 kPa), replace fuel lift pump (WP 0116). If time for maximum pressure (noted during cranking) to drop by one half is less than 30 seconds, replace fuel lift pump (WP 0116).
0007-8
TM 5-3895-379-23-1
0007
MALFUNCTION Cold Start Heater Does Not Operate. CORRECTIVE ACTION
NOTE
Cold start heater is used only when ambient temperatures are below 32F (0C). If cold start heater was not operated when malfunction was noted, notify supervisor that engine cranks but will not start or is hard to start. 1. 2. 3. 4. 5. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch and starting aid switch to ON position (TM 5-3895-379-10) for not more than 20 seconds. Turn engine start switch and starting aid switch to OFF position (TM 5-3895-379-10). Check cold start heater and area of intake manifold around cold start heater for warmth. Turn battery disconnect switch to OFF position (TM 5-3895-379-10). a. b. If cold start heater and area of intake manifold around cold start heater are warm, notify supervisor that engine cranks but will not start or is hard to start. If cold start heater and area of inlet manifold around cold start heater are not warm, close left and right-side door assemblies (TM 5-3895-379-10). Go to next malfunction.
WIRE 377-OR
INTAKE MANIFOLD
FUEL LINE
COLD START HEATER

T0044SWR
Figure 5. Engine Cold Start Heater.
0007-9
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0007
MALFUNCTION No Power To Cold Start Heater or Cold Start Heater Faulty. CORRECTIVE ACTION
WARNING
Use caution while working under operator platform assembly. Falling platform may cause injury or death. 1. 2. 3. 4. 5. Raise operator platform (Volume 2, WP 0235). Turn battery disconnect switch to ON position (TM 5-3895-379-10). Have assistant turn engine start switch and starting aid switch to ON position (TM 5-3895-379-10). Touch positive (+) probe of multimeter to wire 377-OR. Touch negative (-) probe of multimeter to engine block. a. If less than 12 to 14 VDC are measured at wire 377-OR, perform the following: (1) (2) (3) (4) b. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Lower operator platform (Volume 2, WP 0235). Go to Electrical Symptom: STARTING AID SWITCH DOES NOT WORK (WP 0034).
If more than 14 VDC are measured at wire 377-OR, starting aid resistor and cold start heater are damaged, perform the following: (1) (2) (3) (4) (5) Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Lower operating platform (Volume 2, WP 0235). Replace cold start heater (WP 0130). Replace starting aid resistor (WP 0174).
c.
If 12 to 14 VDC are measured at wire 377-OR, go to next malfunction.
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0007
WIRE 377-OR
INTAKE MANIFOLD
FUEL LINE
COLD START HEATER

T0227SWR
0007-11
TM 5-3895-379-23-1
0007
MALFUNCTION Cold Start Heater Current Draw Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. Attach clamp-on multimeter to wire 377-OR. Have an assistant turn engine start switch and starting aid switch to ON position (TM 5-3895-379-10). The current draw should be 16-18 amperes at 12 volts. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). a. If current draw is more than 18 or less than 16 amperes, perform the following: (1) (2) b. Replace cold start heater (WP 0130). Close left and/or right-side door assemblies (TM 5-3895-379-10).
If current draw is between 18 and 16 amperes, remove clamp-on multimeter and go to next malfunction.
WIRE 377-OR
INTAKE MANIFOLD
FUEL LINE
COLD START HEATER

T0228SWR
0007-12
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0007
MALFUNCTION Cold Start Heater Leaking Fuel. CORRECTIVE ACTION
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. 1. 2. 3. 4. Remove fuel line and cold start heater from inlet manifold (WP 0105). Connect an air supply with maximum 20 psi (140 kPa) to fuel inlet passage of cold start heater. Submerge cold start heater in a container of clean diesel fuel for 10 seconds. No air bubbles should be visible from cold start heater. a. b. If bubbles are visible from the cold start heater, replace cold start heater (WP 0130). If bubbles are not visible from the cold start heater, install cold start heater (WP 0130) and notify supervisor that engine cranks but will not start or is hard to start.
WIRE 377-OR
INTAKE MANIFOLD
FUEL LINE
COLD START HEATER

T0229SWR
Figure 8. Engine Cold Start Heater. END OF WORK PACKAGE
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0008
FIELD MAINTENANCE ENGINE EXHAUST SMOKES EXCESSIVELY (BLACK OR GRAY SMOKE)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Personnel Required Construction Equipment Repairer 91L (2) References WP 0034 References (cont.) WP 0105 WP 0121 WP 0130 WP 0174 Volume 2, WP 0235 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
TROUBLESHOOTING PROCEDURE SYMPTOM ENGINE EXHAUST SMOKES EXCESSIVELY (BLACK OR GRAY SMOKE) MALFUNCTION Turbocharger Damaged. CORRECTIVE ACTION
WARNING
Use caution while working under operator platform assembly. Falling platform may cause injury or death. 1. 2. 3. 4. Raise operator platform (Volume 2, WP 0235). Loosen clamp and remove inlet hose from turbocharger (WP 0121). Inspect impeller for cracks. Impeller should spin freely.
0008-1
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0008
NOTE
Acceptable impeller shaft end play is 0.001-0.004 inches (0.03-0.10 mm). Acceptable impeller shaft radial play is 0.003-0.006 inches (0.08-0.15 mm). 5. Measure impeller shaft play. a. If impeller is restricted, perform the following: (1) (2) (3) b. c. Remove restriction. Install hose on turbocharger and tighten clamp. Lower operator platform (Volume 2, WP 0235).
If turbocharger impeller is cracked, does not spin freely, or has too much shaft play, replace turbocharger (WP 0121). If impeller is not damaged or restricted, install inlet hose on turbocharger and tighten clamp (WP 0121). Go to next malfunction.
WARNING
NOTE
Cold start heater is used only when ambient temperatures are below 32F (0C). If cold start heater was not operated when malfunction was noted, notify supervisor. 1. 2. 3. 4. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch and starting aid switch to ON position (TM 5-3895-379-10) for not more than 20 seconds. Turn engine start switch and starting aid switch to OFF position (TM 5-3895-379-10). Check cold start heater and area of intake manifold around cold start heater for warmth.
0008-2
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0008
CORRECTIVE ACTION - Continued a. If cold start heater and area of intake manifold around cold start heater are warm, turn battery disconnect switch to OFF position (TM 5-3895-379-10) and notify supervisor that engine smokes excessively. If cold start heater and area of intake manifold around cold start heater are not warm, go to next malfunction.
WIRE 377-OR INTAKE MANIFOLD
b.
FUEL LINE
COLD START HEATER

T0054SWR
0008-3
TM 5-3895-379-23-1
0008
MALFUNCTION No Power To Cold Start Heater or Cold Start Heater Faulty. CORRECTIVE ACTION 1. 2. 3. 4. Raise operator platform (Volume 2, WP 0235). Have assistant turn engine start switch and starting aid switch to ON position (TM 5-3895-379-10). Touch positive (+) probe of multimeter to wire 377-OR. Touch negative (-) probe of multimeter to engine block. a. If 12 to 14 VDC are not measured at wire 377-OR, perform the following: (1) (2) (3) b. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Go to Electrical Symptom: STARTING AID SWITCH DOES NOT WORK.
If more than 14 VDC are measured at wire 377-OR, starting aid resistor and cold start heater are damaged. Perform the following: (1) (2) (3) (4) Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Replace cold start heater (WP 0130). Replace starting aid resistor (WP 0174).
c.

WIRE 377-OR INTAKE MANIFOLD
FUEL LINE
COLD START HEATER

T0231SWR
0008-4
TM 5-3895-379-23-1
0008
MALFUNCTION Cold Start Heater Current Draw Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. Attach clamp-on multimeter to wire 377-OR. Have assistant turn engine start switch and starting aid switch to ON position (TM 5-3895-379-10). The current draw should be 16 to 18 amperes at 12 volts. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). a. b. If current draw is more than 18 or less than 16 amperes, replace cold start heater (WP 0130). Close left and right-side door assemblies (TM 5-3895-379-10). If current draw is between 18 and 16 amperes, remove clamp on multimeter and go to next malfunction.
MALFUNCTION Cold Start Heater Leaking Fuel. CORRECTIVE ACTION 1. Remove fuel line and cold start heater from intake manifold (WP 0105).
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. Connect an air supply with maximum 20 psi (140 kPa) to fuel inlet passage of cold start heater. Submerge cold start heater in a container of clean diesel fuel for 10 seconds. No air bubbles should be visible from cold start heater. a. b. If bubbles are visible from the cold start heater, replace cold start heater (WP 0130). If bubbles are not visible from the cold start heater, install cold start heater (WP 0130) and notify supervisor that engine exhaust smokes excessively.
END OF WORK PACKAGE
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0009
FIELD MAINTENANCE ENGINE EXHAUST SMOKES EXCESSIVELY (WHITE OR BLUE SMOKE)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Personnel Required Construction Equipment Repairer 91L (2) References WP 0034 WP 0077 WP 0109 References (cont.) WP 0110 WP 0114 WP 0115 WP 0130 WP 0140 WP 0141 WP 0174 Volume 2, WP 0235 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
TROUBLESHOOTING PROCEDURE SYMPTOM ENGINE EXHAUST SMOKES EXCESSIVELY (WHITE OR BLUE SMOKE) MALFUNCTION Engine Oil Low. CORRECTIVE ACTION Check engine oil (TM 5-3895-379-10). If engine oil level is too high, drain engine oil until level is correct (WP 0077). MALFUNCTION Thermostat Faulty. CORRECTIVE ACTION Remove and test thermostat (WP 0140) or (WP 0141). a. b. If thermostat is bad, install thermostat (WP 0140) or (WP 0141). If thermostat is OK, replace thermostat gasket and install thermostat (WP 0140) or (WP 0141).
0009-1
TM 5-3895-379-23-1
0009
MALFUNCTION Fuel Lines and Fittings Leaking, Kinked, or Damaged. CORRECTIVE ACTION
WARNING
DO NOT perform fuel system checks, inspections or maintenance while smoking or near fire, flames or sparks. Fuel may ignite, causing injury or death, or damage to machine. Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel, properly wash exposed skin and change fuel-soaked clothing. Fuel and oil are very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury. 1. 2. Open left-side door assembly (TM 5-3895-379-10). Check fuel lines and fitting for looseness or damage such as kinks, tears, or restrictions. a. b. If fuel lines or fittings are loose, tighten. If fuel lines or fittings are damaged, perform the following as needed: (1) (2) (3) (4) Replace fuel injector and nozzle (CB534B) (WP 0109). Replace fuel injector and nozzle (CB534C) (WP 0110). Replace fuel lines and fittings (CB534B) (WP 0114). Replace fuel lines and fittings (CB534C) (WP 0115).
DRAIN VALVE
DRAIN VALVE
T0055SWR
0009-2
TM 5-3895-379-23-1
0009
NOTE
Cold start heater is used only when ambient temperatures are below 32F (0C). If cold start heater was not operated when malfunction was noted, notify supervisor that engine smokes excessively. 1. 2. 3. Turn engine start switch and starting aid switch to ON position (TM 5-3895-379-10) for not more than 20 seconds. Turn engine start switch and starting aid switch to OFF position (TM 5-3895-379-10). Check cold start heater and area of intake manifold around cold start heater for warmth. If cold start heater and area of intake manifold around cold start heater are not warm, go to next malfunction.
WIRE 377-OR
INTAKE MANIFOLD
FUEL LINE
COLD START HEATER

T0056SWR
0009-3
TM 5-3895-379-23-1
0009
MALFUNCTION No Power To Cold Start Heater or Cold Start Heater Faulty. CORRECTIVE ACTION
WARNING
Use caution while working under operator platform assembly. Falling platform may cause injury or death. 1. 2. 3. 4. 5. Raise operator platform (Volume 2, WP 0235). Turn battery disconnect switch to ON position (TM 5-3895-379-10). Have assistant turn engine start switch and starting aid switch to ON position (TM 5-3895-379-10). Touch positive (+) probe of multimeter to wire 377-OR. Touch negative (-) probe of multimeter to engine block. a. If less than 12 to 14 VDC are measured at wire 377-OR, perform the following: (1) (2) (3) (4) b. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Lower operator platform (Volume 2, WP 0235). Go to Electrical Symptom: STARTING AID SWITCH DOES NOT WORK (WP 0034).
If more than 14 VDC are measured at wire 377-OR, starting aid resistor and cold start heater are damaged, perform the following: (1) (2) (3) (4) (5) Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Lower operating platform (Volume 2, WP 0235). Replace cold start heater (WP 0130). Replace starting aid resistor (WP 0174).
c.
0009-4
TM 5-3895-379-23-1
0009
WIRE 377-OR
INTAKE MANIFOLD
FUEL LINE
COLD START HEATER

T0057SWR
0009-5
TM 5-3895-379-23-1
0009
MALFUNCTION Cold Start Heater Current Draw Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. Attach clamp-on multimeter to wire 377-OR. Have an assistant attempt to start engine (TM 5-3895-379-10). Note the current draw indication. The current draw should be 16 to 18 amperes at 12 volts. Connect wire 377-OR to cold start heater. Turn engine start switch OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). a. b. If current draw is more than 18 or less than 16 amperes, replace cold start heater (WP 0130). Lower operating platform (Volume 2, WP 0235). If current draw is between 18 and 16 amperes, remove clamp-on multimeter. Go to next malfunction.
WIRE 377-OR
INTAKE MANIFOLD
FUEL LINE
COLD START HEATER

T0187SWR
0009-6
TM 5-3895-379-23-1
0009
MALFUNCTION Cold Start Heater Leaking Fuel. CORRECTIVE ACTION
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. 1. 2. 3. 4. Remove fuel line and cold start heater from intake manifold (WP 0105). Connect an air supply with maximum 20 psi (140 kPa) to fuel inlet passage of cold start heater. Submerge cold start heater in a container of clean diesel fuel for 10 seconds. No air bubbles should be visible from cold start heater. a. b. If bubbles are visible from the cold start heater, replace cold start heater (WP 0130). If bubbles are not visible from the cold start heater, install cold start heater (WP 0130) and notify supervisor that engine exhaust smokes excessively.
END OF WORK PACKAGE
0009-7/8 blank
TM 5-3895-379-23-1
0010
FIELD MAINTENANCE ENGINE IS SLUGGISH
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Personnel Required Construction Equipment Repairer 91L (2) References WP 0109 WP 0110 References (cont.) WP 0114 WP 0115 WP 0116 WP 0121 WP 0124 WP 0129 WP 0131 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0010-1
TM 5-3895-379-23-1
0010
TROUBLESHOOTING PROCEDURE SYMPTOM ENGINE IS SLUGGISH MALFUNCTION Fuel Contaminated. CORRECTIVE ACTION
WARNING
DO NOT perform fuel system checks, inspections or maintenance while smoking or near fire, flames or sparks. Fuel may ignite, causing injury or death, or damage to machine. Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel, properly wash exposed skin and change fuel-soaked clothing. Fuel and oil are very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury. 1. Open right-side door assembly (TM 5-3895-379-10).
NOTE
Use drain pan to catch any fuel that may drain from system. Dispose of fuel In Accordance With (IAW) local policy and ordinances. Ensure all spills are cleaned. 2. 3. 4. Place drain pan under fuel filter element. Open drain valve on bottom of fuel filter and collect sample in container. Close drain valve. If fuel is contaminated, perform the following: (1) (2) (3) Drain and flush fuel tank (WP 0124). Replace fuel filter element (WP 0127). Replace fuel/water separator element (WP 0129).
0010-2
TM 5-3895-379-23-1
0010
DRAIN VALVE CLOSE OPEN FUEL FILTER ELEMENT

T0048SWR
Figure 1. Fuel Filter Drain Valve. MALFUNCTION Fuel Lines and Fittings Leaking, Kinked, or Damaged. CORRECTIVE ACTION 1. 2. Open left-side door assembly (TM 5-3895-379-10). Check fuel lines and fittings for looseness and damage such as kinks, tears, or restrictions. a. b. If fuel lines or fittings are loose, tighten. If fuel lines or fittings are damaged, perform the following as needed: (1) (2) (3) (4) Replace fuel injector and nozzle (CB534B) (WP 0109). Replace fuel injector and nozzle (CB534C) (WP 0110). Replace fuel lines and fittings (CB534B) (WP 0114). Replace fuel lines and fittings (CB534C) (WP 0115).
0010-3
TM 5-3895-379-23-1
0010
MALFUNCTION Fuel Lift Pump Pressure Low. CORRECTIVE ACTION 1. 2. 3. 4. 5. Remove fuel lines from output side of fuel lift pump (WP 0116). Attach pressure gauge to output side of fuel lift pump. Lock steering frame (TM 5-3895-379-10). Turn battery disconnect switch to ON position (TM 5-3895-379-10). Have an assistant crank engine for 10 seconds.
NOTE
NOTE
Time should be greater than 30 seconds. 9. Observe amount of time for maximum pressure noted during cranking to drop by one half. a. b. c. If fuel lift pump outlet pressure is below 4.5 (30 kPa), replace fuel lift pump (WP 0116). If time for maximum pressure noted during cranking to drop by one half is less than 30 seconds, replace fuel lift pump (WP 0116). If fuel lift pump pressure is OK, install fuel line (WP 0116) and go to next malfunction.
FUEL LINE LIFT PUMP
OUTPUT PORT
T0049SWR
Figure 2. Fuel Lift Pump.
0010-4
TM 5-3895-379-23-1
0010
MALFUNCTION Throttle Cable Damaged or Cable Travel Restricted (CB534B). CORRECTIVE ACTION
NOTE
For CB534B Roller only. 1. 2. 3. Inspect throttle cable for damage such as kinking, bent condition, stripped threads, or broken sleeve. Check for full travel of throttle cable at fuel injection pump while assistant operates throttle control fully up and down. Check throttle cable adjustment (WP 0131). a. b. c. If throttle cable is not properly adjusted, adjust linkage (WP 0131). If throttle cable is damaged, replace throttle cable (WP 0131). If throttle cable is OK, close right-side door assembly (TM 5-3895-379-10) and go to next malfunction.
THROTTLE CABLE
FUEL INJECTOR PUMP
THROTTLE CONTROL
T0050SWR
Figure 3. Throttle Cable.
0010-5
TM 5-3895-379-23-1
0010
MALFUNCTION Turbocharger Damaged. CORRECTIVE ACTION 1. 2. 3. Loosen clamp and remove inlet hose from turbocharger (WP 0121). Inspect impeller for cracks. The impeller should spin freely.
NOTE
Acceptable impeller shaft end play is 0.001-0.04 inches (0.03-0.10 mm). Acceptable impeller shaft radial play is 0.003-0.006 inches (0.08-0.15 mm). 4. Measure impeller shaft play. a. If impeller is restricted, perform the following: (1) (2) (3) b. c. Remove restriction. Install hose on turbocharger and tighten clamp (WP 0121). Close left-side door assembly (TM 5-3895-379-10).
If turbocharger impeller is cracked, does not spin freely, or has too much shaft play, replace turbocharger (WP 0121). If turbocharger impeller is OK, install inlet hose on turbocharger and tighten clamp (WP 0121). Notify supervisor that engine is sluggish.
TURBOCHARGER
IMPELLER CLAMP INLET HOSE
T0051SWR
Figure 4. Turbocharger. END OF WORK PACKAGE
0010-6
TM 5-3895-379-23-1
0011
FIELD MAINTENANCE ENGINE IS UNUSUALLY NOISY
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References WP 0109 WP 0110 WP 0114 WP 0115 References (cont.) WP 0121 WP 0123 WP 0134 WP 0146 WP 0147 Volume 2, WP 0235 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
TROUBLESHOOTING PROCEDURE SYMPTOM ENGINE IS UNUSUALLY NOISY MALFUNCTION Exhaust System Leaks or Is Damaged. CORRECTIVE ACTION 1. 2. Check muffler and exhaust system for loose or damaged components. Inspect exhaust system for holes rusted through muffler or pipes, torn muffler or pipes, or bent muffler or pipes. a. b. c. If muffler or exhaust system is loose, tighten loose components (WP 0134). If muffler or exhaust is damaged, replace damaged components (WP 0134). If muffler and exhaust system are not loose or damaged, go to next malfunction.
0011-1
TM 5-3895-379-23-1
0011
MALFUNCTION Fan Assembly and Guard Loose or Damaged. CORRECTIVE ACTION
WARNING
Use caution while working under operator platform assembly. Falling platform may cause injury or death. 1. 2. Raise operator platform (Volume 2, WP 0235). Check fan assembly and guard for looseness or damage such as cracked or missing fan blade(s), loose nuts and screws, bent or cracked fan pulley, or damage or wear from extreme fan blade wobble. a. b. If fan assembly and guard are loose or damaged, tighten or replace loose or damaged parts (WP 0146). If fan assembly and guard are not loose or damaged, go to next malfunction.
FAN V-BELTS
FAN DRIVE HOUSING ASSEMBLY
FAN PULLEY
FAN BLADE
T0065SWR
Figure 1. Engine Fan Assembly.
0011-2
TM 5-3895-379-23-1
0011
MALFUNCTION V-belts Loose or Damaged. CORRECTIVE ACTION 1. 2. 3. Check fan V-belts for damage such as cracks to the belt fiber, one or more cracks 1/8 inch in depth or 50% of belt thickness, splits, grease buildup, glazed sides, and peeling. Attach belt tension gauge to fan V-belts. Correct belt tension is 80 lb (36.3 kg). a. b. c. If fan V-belts are damaged, replace fan V-belts (WP 0147). If belt tension is 50 lb (22.8 kg) or less, adjust fan V-belt tension (WP 0147). If fan V-belts are not damaged or loose, remove belt tension gauge from fan V-belts. Go to next malfunction.
MALFUNCTION Turbocharger Inlet Hose Leaking or Damaged. CORRECTIVE ACTION 1. 2. Open left-side door assembly (TM 5-3895-379-10). Check turbocharger inlet hose for damage or leakage. If turbocharger inlet hose is damaged or leaking, replace turbocharger inlet hose (WP 0123).
TURBOCHARGER
T0066SWR
Figure 2. Turbocharger.
0011-3
TM 5-3895-379-23-1
0011
MALFUNCTION Turbocharger Damaged. CORRECTIVE ACTION 1. 2. 3. Loosen clamp and remove inlet hose from turbocharger. Inspect impeller for cracks. The impeller should spin freely.
NOTE
Acceptable impeller shaft play is 0.001-0.004 inches (0.03-0.10 mm). Acceptable impeller shaft radial play is 0.003-0.006 inches (0.08-0.15 mm). 4. Measure impeller shaft play. a. If impeller is restricted, perform the following: (1) (2) (3) b. c. Remove restriction. Install hose on turbocharger and tighten clamp. Close left-side door assembly (TM 5-3895-379-10).
If turbocharger impeller is cracked, does not spin freely, or has too much shaft play, replace turbocharger (WP 0121). If impeller is not damaged or restricted, install inlet hose on turbocharger and tighten clamp. Go to next malfunction.
0011-4
TM 5-3895-379-23-1
0011
MALFUNCTION Fuel Lines and Fittings Leaking, Kinked, or Damaged. CORRECTIVE ACTION Check fuel lines and fittings for looseness or damage such as kinks, tears, or restrictions. a. b. If fuel lines or fittings are loose, tighten. If fuel lines or fittings are damaged, perform the following as needed: (1) (2) (3) (4) Replace fuel injector and nozzle (CB534B) (WP 0109). Replace fuel injector and nozzle (CB534C) (WP 0110). Replace fuel lines and fittings (CB534B) (WP 0114). Replace fuel lines and fittings (CB534C) (WP 0115).
T0067SWR
Figure 3. Fuel Lines. END OF WORK PACKAGE
0011-5/6 blank
TM 5-3895-379-23-1
0012
FIELD MAINTENANCE ENGINE IS USING MORE FUEL THAN USUAL
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References WP 0118 References (cont.) WP 0121 WP 0123 Volume 2, WP 0235 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0012-1
TM 5-3895-379-23-1
0012
TROUBLESHOOTING PROCEDURE SYMPTOM ENGINE IS USING MORE FUEL THAN USUAL MALFUNCTION Air Filter Plugged or Faulty. CORRECTIVE ACTION 1. 2. 3. Open left-side door assembly (TM 5-3895-379-10). Remove and inspect air cleaner elements (WP 0118). Check air cleaner assembly for damage or blockage. a. b. c. d. If air cleaner elements are damaged or clogged, replace elements (WP 0118). If air cleaner assembly is damaged, replace air cleaner assembly (WP 0118). If any air blockage is found in assembly, remove blockage and install elements (WP 0118). If air cleaner assembly is OK, install elements (WP 0118) and go to next malfunction.
AIR CLEANER HOUSING
SECONDARY ELEMENT PRIMARY ELEMENT
AIR CLEANER HOUSING LATCHES
AIR CLEANER HOUSING COVER
T0069SWR
Figure 1. Engine Air Intake System.
0012-2
TM 5-3895-379-23-1
0012
MALFUNCTION Turbocharger Inlet Hose Leaking or Damaged. CORRECTIVE ACTION Check turbocharger inlet hose for damage or leakage. If turbocharger inlet hose is damaged or leaking, replace turbocharger inlet hose (WP 0123).
TURBOCHARGER
T0070SWR
Figure 2. Turbocharger.
0012-3
TM 5-3895-379-23-1
0012
MALFUNCTION Turbocharger Damaged. CORRECTIVE ACTION 1. 2. 3. Loosen clamp and remove inlet hose from turbocharger. Inspect impeller for cracks. The impeller should spin freely.
NOTE
Acceptable impeller shaft end play is 0.001-0.004 inches (0.03-0.10 mm). Acceptable impeller shaft radial play is 0.003-0.006 inches (0.08-0.15 mm). 4. Measure impeller shaft play. a. b. c. If impeller is restricted, remove restriction. Install hose on turbocharger and tighten clamp (WP 0121). If turbocharger impeller is cracked, does not spin freely, or has too much shaft play, replace turbocharger (WP 0121). If turbocharger impeller is OK, notify supervisor that engine is using excessive fuel.
TURBOCHARGER
T0204SWR
0012-4
TM 5-3895-379-23-1
0013
FIELD MAINTENANCE ENGINE IS USING MORE OIL THAN USUAL
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
TROUBLESHOOTING PROCEDURE SYMPTOM ENGINE IS USING MORE OIL THAN USUAL MALFUNCTION Engine Oil Level Low. CORRECTIVE ACTION 1. 2. 3. Open left- and right-side door assemblies (TM 5-3895-379-10). Check engine for oil leaks. Leaks may come from loose components, damaged or decayed gaskets or seals, broken turbocharger oil lines, or loose fittings. a. b. Tighten items found to be loose. Replace items found to be damaged. If problem persists, problem is probably internal engine wear. Notify supervisor that engine uses excessive oil.
END OF WORK PACKAGE
0013-1/2 blank
TM 5-3895-379-23-1
0014
FIELD MAINTENANCE ENGINE MISFIRES OR IDLES ROUGH
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Personnel Required Construction Equipment Repairer 91L (2) References WP 0109 WP 0110 References (cont.) WP 0114 WP 0115 WP 0116 WP 0124 WP 0127 WP 0129 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0014-1
TM 5-3895-379-23-1
0014
TROUBLESHOOTING PROCEDURE SYMPTOM ENGINE MISFIRES OR IDLES ROUGH MALFUNCTION Fuel Contaminated. CORRECTIVE ACTION
WARNING
DO NOT perform fuel system checks, inspections or maintenance while smoking or near fire, flames or sparks. Fuel may ignite, causing injury or death, or damage to machine. Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel, properly wash exposed skin and change fuel-soaked clothing. Fuel and oil are very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury. 1. Open right-side door assembly (TM 5-3895-379-10).
NOTE
Use drain pan to catch any fuel that may drain from system. Dispose of fuel In Accordance With (IAW) local policy and ordinances. Ensure all spills are cleaned. 2. 3. 4. Place drain pan under fuel filter element. Open drain valve on bottom of fuel filter and collect sample in container. Close drain valve. If fuel is contaminated, perform the following: (1) (2) (3) Drain and flush the fuel tank (WP 0124). Replace fuel filter element (WP 0127). Replace fuel/water separator element (WP 0129).
0014-2
TM 5-3895-379-23-1
0014

T0058SWR
0014-3
TM 5-3895-379-23-1
0014
MALFUNCTION Fuel Lines and Fittings Leaking, Kinked, or Damaged. CORRECTIVE ACTION 1. 2. Open left-side door assembly (TM 5-3895-379-10). Check fuel lines and fitting for looseness or damage such as kinks, tears, or restrictions. a. b. If fuel lines or fittings are loose, tighten. If fuel lines or fittings are damaged, perform the following as needed: (1) (2) (3) (4) Replace fuel injector and nozzle (CB534B) (WP 0109). Replace fuel injector and nozzle (CB534C) (WP 0110). Replace fuel lines and fittings (CB534B) (WP 0114). Replace fuel lines and fittings (CB534C) (WP 0115).
FUEL LINES AND FITTINGS FUEL LINES AND FITTINGS
T0059SWR
0014-4
TM 5-3895-379-23-1
0014
MALFUNCTION Fuel Lift Pump Pressure Low. CORRECTIVE ACTION
WARNING
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 from crushing. Unlock steering frame before operation to prevent loss of steering. 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. 1. 2. 3. 4. 5. Remove fuel line from output port of fuel lift pump (WP 0116). Attach pressure gauge to output port of fuel lift pump. Lock steering frame (TM 5-3895-379-10). Turn battery disconnect switch to ON position (TM 5-3895-379-10). Have assistant crank engine for 10 seconds.
NOTE
NOTE
Time should be greater than 30 seconds. 9. Observe amount of time for maximum pressure noted during cranking to drop by one half.
0014-5
TM 5-3895-379-23-1
0014
CORRECTIVE ACTION - Continued 10. Remove pressure gauge from fuel lift pump. a. b. c. If fuel lift pump outlet pressure is below 4.5 psi (30 kPa), replace fuel lift pump (WP 0116). If time for maximum pressure noted during cranking to drop by one half is less than 30 seconds, replace fuel lift pump (WP 0116). If lift pump pressure checks are OK, install fuel line (WP 0116) and notify supervisor that engine misfires or idles rough.
FUEL LINE LIFT PUMP
OUTPUT PORT
T0060SWR
Figure 3. Fuel Lift Pump. END OF WORK PACKAGE
0014-6
TM 5-3895-379-23-1
0015
FIELD MAINTENANCE ENGINE OIL PRESSURE IS LOW (WARNING LIGHT AND WARNING HORN ON)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Personnel Required Construction Equipment Repairer 91L References WP 0006 References (cont.) WP 0077 WP 0116 WP 0172 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0015-1
TM 5-3895-379-23-1
0015
TROUBLESHOOTING PROCEDURE SYMPTOM ENGINE OIL PRESSURE IS LOW (WARNING LIGHT AND WARNING HORN ON) MALFUNCTION Engine Oil Level Low. CORRECTIVE ACTION
WARNING
DO NOT perform fuel system checks, inspections or maintenance while smoking or near fire, flames or sparks. Fuel may ignite, causing injury or death, or damage to machine. Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel, properly wash exposed skin and change fuel-soaked clothing. Fuel and oil are very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury. Check engine oil for contamination and proper level (TM 5-3895-379-10). Add oil as required or change engine oil and filter (WP 0077). If oil pressure is still low, go to next malfunction.
0015-2
TM 5-3895-379-23-1
0015
LOW MARK
HIGH MARK ENGINE OIL GAGE ROD (DIPSTICK) TUBE
T0062SWR
Figure 1. Engine Oil Level Check.
0015-3
TM 5-3895-379-23-1
0015
MALFUNCTION Oil Pressure Switch Faulty. CORRECTIVE ACTION
WARNING
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 burns. DO NOT remove cooling system 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 burns. Wear effective eye, glove, and skin protection when handling coolants. Failure to do so may cause injury. 1. 2. 3. 4. 5. 6. Remove engine oil pressure switch from elbow (WP 0172). Attach pressure gauge to elbow. Start engine and allow engine to warm up. Engine oil pressure should be between 13-40 psi (90-276 kPa). Turn engine start switch to OFF position (TM 5-3895-379-10). Remove pressure gauge. a. If oil pressure is not between 13-40 psi (90-276 kPa), perform the following: (1) (2) b. Install engine oil pressure switch on elbow (WP 0172). Tighten switch to 15-18 lb-ft (20-25 Nm) and go to next malfunction.
If oil pressure is between 13-40 psi (90-276 kPa), replace engine oil pressure switch (WP 0172).
0015-4
TM 5-3895-379-23-1
0015
OIL PRESSURE SWITCH ELBOW
T0061SWR
Figure 2. Oil Pressure Switch.
0015-5
TM 5-3895-379-23-1
0015
MALFUNCTION Oil In Coolant. CORRECTIVE ACTION 1. 2. 3. 4. 5. Check for oil in coolant. Pull back lever and open access door on operator's platform (TM 5-3895-379-10). Release lever and remove radiator cap. Check for oil in coolant. Install radiator cap (TM 5-3895-379-10) and close access door. If oil is present in coolant go to Engine Symptom: COOLANT IN ENGINE OIL/ENGINE OIL IN COOLANT (WP 0006).
ACCESS DOOR RADIATOR CAP
LEVER
T0063SWR
Figure 3. Engine Oil Level Check.
0015-6
TM 5-3895-379-23-1
0015
MALFUNCTION Fuel In Oil. CORRECTIVE ACTION Remove fuel lift pump (WP 0116) and check for cracks or damage which would allow fuel to leak into engine crankcase. a. If fuel lift pump is cracked or damaged, perform the following: (1) (2) b. Replace fuel lift pump (WP 0116). Change oil (WP 0077).
If fuel lift pump is OK, install fuel lift pump (WP 0116) and notify supervisor that engine oil pressure is low.
FUEL LINE LIFT PUMP
OUTPUT PORT
T0064SWR
0015-7/8 blank
TM 5-3895-379-23-1
0016
FIELD MAINTENANCE ENGINE OPERATING TEMPERATURE IS TOO HIGH (WARNING LIGHT AND WARNING HORN ON)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References WP 0077 WP 0095 WP 0096 WP 0097 WP 0135 WP 0136 References (cont.) WP 0138 WP 0139 WP 0140 WP 0141 WP 0144 WP 0145 WP 0146 WP 0147 Volume 2, WP 0235 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0016-1
TM 5-3895-379-23-1
0016
TROUBLESHOOTING PROCEDURE SYMPTOM ENGINE OPERATING TEMPERATURE IS TOO HIGH (WARNING LIGHT AND WARNING HORN ON) MALFUNCTION Coolant Level Low or Radiator Cap Faulty. CORRECTIVE ACTION
WARNING
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 burns. DO NOT remove cooling system 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 burns. Wear effective eye, glove, and skin protection when handling coolants. Failure to do so may cause injury. 1. 2. 3. 4. 5. Open right-side door assembly (TM 5-3895-379-10). Pull back lever and open access door. Check radiator coolant level (WP 0139). Coolant level should be approximately 3 in. (7.6 cm) below fill port. The sealing surface of radiator cap should be clean and free of cracks, nicks, or dents. a. b. If coolant level is not correct, add coolant (WP 0139). If sealing surface of radiator cap is cracked, nicked, or dented, perform the following: (1) (2) (3) c. Replace radiator cap. Pull back lever and close access door. Release lever and close right-side door assembly (TM 5-3895-379-10).
If coolant level is correct and pressure cap is OK, perform the following: (1) (2) (3) Install radiator cap. Pull back lever and close access door. Release lever and go to next malfunction.
0016-2
TM 5-3895-379-23-1
0016
LEVER
T0072SWR
Figure 1. Radiator Cap Assembly. MALFUNCTION Radiator Assembly and Hoses Leak or Are Damaged. CORRECTIVE ACTION 1. 2. 3. Inspect radiator assembly and hoses for leaks, damage, and deterioration. Check radiator assembly for bent fins, restrictions, and holes. Check radiator hoses for cuts, cracks, leaks, and loose clamps. a. b. c. d. e. f. If radiator assembly fins are bent, straighten fins. If radiator assembly air flow is restricted, remove restriction. If radiator assembly has leaks, repair or replace radiator assembly (WP 0136). If hose clamps are loose, tighten hose clamps. Close right-side door assembly (TM 5-3895-379-10). If radiator hoses are cut, cracked, or leaking, replace radiator hoses (WP 0138). If radiator assembly and hoses are OK, go to next malfunction.
0016-3
TM 5-3895-379-23-1
0016
MALFUNCTION Radiator Does Not Hold Pressure. CORRECTIVE ACTION Perform coolant system pressure test (WP 0135). If coolant system shows signs of leaks, repair or replace faulty components.
LEVER
T0073SWR
Figure 2. Radiator Cap Assembly.
0016-4
TM 5-3895-379-23-1
0016
MALFUNCTION V-belts Loose or Damaged. CORRECTIVE ACTION
WARNING
Use caution while working under operator platform assembly. Falling platform may cause injury or death. 1. 2. 3. 4. Raise operator platform (Volume 2, WP 0235). Check V-belts for damage such as cracks to belt fiber, one or more cracks 1/8 inch in depth or 50% of belt thickness, splits, grease buildup, glazed sides, and peeling (WP 0147). Attach belt tension gauge to fan V-belts (WP 0147). Correct belt tension is 80 lb (36.3 kg). a. b. c. If fan V-belts are damaged, replace fan V-belts (WP 0147). If belt tension is 50 lb (22.7 kg) or less, adjust alternator V-belt tension (WP 0147). If fan V-belts are not damaged or loose, go to next malfunction.
FAN V-BELTS
FAN BLADE
FAN PULLEY
T0074SWR
0016-5
TM 5-3895-379-23-1
0016
MALFUNCTION Fan Assembly and Guard and/or Fan Drive Housing Assembly Loose or Damaged. CORRECTIVE ACTION Check fan assembly, fan drive housing, and guard for looseness or damage such as cracked or missing fan blades, loose nuts and screws, bent or cracked fan pulley, or damage or wear resulting from extreme fan wobble. a. b. c. If fan assembly and guard are loose or damaged, tighten or replace damaged parts (WP 0146). If fan drive housing assembly is loose or damaged, tighten or replace fan drive housing assembly (WP 0145). If fan assembly, fan drive housing, and guard are not loose or damaged, go to next malfunction.
FAN V-BELTS
FAN BLADE
FAN PULLEY
T0219SWR
0016-6
TM 5-3895-379-23-1
0016
MALFUNCTION Water Pump Leaks. CORRECTIVE ACTION
NOTE
Class I leakage at water pump bleed holes is normal. Any Class II or Class III leakage represents a problem with water pump. 1. Check water pump for signs of leakage (discoloration, corrosion, wetness).
NOTE
There are two failure bleed holes located on engine side of water pump. 2. Check failure bleed holes for Class II and Class III leakage of engine oil or coolant. If coolant is leaking from either failure bleed hole or water pump shows signs of leakage, perform the following: (1) (2) Replace water pump (WP 0144). Replace coolant system fluid (WP 0139).
WATER PUMP WATER PUMP
WATER PUMP SHOWN REMOVED FOR CLARITY
FAILURE BLEED HOLES

T0075SWR
Figure 5. Water Pump.
0016-7
TM 5-3895-379-23-1
0016
MALFUNCTION Thermostat Faulty. CORRECTIVE ACTION Test thermostat (WP 0140) or (WP 0141). If thermostat is bad, replace thermostat (WP 0140) or (WP 0141). MALFUNCTION Oil Leak At Oil Cooler. CORRECTIVE ACTION 1. 2. Check engine oil cooler and lines for signs of leakage or damage. Damage can include torn, cracked, or bent lines and cooler components. a. b. If engine oil cooler lines are leaking or damaged, replace faulty components (WP 0096) or (WP 0097). Tighten loose components. If engine oil cooler or components are damaged, perform the following: (1) (2) (3) (4) c. Replace oil cooler or components (WP 0095). Change engine oil and filter (WP 0077). Replace coolant system fluid (WP 0139). Lower operator platform (Volume 2, WP 0235).
If engine cooler is OK, notify supervisor that engine is overheating.
0016-8
TM 5-3895-379-23-1
0016
OIL COOLER LINE
OIL COOLER LINES
OIL COOLER LINE OIL COOLER

T0076SWR
Figure 6. Engine Oil Cooler Lines. END OF WORK PACKAGE
0016-9/10 blank
TM 5-3895-379-23-1
0017
FIELD MAINTENANCE ENGINE STARTS BUT WILL NOT KEEP RUNNING
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Personnel Required Construction Equipment Repairer 91L (2) References WP 0109 WP 0110 References (cont.) WP 0114 WP 0115 WP 0116 WP 0124 WP 0127 WP 0129 WP 0134 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
TROUBLESHOOTING PROCEDURE
WARNING
0017-1
TM 5-3895-379-23-1
0017
SYMPTOM ENGINE STARTS BUT WILL NOT KEEP RUNNING MALFUNCTION Fuel Filter and Fuel/Water Separator Contaminated. CORRECTIVE ACTION 1. Open right-side door assembly (TM 5-3895-379-10).
NOTE
Use drain pan to catch any fuel that may drain from system. Dispose of fuel IAW local policy and ordinances. Ensure all spills are cleaned. 2. 3. 4. Place drain pan under fuel filter element. Open drain valve on bottom of fuel filter and collect sample in container. Close drain valve. If fuel is not clear but is cloudy, showing evidence of contamination, perform the following: (1) (2) (3) Drain and flush fuel tank (WP 0124). Replace fuel filter element (WP 0127). Replace fuel/water separator element (WP 0129).

T0045SWR
0017-2
TM 5-3895-379-23-1
0017
MALFUNCTION Fuel Lines and Fittings Leaking, Kinked, or Damaged. CORRECTIVE ACTION 1. 2. Open left-side door assembly (TM 5-3895-379-10). Check fuel lines and fittings for looseness or damage such as kinks, tears, or restrictions. a. b. If fuel lines or fittings are loose, tighten. If fuel lines or fittings are damaged, perform the following as needed: (1) (2) (3) (4) Replace fuel injector and nozzle (CB534B) (WP 0109). Replace fuel injector and nozzle (CB534C) (WP 0110). Replace fuel lines and fittings (CB534B) (WP 0114). Replace fuel lines and fittings (CB534C) (WP 0115).
T0046SWR
0017-3
TM 5-3895-379-23-1
0017
MALFUNCTION Muffler and/or Exhaust System Plugged. CORRECTIVE ACTION 1. 2. Remove muffler and exhaust system (WP 0134). Inspect for restrictions such as bent or torn pipes and blocked muffler. a. b. If muffler and exhaust system are restricted, remove restriction. Replace any damaged parts. Install or replace exhaust system (WP 0134). If muffler and exhaust system are not restricted, install muffler and exhaust system (WP 0116). Go to next malfunction.
MALFUNCTION Fuel Lift Pump Pressure Low. CORRECTIVE ACTION
WARNING
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 from crushing. Unlock steering frame before operation to prevent loss of steering. 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. 1. 2. 3. 4. 5. Remove fuel line from output port of fuel limp pump (WP 0116). Attach a pressure gauge to output port of fuel lift pump. Lock steering frame (TM 5-3895-379-10). Turn battery disconnect switch to ON position (TM 5-3895-379-10). Have an assistant crank engine for 10 seconds.
NOTE
0017-4
TM 5-3895-379-23-1
0017
NOTE
Time should be greater than 30 seconds. 9. 10. Observe amount of time maximum pressure noted during cranking to drop by one half. Remove pressure gauge from fuel lift pump. a. b. c. If fuel pump outlet pressure is below 4.5 psi (30 kPa), replace fuel lift pump (WP 0116). If time for maximum pressure noted during cranking to drop by one half is less than 30 seconds, replace fuel lift pump (WP 0116). If fuel lift pump pressure is OK, install fuel line (WP 0116) and notify supervisor that engine starts but will not keep running.
FUEL LINE LIFT PUMP
OUTPUT PORT
T0047SWR
0017-5/6 blank
TM 5-3895-379-23-1
0018
FIELD MAINTENANCE ENGINE SURGES (SPEED CHANGES)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Personnel Required Construction Equipment Repairer 91L References WP 0109 References (cont.) WP 0110 WP 0114 WP 0115 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0018-1
TM 5-3895-379-23-1
0018
WARNING
DO NOT perform fuel system checks, inspections or maintenance while smoking or near fire, flames or sparks. Fuel may ignite, causing injury or death, or damage to machine. Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel, properly wash exposed skin and change fuel-soaked clothing. Fuel and oil are very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury. SYMPTOM ENGINE SURGES (SPEED CHANGES) MALFUNCTION Fuel Lines and Fittings Leaking, Kinked, or Damaged. CORRECTIVE ACTION 1. 2. Open left-side door assembly (TM 5-3895-379-10). Check fuel lines and fittings for looseness or damage such as kinks, tears, or restrictions. a. b. If fuel lines or fittings are loose, tighten. If fuel lines or fittings are damaged, perform the following as needed: (1) (2) (3) (4) c. Replace fuel injector and nozzle (CB534B) (WP 0109). Replace fuel injector and nozzle (CB534C) (WP 0110). Replace fuel lines and fittings (CB534B) (WP 0114). Replace fuel lines and fittings (CB534C) (WP 0115).
If fuel lines and fittings are OK, notify supervisor that engine surges.
0018-2
TM 5-3895-379-23-1
0018
FUEL LINES AND FITTINGS FUEL LINES AND FITTINGS
T0068SWR
0018-3/4 blank
TM 5-3895-379-23-1
0019
FIELD MAINTENANCE ENGINE VIBRATES EXCESSIVELY
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Personnel Required Construction Equipment Repairer 91L References WP 0080 References (cont.) WP 0081 WP 0109 WP 0110 WP 0114 WP 0115 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0019-1
TM 5-3895-379-23-1
0019
TROUBLESHOOTING PROCEDURE SYMPTOM ENGINE VIBRATES EXCESSIVELY MALFUNCTION Engine Mounts Are Loose. CORRECTIVE ACTION Check front and rear engine mounts for damage and loose or missing nuts and bolts. a. b. c. If nuts or bolts are loose, tighten or replace nuts or bolts. Front engine mounts (WP 0080) or rear engine mounts (WP 0081). If front or rear engine mount(s) are damaged, replace mount(s). Front engine mounts (WP 0080) or rear engine mounts (WP 0081). If front and rear engine mounts are OK, go to next malfunction.
BOLTS ENGINE MOUNT
NUTS BOLTS
NUTS
T0077SWR
Figure 1. Engine Mounts.
0019-2
TM 5-3895-379-23-1
0019
MALFUNCTION Fuel Lines and Fittings Leaking, Kinked, or Damaged. CORRECTIVE ACTION
WARNING
DO NOT perform fuel system checks, inspections or maintenance while smoking or near fire, flames or sparks. Fuel may ignite, causing injury or death, or damage to machine. Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel, properly wash exposed skin and change fuel-soaked clothing. Fuel and oil are very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury. Check fuel lines and fittings for looseness or damage such as kinks, tears, or restrictions. a. b. If fuel lines or fittings are loose, tighten. If fuel lines or fittings are damaged, perform the following as needed: (1) (2) (3) (4) Replace fuel injector and nozzle (CB534B) (WP 0109). Replace fuel injector and nozzle (CB534C) (WP 0110). Replace fuel lines and fittings (CB534B) (WP 0114). Replace fuel lines and fittings (CB534C) (WP 0115).
T0078SWR
0019-3/4 blank
TM 5-3895-379-23-1
0020
FIELD MAINTENANCE ENGINE WILL NOT STOP RUNNING
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References WP 0166 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0020-1
TM 5-3895-379-23-1
0020
TROUBLESHOOTING PROCEDURE SYMPTOM ENGINE WILL NOT STOP RUNNING MALFUNCTION Engine Start Switch Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. Remove engine start switch (WP 0166). Set multimeter to measure ohms. Turn engine start switch to OFF position (TM 5-3895-379-10). Touch positive (+) probe of multimeter to RELAY terminal. Touch negative (-) probe of multimeter to BAT terminal. a. b. If less than infinite ohms are measured, replace engine start switch (WP 0166). If engine start switch is OK, install engine start switch (WP 0166) and notify supervisor that engine will not stop running.
RELAY TERMINAL
BAT TERMINAL
T0167SWR
Figure 1. Engine Start Switch. END OF WORK PACKAGE
0020-2
TM 5-3895-379-23-1
0021
FIELD MAINTENANCE OIL LEAKING FROM EXHAUST
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References WP 0121 Volume 2, WP 0235 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0021-1
TM 5-3895-379-23-1
0021
TROUBLESHOOTING PROCEDURE SYMPTOM OIL LEAKING FROM EXHAUST MALFUNCTION Turbocharger Damaged. CORRECTIVE ACTION 1. 2. 3. 4. Raise operator platform (Volume 2, WP 0235). Loosen clamp and remove inlet hose from turbocharger (WP 0121). Inspect impeller for cracks. The impeller should spin freely.
NOTE
Acceptable impeller shaft end play is 0.001-0.004 inches (0.03-0.10 mm). Acceptable impeller shaft radial play is 0.003-0.006 inches (0.08-0.15 mm). 5. Measure impeller shaft play. a. If impeller is restricted, perform the following: (1) (2) (3) b. c. Remove restriction. Install hose on turbocharger and tighten clamp (WP 0121). Lower operator platform (Volume 2, WP 0235).
If turbocharger impeller is cracked, does not spin freely, or has too much play, replace turbocharger (WP 0121). If turbocharger is OK, notify supervisor that oil is leaking into exhaust.
0021-2
TM 5-3895-379-23-1
0021
TURBOCHARGER
T0053SWR
0021-3/4 blank
TM 5-3895-379-23-1
0022
FIELD MAINTENANCE THROTTLE CONTROL WILL NOT CHANGE ENGINE SPEED (CB534B)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Personnel Required Construction Equipment Repairer 91L (2) References WP 0131 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0022-1
TM 5-3895-379-23-1
0022
TROUBLESHOOTING PROCEDURE SYMPTOM THROTTLE CONTROL WILL NOT CHANGE ENGINE SPEED (CB534B) MALFUNCTION Throttle Cable Damaged. CORRECTIVE ACTION
WARNING
NOTE
For CB534B Roller only. 1. 2. 3. 4. Open right-side door assembly (TM 5-3895-379-10). Check throttle cable for damage such as kinking, bent condition, stripped threads, or broken sleeve. Check for full travel of throttle cable at fuel injection pump while assistant operates throttle control fully up and fully down. Check throttle cable adjustment (WP 0131). a. b. c. If throttle cable is not properly adjusted, adjust linkage (WP 0131). If throttle cable is damaged, replace throttle cable (WP 0131). If throttle cable is OK, notify supervisor that throttle cable will not change engine speed.
0022-2
TM 5-3895-379-23-1
0022
THROTTLE CABLE
THROTTLE CONTROL
T0071SWR
Figure 1. Throttle Control Cable. END OF WORK PACKAGE
0022-3/4 blank
TM 5-3895-379-23-1
0023
FIELD MAINTENANCE ALTERNATOR INDICATOR IS ON
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References WP 0145 WP 0146 WP 0147 References (cont.) WP 0148 WP 0190 WP 0191 WP 0192 WP 0195 Volume 2, WP 0235 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0023-1
TM 5-3895-379-23-1
0023
TROUBLESHOOTING PROCEDURE SYMPTOM ALTERNATOR INDICATOR IS ON MALFUNCTION V-belts Loose or Damaged. CORRECTIVE ACTION
WARNING
Remove all jewelry such as rings, dog tags and bracelets. If jewelry contacts electrical connection, a direct short may occur resulting in injury or death and damage to equipment. 1. 2. 3. Raise operator platform (Volume 2, WP 0235). Check fan V-belts for damage such as cracks to belt fiber, one or more cracks 1/8 inch (0.3 cm) in depth or 50% of belt thickness, splits, grease buildup, glazed sides, and peeling. Attach belt tension gauge to fan V-belts.
0023-2
TM 5-3895-379-23-1
0023
CORRECTIVE ACTION - Continued 4. Correct belt tension is 80 lb (36.3 kg). a. b. c. If fan V-belts are damaged, replace fan V-belts (WP 0147). If belt tension is 50 lb (22.7 kg) or less, adjust alternator V-belt tension (WP 0147). If fan V-belts are not damaged or loose, go to next malfunction.
FAN ASSEMBLY
FAN V-BELTS
FAN DRIVE HOUSING FAN PULLEY
T0237SWR
0023-3
TM 5-3895-379-23-1
0023
MALFUNCTION Fan Assembly and Pulley and/or Fan Drive Housing Loose or Damaged. CORRECTIVE ACTION Check fan assembly, fan drive housing assembly, and fan pulley for looseness or damage such as cracked or missing fan blades, loose nuts and screws, bent or cracked fan pulley, damage or wear resulting from extreme fan blade wobble. a. b. If fan assembly and pulley are loose or damaged, tighten or replace loose or damaged parts (WP 0146). If fan drive housing assembly is loose or damaged, tighten or replace fan drive housing assembly (WP 0145).
FAN ASSEMBLY
FAN V-BELTS
T0106SWR
0023-4
TM 5-3895-379-23-1
0023
MALFUNCTION Alternator Wiring Faulty. CORRECTIVE ACTION Check for loose or damaged wiring connections at alternator. a. b. c. If connections are loose, tighten connections. If connectors or wiring is damaged, repair or replace connectors or wiring (WP 0195). If there are not loose or damaged connections or damaged wiring, go to next malfunction.
ALTERNATOR
B+ TERMINAL
D+ TERMINAL B- TERMINAL R TERMINAL

T0107SWR
Figure 3. Alternator Wiring.
0023-5
TM 5-3895-379-23-1
0023
MALFUNCTION Batteries Faulty. CORRECTIVE ACTION Inspect and test batteries (WP 0190). If batteries are damaged or bad, replace batteries (WP 0190).
BATTERIES
BATTERY CABLES
T0226SWR
Figure 4. Batteries and Battery Cables.
0023-6
TM 5-3895-379-23-1
0023
MALFUNCTION Battery Cables Faulty. CORRECTIVE ACTION Check battery cables and connectors for looseness or damage such as corrosion, fraying, broken terminals, cracked or missing insulation, or kinking. a. b. c. If battery cable connectors are loose, tighten connectors (WP 0192). If battery cable or cable connectors are damaged, replace cable(s) (WP 0192). If battery cables are not damaged and connectors are not loose, go to next malfunction.
BATTERIES
BATTERY CABLES
T0108SWR
0023-7
TM 5-3895-379-23-1
0023
MALFUNCTION Battery Disconnect Switch Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. 9. Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Remove nut, lockwasher, and cable from battery-side terminal. Discard lockwasher. Set multimeter to measure ohms. Touch positive (+) probe of multimeter to battery-side terminal. Touch negative (-) probe of multimeter to frame-side terminal of battery disconnect switch. Multimeter should measure infinite ohms. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Multimeter should measure zero ohms. a. b. c. If infinite ohms are not present across battery disconnect switch terminals in disconnect position, replace battery disconnect switch (WP 0191). If infinite ohms are present across battery disconnect switch in connect position, replace battery disconnect switch (WP 0191). If both ohms checks are OK, perform the following: (1) (2) Install cable on battery disconnect switch with lockwasher and nut. Replace alternator (WP 0148).
BATTERY DISCONNECT SWITCH BATTERY SIDE TERMINAL NUT LOCKWASHER CABLE
FRAME-SIDE TERMINAL
T0109SWR
Figure 6. Battery Disconnect Switch Wiring. END OF WORK PACKAGE
0023-8
TM 5-3895-379-23-1
0024
FIELD MAINTENANCE ALTERNATOR IS NOISY
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References WP 0145 WP 0146 References (cont.) WP 0147 WP 0148 WP 0150 Volume 2, WP 0235 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0024-1
TM 5-3895-379-23-1
0024
WARNING
Use caution while working under operator platform assembly. Falling platform may cause injury or death. SYMPTOM ALTERNATOR IS NOISY MALFUNCTION V-belts Loose or Damaged. CORRECTIVE ACTION 1. 2. 3. 4. Raise operator platform (Volume 2, WP 0235). Check fan V-belts for damage such as cracks to belt fiber, one or more cracks 1/8 inch in depth or 50% of belt thickness, splits, grease buildup, glazed sides, and peeling. Attach belt tension gauge to fan V-belts. Correct belt tension is 80 lb (36.3 kg). a. b. c. If fan V-belts are damaged, replace fan V-belts (WP 0147). If belt tension is 50 lb (22.7 kg) or less, adjust alternator V-belt tension (WP 0147). If alternator is not damaged or loose, remove belt tension gauge from fan V-belts. Go to next malfunction.
FAN ASSEMBLY
FAN V-BELTS
T0110SWR
0024-2
TM 5-3895-379-23-1
0024
MALFUNCTION Fan Assembly and Guard, and/or Fan Drive Housing Assembly, and/or Alternator Loose or Damaged. CORRECTIVE ACTION Check alternator bracket, fan assembly and guard, and fan drive housing assembly for looseness or damage such as cracked or missing fan blade(s), loose nuts and screws, bent or cracked fan pulley, or damage or wear resulting from extreme fan blade wobble. a. b. c. d. If alternator bracket is loose or damaged, tighten or replace alternator bracket (WP 0150). If fan assembly and guard are loose or damaged, tighten or replace damaged parts (WP 0146). If fan drive housing assembly is loose or damaged, tighten or replace fan drive housing assembly (WP 0145). If fan assembly and guard are not loose or damaged, replace alternator (WP 0148).
FAN V-BELTS ALTERNATOR BRACKET
FAN BLADE
FAN PULLEY
T0111SWR
Figure 2. Engine Fan Assembly. END OF WORK PACKAGE
0024-3/4 blank
TM 5-3895-379-23-1
0025
FIELD MAINTENANCE BACKUP ALARM DOES NOT WORK
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References WP 0181 References (cont.) WP 0187 WP 0195 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0025-1
TM 5-3895-379-23-1
0025
TROUBLESHOOTING PROCEDURE SYMPTOM BACKUP ALARM DOES NOT WORK MALFUNCTION No Power To Backup Alarm Sending Unit. CORRECTIVE ACTION
WARNING
Remove all jewelry such as rings, dog tags and bracelets. If jewelry contacts electrical connection, a direct short may occur resulting in injury or death and damage to equipment. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Remove nine screws and washers and remove panel from operator station. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Set multimeter to measure VDC. Touch positive (+) probe of multimeter to terminal 1 (wire 121-YL). Touch negative () probe of multimeter to good ground. Turn engine start switch to OFF position (TM 5-3895-379-10). Connect a jumper wire across terminal 1 (wire 121-YL) and terminal 2 (wire 321-BR). Note if backup alarm sounds. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Remove jumper wire. a. b. If 24 to 28 VDC are not measured at terminal 1 and BACKUP ALARM fuse is good, repair or replace wiring and connectors to BACKUP ALARM fuse holder (WP 0195). If backup alarm sounds, replace backup alarm sending unit (WP 0181).
0025-2
TM 5-3895-379-23-1
0025
SCREW WASHER SCREW WASHER
PANEL ASSEMBLY WIRE 121-YL TERMINAL 1
WIRE 321-BR TERMINAL 2 OPERATOR STATION

Figure 1. Backup Alarm Sending Unit Wiring.
T0104SWR
0025-3
TM 5-3895-379-23-1
0025
MALFUNCTION Backup Alarm Circuit Wiring Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove decontamination kit from decontamination kit bracket (Volume 2, WP 0230). Remove four screws, washers, and plate assembly from rear support assembly. Loosen two screws and pull backup alarm from rear support assembly. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Touch positive (+) probe of multimeter to terminal 1 (wire 321-BR). Touch negative () probe of multimeter to support assembly. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). If 24 to 28 VDC are not measured at wire 321-BR, repair or replace wiring and connectors from backup alarm to backup alarm sending unit (WP 0195).
WIRE 200-BK REAR SUPPORT ASSEMBLY COVER WIRE 321-BR SCREW
WASHER SCREW
BACKUP ALARM
T0105SWR
Figure 2. Backup Alarm Wiring.
0025-4
TM 5-3895-379-23-1
0025
MALFUNCTION Backup Alarm Wiring or Backup Alarm Faulty. CORRECTIVE ACTION 1. 2. 3. 4. Loosen screw and remove wire 200-BK from backup alarm. Set multimeter to measure ohms. Touch positive (+) probe of multimeter to 200-BK. Touch negative () probe of multimeter to good ground. a. b. If zero ohms are measured, ground is OK. Replace backup alarm (WP 0187). If infinite ohms are measured, ground is bad. Repair or replace wire 200-BK and connectors from backup alarm to ground connection at frame (WP 0195).
WIRE 200-BK REAR SUPPORT ASSEMBLY COVER WIRE 321-BR SCREW
WASHER SCREW
BACKUP ALARM
T0174SWR
Figure 3. Backup Alarm Wiring. END OF WORK PACKAGE
0025-5/6 blank
TM 5-3895-379-23-1
0026
FIELD MAINTENANCE FEET PER MINUTE (FPM) METER DOES NOT WORK (CB534C)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References WP 0170 WP 0195 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0026-1
TM 5-3895-379-23-1
0026
WARNING
Remove all jewelry such as rings, dog tags and bracelets. If jewelry contacts electrical connection, a direct short may occur resulting in injury or death and damage to equipment. SYMPTOM FEET PER MINUTE (FPM) METER DOES NOT WORK (CB534C) MALFUNCTION Wire 449-RD To Feet Per Minute (FPM) Meter Faulty. CORRECTIVE ACTION
NOTE
Wire 449 (part of instrument wiring harness) becomes wire 449-RD (part of main wiring harness) at connector (R1/P1). For CB534C Roller only. 1. 2. 3. 4. 5. 6. 7. 8. Remove two shoulder screws, washers, and vandal guard from box assembly. Remove three screws and washers and lift box assembly up from operator station. Set multimeter to measure VAC. Start engine and turn vibratory system on for not more than 10 seconds. Touch positive (+) probe of multimeter to terminal S (449-WH) of FPM meter. Touch negative (-) probe of multimeter to good ground. Multimeter should measure minimum of 2.4 VAC peaks. Turn engine start switch to OFF position (TM 5-3895-379-10). a. b. If minimum 2.4 VAC peaks are not measured at terminal S (wire 449-WH), repair or replace wire 449-WH/449-RD and connectors from FPM meter to speed sensor (WP 0195). If minimum 2.4 VAC peaks are present at terminal S (wire 449-WH), go to next malfunction.
0026-2
TM 5-3895-379-23-1
0026
MALFUNCTION No Power To Feet Per Minute (FPM) Meter. CORRECTIVE ACTION 1. 2. 3. 4. Set multimeter to measure VDC. Turn engine start switch to ON position (TM 5-3895-379-10). Touch positive (+) probe of multimeter to terminal + (wire 123-WH) of FPM meter. Touch negative (-) probe of multimeter to good ground. a. b. If 24 to 28 VDC are not measured at terminal + (wire 123-WH) and GAUGES fuse is good, repair or replace wiring and connectors to GAUGES fuse holder (WP 0195). If 24 to 28 VDC are present at terminal + (wire 123-WH), replace FPM meter (WP 0170).
123-WH 614-PU 200-BK
449-WH
T0121SWR
Figure 1. Feet Per Minute (FPM) Meter Wiring. END OF WORK PACKAGE
0026-3/4 blank
TM 5-3895-379-23-1
0027
FIELD MAINTENANCE FUEL GAUGE DOES NOT WORK
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Personnel Required Construction Equipment Repairer 91L References WP 0170 References (cont.) WP 0183 WP 0195 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0027-1
TM 5-3895-379-23-1
0027
TROUBLESHOOTING PROCEDURE SYMPTOM FUEL GAUGE DOES NOT WORK MALFUNCTION Fuel Level Sending Unit Ground Faulty. CORRECTIVE ACTION 1. 2. 3. Set multimeter to measure ohms. Touch positive (+) probe of multimeter to wire 200-BK. Touch negative (-) probe of multimeter to good ground. If infinite ohms are measured, repair or replace wire 200-BK and connectors to fuel level sending unit (WP 0195).
WIRE 447-PK
WIRE 200-BK
T0116SWR
Figure 1. Fuel Level Sending Unit Wiring.
0027-2
TM 5-3895-379-23-1
0027
MALFUNCTION Fuel Level Sending Unit Faulty. CORRECTIVE ACTION
WARNING
DO NOT perform fuel system checks, inspections or maintenance while smoking or near fire, flames or sparks. Fuel may ignite, causing injury or death, or damage to machine. Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel, properly wash exposed skin and change fuel-soaked clothing. Fuel and oil are very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury. 1. 2. 3. 4. 5. 6. 7. 8. Remove fuel level sending unit (WP 0183). Cap hole in fuel tank with clean rags. Dry fuel from fuel level sending unit. Check float for damage such as nicks, cuts, and gouges. Set multimeter to measure ohms. Touch positive (+) probe of multimeter to input terminal. Touch negative (-) probe of multimeter to ground terminal. Move float up and down while observing multimeter. Float should move freely. Ohms should vary as float moves. a. b. c. If float is damaged or does not move freely, replace fuel level sending unit with new parts (WP 0183). If ohms does not change as float is moved up and down, replace fuel level sending unit (WP 0183). If fuel level sending unit operates correctly, install fuel level sending unit (WP 0183) and go to next malfunction.
0027-3
TM 5-3895-379-23-1
0027
MALFUNCTION No Power To Fuel Level Gauge. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove two shoulder screws, washers, and vandal guard from box assembly. Remove three screws and washers and lift box assembly up from operator station. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Set multimeter to measure VDC. Touch positive (+) probe of multimeter to terminal + (wire 123-WH) of fuel level gauge. Touch negative (-) probe of multimeter to good ground. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). If 24 to 28 VDC are not present at terminal + (wire 123-WH), and GAUGES fuse is good, replace or repair wiring and connectors to GAUGES fuse holder (WP 0195).
0027-4
TM 5-3895-379-23-1
0027
MALFUNCTION Fuel Gauge or Fuel Level Sensor Circuit Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. Set multimeter to measure ohms. Remove nut, lockwasher, and wire 447-PK from terminal SIG of fuel level gauge. Remove nut, lockwasher, and wire 447-PK from center terminal of fuel level sending unit. Touch positive (+) probe of multimeter to wire 447-PK at fuel level gauge. Touch negative (-) probe of multimeter to wire 447-PK at fuel level sending unit. a. If zero ohms are measured, perform the following: (1) (2) b. Install wire 447-PK on fuel level sending unit and fuel level gauge with two lockwashers and nuts. Replace fuel level gauge (WP 0170).
If infinite ohms are measured, replace or repair wire 447-PK and connectors from fuel level gauge to fuel level sending unit (WP 0183).
VANDAL GUARD WASHER
TERMINAL SIG
WIRE 447-PK
WIRE 123-WH
SHOULDER SCREW WASHER SCREW TERMINAL +

T0117SWR
Figure 2. Fuel Gauge Wiring. END OF WORK PACKAGE
0027-5/6 blank
TM 5-3895-379-23-1
0028
FIELD MAINTENANCE HORN DOES NOT WORK
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L (2) References WP 0188 References (cont.) WP 0189 WP 0195 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0028-1
TM 5-3895-379-23-1
0028
TROUBLESHOOTING PROCEDURE SYMPTOM HORN DOES NOT WORK MALFUNCTION Horn Faulty. CORRECTIVE ACTION
WARNING
Remove all jewelry such as rings, dog tags and bracelets. If jewelry contacts electrical connection, a direct short may occur resulting in injury or death and damage to equipment. 1. 2. 3. 4. 5. 6. Remove four screws, washers, and cover from front support assembly. Have an assistant turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Press down horn switch (TM 5-3895-379-10). Set multimeter to measure VDC. Touch positive (+) probe of multimeter to terminal 1 (wire 322-GY).
0028-2
TM 5-3895-379-23-1
0028
CORRECTIVE ACTION - Continued 7. Touch negative (-) probe of multimeter to good ground. If 24-28 VDC are measured, ground is OK. Replace horn assembly (WP 0189).
HORN
WIRE 322-GY
WIRE 200-BK SCREW
COVER
WASHER SCREW
SUPPORT ASSEMBLY
Figure 1. Horn Wiring. MALFUNCTION No Ground At Horn. CORRECTIVE ACTION 1. 2. 3. 4. Loosen screw and remove wire 200-BK from horn assembly. Set multimeter to measure ohms. Touch positive (+) probe of multimeter to 200-BK. Touch negative (-) probe of multimeter to good ground.
T0114SWR
If zero ohms is not measured, ground is bad. Repair or replace wiring and connectors from horn to ground connection at frame (WP 0195).
0028-3
TM 5-3895-379-23-1
0028
MALFUNCTION No Power To Horn Switch. CORRECTIVE ACTION 1. 2. 3. 4. 5. Remove nine screws and washers and remove panel from operator station. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Touch positive (+) probe of multimeter to terminal 1 (wire 121-YL). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured (wire 121-YL) and BACKUP ALARM fuse is good, perform the following: (1) (2) (3) Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Repair or replace wiring and connectors to water spray fuse holder (WP 0195).
PANEL ASSEMBLY
HORN SWITCH
WIRE 322-GY WIRE 121-YL
COVER
Figure 2. Horn Switch Wiring.
T0223SWR
0028-4
TM 5-3895-379-23-1
0028
MALFUNCTION Horn Switch Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. Press and hold horn switch down (TM 5-3895-379-10). Touch positive (+) probe of multimeter to (wire 322-GY). Touch negative (-) probe of multimeter to good ground. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). a. b. If 24 to 28 VDC are not measured at (wire 322-GY), replace horn switch (WP 0188). If 24 to 28 VDC are measured at (wire 322-GY), repair or replace wire 322-GY and connectors from horn switch to horn assembly (WP 0195).
PANEL ASSEMBLY
HORN SWITCH
WIRE 322-GY WIRE 121-YL
COVER
Figure 3. Horn Switch Wiring. END OF WORK PACKAGE
T0115SWR
0028-5/6 blank
TM 5-3895-379-23-1
0029
FIELD MAINTENANCE NO POWER TO ACCESSORIES WITH THE ENGINE RUNNING
0029-1
TM 5-3895-379-23-1
0029
TROUBLESHOOTING PROCEDURE SYMPTOM NO POWER TO ACCESSORIES WITH THE ENGINE RUNNING MALFUNCTION No Power At Main Relay From Alternator Relay. CORRECTIVE ACTION 1. 2. 3. 4. Remove nine screws and washers and remove panel from operator station. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Touch positive (+) probe of multimeter to input terminal of main relay (wire 109-OR). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured at input terminal of main relay (wire 109-OR), repair or replace wire 109-OR and connectors (WP 0195).
SCREW WASHER PANEL ASSEMBLY
WASHER WIRE 112-PU SCREW WIRE 308-YL MAIN RELAY WIRE 109-OR
HARNESS MAIN RELAY CONNECTOR OPERATOR CONNECTOR STATION
T0122SWR
Figure 1. Main Relay Wiring.
0029-2
TM 5-3895-379-23-1
0029
MALFUNCTION No Power To Main Relay Coil. CORRECTIVE ACTION 1. 2. 3. 4. Disconnect main relay connector from harness connector. Turn engine start switch to ON position (TM 5-3895-379-10). Touch positive (+) probe of multimeter to terminal 1 (wire 308-YL). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured at terminal 1 (wire 308-YL) and KEY START fuse is good, perform the following: (1) (2) Turn engine start switch to OFF position (TM 5-3895-379-10). Go to Malfunction: No power to engine start switch.
PANEL ASSEMBLY
SCREW WASHER
HARNESS MAIN RELAY CONNECTOR OPERATOR CONNECTOR STATION
T0188SWR
0029-3
TM 5-3895-379-23-1
0029
MALFUNCTION Main Relay or Wire 112-PU Faulty. CORRECTIVE ACTION 1. 2. 3. 4. Connect main relay connector to harness connector. Turn engine start switch to ON position (TM 5-3895-379-10). Touch positive (+) probe of multimeter to output terminal of main relay (wire 112-PU). Touch negative (-) probe of multimeter to good ground. a. b. If 24 to 28 VDC are not measured at output terminal of main relay (wire 112-PU), replace main relay (WP 0154). If 24 to 28 VDC are measured at output terminal of main relay, repair or replace (wire 112 - PU) and connectors to fuses (WP 0195).
OPERATOR STATION
MAIN RELAY HARNESS CONNECTOR CONNECTOR

T0189SWR
0029-4
TM 5-3895-379-23-1
0029
MALFUNCTION No Power To Engine Start Switch. CORRECTIVE ACTION 1. 2. 3. 4. Remove two shoulder screws, washers, and vandal guard from box assembly. Remove three screws and washers and lift box assembly up from operator station. Touch positive (+) probe of multimeter to BAT terminal (wire 105-BR) of engine start switch. Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not present at BAT terminal (wire 105-BR) and KEY START fuse is good, repair or replace wiring and connectors to KEY START fuse holder (WP 0195).
SHOULDER WASHER SCREW START TERMINAL VANDAL GUARD OPERATOR STATION INSTRUMENT PANEL WASHER SCREW BAT TERMINAL WIRE 105-BR
WIRE 307-OR
WIRE 103-YL
ENGINE START SWITCH
RELAY TERMINAL
T0123SWR
Figure 4. Engine Start Switch Wiring.
0029-5
TM 5-3895-379-23-1
0029
MALFUNCTION No Power To Output Terminal Of Engine Start Switch. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. Push propel control lever forward to prevent engine start-up. Touch positive (+) probe of multimeter to RELAY terminal (wire 103-YL) of engine start switch. Touch negative (-) probe of multimeter to good ground. Turn and hold engine start switch to START (full right) position (TM 5-3895-379-10). Measure voltage output. Move positive (+) probe of multimeter to START terminal (wire 307-OR) of engine start switch. Measure voltage output. Turn engine start switch to OFF position (TM 5-3895-379-10). a. b. c. If 24 to 28 VDC are not present at RELAY terminal (wire 103-YL), replace engine start switch (WP 0166). If 24 to 28 VDC are not present at START terminal (wire 307-OR), replace engine start switch (WP 0166). If 24 to 28 VDC are present at START and RELAY terminals, repair or replace wiring (wire 103-YL or 307-OR) and connectors to engine start switch (WP 0195).
WASHER WIRE 307-OR START TERMINAL BAT TERMINAL WIRE 105-BR
SHOULDER SCREW
VANDAL GUARD OPERATOR STATION WASHER SCREW
WIRE 103-YL
INSTRUMENT PANEL
ENGINE START SWITCH
RELAY TERMINAL
T0190SWR
Figure 5. Engine Start Switch Wiring. END OF WORK PACKAGE
0029-6
TM 5-3895-379-23-1
0030
FIELD MAINTENANCE ROLLER HAS NO ELECTRICAL POWER
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Personnel Required Construction Equipment Repairer 91L References WP 0151 WP 0154 References (cont.) WP 0166 WP 0190 WP 0191 WP 0192 WP 0195 Volume 2, WP 0235 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0030-1
TM 5-3895-379-23-1
0030
TROUBLESHOOTING PROCEDURE SYMPTOM ROLLER HAS NO ELECTRICAL POWER MALFUNCTION No Battery Power At Starter Solenoid. CORRECTIVE ACTION
WARNING
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 a 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 the corrosive burning effects. Failure to follow these procedures may cause injury or death. 1. 2. 3. 4. 5. Lock steering frame (TM 5-3895-379-10). Turn battery disconnect switch to ON position (TM 5-3895-379-10). Set multimeter to measure VDC. Touch positive (+) probe of multimeter to battery terminal of starter solenoid. Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are present at battery terminal of starter solenoid, go to Malfunction: No power at alternator circuit breaker.
0030-2
TM 5-3895-379-23-1
0030
MALFUNCTION Batteries Faulty. CORRECTIVE ACTION Inspect batteries and test batteries (WP 0190). If batteries are damaged or bad, replace batteries (WP 0190).
BATTERIES
BATTERY CABLES
T0080SWR
Figure 1. Batteries.
0030-3
TM 5-3895-379-23-1
0030
MALFUNCTION Battery Cables Loose, Corroded, or Damaged. CORRECTIVE ACTION Check battery cables and connectors for looseness or damage such as corrosion, fraying, broken terminals, cracked or missing insulation, or kinking. a. b. If battery cable connectors are loose, tighten connectors (WP 0192). If battery cables or cable connectors are damaged, replace cable(s) (WP 0192). If battery cables are not damaged and connectors are not loose, lower operator platform (Volume 2, WP 0235) and go to next malfunction.
STARTER SOLENOID
STARTER VIEW LOOKING UP FROM UNDER ROLLER

T0079SWR
BATTERY TERMINAL
Figure 2. Battery Cable Connections at Starter.
0030-4
TM 5-3895-379-23-1
0030
MALFUNCTION Battery Disconnect Switch Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. 9. Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Remove nut, lockwasher, and cable from battery-side terminal. Discard lockwasher. Set multimeter to measure ohms. Touch positive (+) probe of multimeter to battery-side terminal. Touch negative (-) probe of multimeter to frame-side terminal of battery disconnect switch. Multimeter should measure infinite ohms. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Multimeter should measure zero ohms. a. b. c. If infinite ohms are not present across battery disconnect switch terminals in disconnect position, replace battery disconnect switch (WP 0191). If more than 5 ohms are present across battery disconnect switch in connect position, replace battery disconnect switch (WP 0191). If both ohms checks are OK, perform the following: (1) (2) Install cable on battery disconnect switch with lockwasher and nut. Go to Malfunction: Battery cables loose, corroded, or damaged.
NUT SWITCH LOCKWASHER CABLE
BATTERY SIDE TERMINAL
FRAME-SIDE TERMINAL
T0082SWR
Figure 3. Battery Disconnect Switch Wiring.
0030-5
TM 5-3895-379-23-1
0030
MALFUNCTION No Power At Alternator Circuit Breaker. CORRECTIVE ACTION 1. 2. 3. 4. Open left-side door assembly (TM 5-3895-379-10). Set multimeter to measure VDC. Touch positive (+) probe of multimeter to battery-side terminal (wire 101-RD). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not present at battery-side terminal (wire 101-RD), repair or replace wire 101-RD and connectors (WP 0195).
ALTERNATOR CIRCUIT BREAKER BUTTON ALTERNATOR CIRCUIT BREAKER OUTPUT-SIDE TERMINAL BATTERY-SIDE TERMINAL
WIRE 101-RD WIRE 109-OR
T0195SWR
Figure 4. Alternator Circuit Breaker Wiring.
0030-6
TM 5-3895-379-23-1
0030
MALFUNCTION Alternator Circuit Breaker Faulty. CORRECTIVE ACTION 1. 2. 3. Touch positive (+) probe of multimeter to output-side terminal (wire 109-OR). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not present at output-side terminal (wire 109-OR), press alternator circuit breaker button and repeat. If 24 to 28 VDC are not present at output-side terminal (wire 109-OR), replace alternator circuit breaker (WP 0151).
ALTERNATOR CIRCUIT BREAKER BUTTON ALTERNATOR CIRCUIT BREAKER OUTPUT-SIDE TERMINAL BATTERY-SIDE TERMINAL
WIRE 101-RD WIRE 109-OR
T0165SWR
Figure 5. Alternator Circuit Breaker Wiring.
0030-7
TM 5-3895-379-23-1
0030
MALFUNCTION No Power At Main Relay. CORRECTIVE ACTION 1. 2. 3. Remove nine screws and washers and remove panel from operator station. Touch positive (+) probe of multimeter to input terminal (wire 109-OR). Touch negative (-) probe of multimeter to good ground. a. b. If 24 to 28 VDC are not measured at input terminal (wire 109-OR), repair or replace wire 109 - OR and connectors (WP 0195). If 24 to 28 VDC are measured at input terminal (wire 109-OR), go to next malfunction.
SCREW WASHER
PANEL ASSEMBLY
WASHER SCREW WIRE 112-PU WIRE 308-YL MAIN RELAY WIRE 109-OR
OPERATION STATION
HARNESS MAIN RELAY CONNECTOR CONNECTOR

T0196SWR
0030-8
TM 5-3895-379-23-1
0030
MALFUNCTION No Power To Coil Of Main Relay. CORRECTIVE ACTION 1. 2. 3. 4. Disconnect main relay connector from harness connector. Turn engine start switch to ON position (TM 5-3895-379-10). Touch positive (+) probe of multimeter to terminal 1 (wire 308-YL). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured at terminal 1 (wire 308-YL) and KEY START fuse is good, perform the following: (1) (2) Turn engine start switch to OFF position (TM 5-3895-379-10). Go to Malfunction: No power at start switch.
SCREW WASHER
PANEL ASSEMBLY
OPERATION STATION

T0197SWR
0030-9
TM 5-3895-379-23-1
0030
MALFUNCTION Main Relay Faulty. CORRECTIVE ACTION 1. 2. 3. 4. Connect main relay connector to harness connector. Turn engine start switch to ON position (TM 5-3895-379-10). Touch positive (+) probe of multimeter to output terminal of main relay (wire 112-PU). Touch negative (-) probe of multimeter to good ground. a. b. If 24 to 28 VDC are not measured at output terminal of main relay (wire 112-PU), replace main relay (WP 0154). If 24 to 28 VDC are measured at output terminal of main relay, repair or replace wire 112PU and connectors to fuses (WP 0195).
SCREW WASHER
PANEL ASSEMBLY
OPERATION STATION

T0084SWR
0030-10
TM 5-3895-379-23-1
0030
MALFUNCTION No Power At Start Switch. CORRECTIVE ACTION 1. 2. 3. 4. Remove two shoulder screws, washers, and vandal guard from box assembly. Remove three screws and washers and lift box assembly up from operator station. Touch positive (+) probe of multimeter to BAT terminal (wire 105-BR) of engine start switch. Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not present at BAT terminal (wire 105-BR), and KEY START fuse is good, repair or replace wiring and connectors to KEY START fuse holder (WP 0195).
SHOULDER WASHER SCREW
START TERMINAL
WIRE 307-OR
VANDAL GUARD OPERATOR STATION WASHER INSTRUMENT PANEL SCREW
BAT TERMINAL WIRE 105-BR ENGINE START SWITCH RELAY TERMINAL
WIRE 103-YL
T0086SWR
0030-11
TM 5-3895-379-23-1
0030
MALFUNCTION No Power At Output Of Engine Start Switch. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. Push propel control lever forward to prevent engine start-up. Touch positive (+) probe of multimeter to RELAY terminal (wire 103-YL) of engine start switch. Touch negative (-) probe of multimeter to good ground. Turn and hold engine start switch to START position (TM 5-3895-379-10) for no more than 30 seconds. Measure VDC. Move positive (+) probe of multimeter to START terminal (wire 307-OR) of engine start switch. Measure VDC. Turn engine start switch to OFF position (TM 5-3895-379-10). a. b. c. If 24 to 28 VDC are not present at RELAY terminal (wire 103-YL), replace engine start switch (WP 0166). If 24 to 28 VDC are not present at START terminal (wire 307-OR), replace engine start switch (WP 0166). If 24 to 28 VDC are present at START and RELAY terminals, repair or replace wiring (wire 103-YL or 307-OR) and connectors to engine start switch (WP 0195).
START TERMINAL
WIRE 307-OR
BAT TERMINAL WIRE 105-BR ENGINE START SWITCH RELAY TERMINAL
WIRE 103-YL
T0164SWR
0030-12
TM 5-3895-379-23-1
0031
FIELD MAINTENANCE STARTER CONTINUES TO RUN AFTER ENGINE START SWITCH KEY IS RELEASED
0031-1
TM 5-3895-379-23-1
0031
WARNING
Remove all jewelry such as rings, dog tags and bracelets. If jewelry contacts electrical connection, a direct short may occur resulting in injury or death to personnel and damage to equipment. Use caution while working under operator platform assembly. Falling platform may cause injury or death.
CAUTION
Operating starter for more than 30 seconds at a time can cause starter damage due to heat buildup. After 30 seconds, starter must be stopped for 2 minutes to allow starter to cool. SYMPTOM STARTER CONTINUES TO RUN AFTER ENGINE START SWITCH KEY IS RELEASED MALFUNCTION Engine Start Switch Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Open left-side door assembly (TM 5-3895-379-10). Remove harness connector from starter relay switch assembly. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Set multimeter to measure VDC. Touch positive (+) probe of multimeter (wire 306-GN) of harness connector. Touch negative (-) probe of multimeter to good ground. Have assistant turn and hold engine start switch to START position (TM 5-3895-379-10) for no more than 30 seconds. Measure voltage. Turn engine start switch to OFF position (TM 5-3895-379-10). Voltage should drop to zero VDC. If voltage does not drop to zero VDC, replace engine start switch (WP 0166).
0031-2
TM 5-3895-379-23-1
0031
STARTER RELAY WIRE 306-GN
WIRE 200-BK
WIRE 109-OR OUTPUT TERMINAL
WIRE 304-WH INPUT TERMINAL

T0236SWR
Figure 1. Starter Relay Wiring.
0031-3
TM 5-3895-379-23-1
0031
MALFUNCTION Starter Relay or Starter Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. 9. Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Remove nut, washer, and wire 304-WH (to starter) from starter relay switch assembly. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Touch positive (+) probe of multimeter to terminal 1 (wire 306-GN) of starter relay switch assembly. Touch negative (-) probe of multimeter to good ground. Have assistant turn and hold engine start switch to START position (TM 5-3895-379-10) for no more than 30 seconds. Measure voltage. Turn engine start switch to OFF position (TM 5-3895-379-10). Voltage should drop to zero VDC. a. b. If voltage does not drop to zero VDC, replace starter (WP 0152). If voltage does not drop to zero VDC, replace starter relay switch assembly (WP 0153).
WIRE 200-BK

T00095SWR
Figure 2. Starter Relay Wiring. END OF WORK PACKAGE
0031-4
TM 5-3895-379-23-1
0032
FIELD MAINTENANCE STARTER DOES NOT TURN OR TURNS SLOWLY
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L (2) References WP 0152 WP 0153 References (cont.) WP 0155 WP 0166 WP 0190 WP 0192 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0032-1
TM 5-3895-379-23-1
0032
TROUBLESHOOTING PROCEDURE SYMPTOM STARTER DOES NOT TURN OR TURNS SLOWLY MALFUNCTION Starter Voltage Faulty. CORRECTIVE ACTION
WARNING
Remove all jewelry such as rings, dog tags and bracelets. If jewelry contacts electrical connection, a direct short may occur resulting in injury or death and damage to equipment. When working on a running engine, provide shielding for exposed rotating parts. Tools, clothing or hands can get caught and cause injury to personnel. Never lay under roller when engine is running or while attempting to start engine. Roller may accidentally move forward or back and cause injury or death from crushing.
CAUTION
Operating starter for more than 30 seconds at a time can cause starter damage due to heat buildup. After 30 seconds, starter must be stopped for 2 minutes to allow starter to cool. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Set multimeter to measure VDC. Attach positive (+) probe of multimeter to battery terminal of starter. Attach negative (-) probe of multimeter to engine block. Move from under Roller. Have assistant turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn and hold engine start switch to START (full right) position (TM 5-3895-379-10) for not more than 30 seconds. Measure voltage at battery terminal. Have assistant turn engine start switch to OFF position (TM 5-3895-379-10). Move positive (+) probe of multimeter to starter terminal of starter. Move from under Roller. Have assistant turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn and hold engine start switch to START (full right) position (TM 5-3895-379-10) for not more than 30 seconds. Measure voltage at starter terminal.
0032-2
TM 5-3895-379-23-1
0032
CORRECTIVE ACTION - Continued 14. Have assistant turn engine start switch to OFF position (TM 5-3895-379-10). a. b. c. If 24 to 28 VDC are not present at battery terminal of starter solenoid, go to next malfunction. If 24 to 28 VDC are not present at starter terminal of starter solenoid, go to Malfunction: No input or output power at starter relay. If 24 to 28 VDC are present at starter and battery terminal of starter solenoid, go to Malfunction: Starter faulty.
STARTER SOLENOID
STARTER TERMINAL MOTOR
SOLENOID TERMINAL
STARTER VIEW LOOKING UP FROM UNDER ROLLER

T0081SWR
BATTERY TERMINAL
0032-3
TM 5-3895-379-23-1
0032
MALFUNCTION Batteries Faulty. CORRECTIVE ACTION
WARNING
Remove all jewelry such as rings, dog tags and bracelets. If jewelry contacts electrical connection, a direct short may occur resulting in injury or death to personnel and damage to equipment. Use caution while working under operator platform assembly. Falling platform may cause injury or death. Inspect batteries (WP 0190) and test batteries (WP 0190). If batteries are damaged or bad, replace batteries (WP 0190).
BATTERIES
BATTERY CABLES
T0089SWR
0032-4
TM 5-3895-379-23-1
0032
MALFUNCTION Battery Cables Loose, Corroded, or Damaged. CORRECTIVE ACTION Check battery cables and connectors for looseness or damage such as corrosion, fraying, broken terminals, cracked or missing insulation, or kinking. a. b. If battery cable connectors are loose, tighten connectors (WP 0192). If battery cable or cable connectors are damaged, replace cable(s) (WP 0192).
STARTER SOLENOID
SOLENOID TERMINAL
STARTER BATTERY TERMINAL VIEW LOOKING UP FROM UNDER ROLLER

T0088SWR
0032-5
TM 5-3895-379-23-1
0032
MALFUNCTION Starter Faulty. CORRECTIVE ACTION 1. 2. 3. 4. Touch positive (+) probe of multimeter and negative (-) probe of multimeter to locations below. Have assistant turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn and hold engine start switch to START (full right) position (TM 5-3895-379-10) for not more than 30 seconds. Turn engine start switch to OFF position (TM 5-3895-379-10). a. b. If voltage drop is greater than shown below, repair or replace faulty wires (WP 0192). If voltage drop is not greater than shown below, replace starter (WP 0152).
0032-6
TM 5-3895-379-23-1
0032
Table 1.
Maximum Acceptable System Voltage Drops During Cranking. CIRCUIT 24V SYSTEM 1.4 Volts 1.0 Volts 1.0 Volts 0.8 Volts
Battery (-) post to starter (-) terminal Drop across battery disconnect switch Battery (+) post to starter solenoid (+) terminal Starter solenoid BAT terminal to MTR terminal
STARTER SOLENOID
SOLENOID TERMINAL
STARTER BATTERY TERMINAL VIEW LOOKING UP FROM UNDER ROLLER

T0198SWR
0032-7
TM 5-3895-379-23-1
0032
MALFUNCTION No Input or Output Power At Starter Relay. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Check power at starter relay. Open left-side door assembly (TM 5-3895-379-10). Attach positive (+) probe of multimeter to input terminal (wire 109-OR) of starter relay. Attach negative (-) probe of multimeter to frame. Measure voltage. Attach positive (+) probe of multimeter to output terminal (wire 304-WH) of starter relay. Move back from Roller. Have assistant turn and hold engine start switch to START (full right) position (TM 5-3895-379-10) for not more than 30 seconds. Measure voltage. Have assistant turn engine start switch to OFF position (TM 5-3895-379-10). a. b. c. If 24 to 28 VDC are present at input terminal (wire 109-OR), but not at output terminal (wire 304-WH), go to next malfunction. If 24 to 28 VDC are not present at input terminal (wire 109-OR) and roller otherwise has power, repair or replace wire (wire 109-OR) and connectors (WP 0195). If 24 to 28 VDC are present at output terminal (wire 304-WH), repair or replace wire (wire 304-WH) and connectors (WP 0195).
0032-8
TM 5-3895-379-23-1
0032
WIRE 200-BK

T0090SWR
0032-9
TM 5-3895-379-23-1
0032
MALFUNCTION Faulty Ground At Starter Relay. CORRECTIVE ACTION 1. 2. 3. 4. 5. Remove starter relay connector from wiring harness connector. Set multimeter to measure ohms. Touch positive (+) probe of multimeter to (wire 200-BK) of starter relay. Touch negative (-) probe of multimeter to frame. Zero ohms should be measured. If infinite ohms are measured, repair or replace wire 200-BK and connectors (WP 0195).
WIRE 200-BK

T0199SWR
0032-10
TM 5-3895-379-23-1
0032
MALFUNCTION Starter Relay Faulty. CORRECTIVE ACTION 1. 2. 3. Have assistant turn and hold engine start switch to START (full right) position (TM 5-3895-379-10) for not more than 30 seconds. Touch positive (+) probe of multimeter to (wire 306-GN) of starter relay. Touch negative (-) probe of multimeter to frame. a. b. If 24 to 28 VDC are not present at start relay output, go to next malfunction. If 24 to 28 VDC are present at (wire 306-GN), replace starter relay (WP 0153).
WIRE 200-BK

T0200SWR
0032-11
TM 5-3895-379-23-1
0032
MALFUNCTION No Power At Neutral Start Relay. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Remove nine screws and washers and remove panel from operator station. Remove harness connector from neutral start relay No. 1. Turn and hold engine start switch to START (full right) position (TM 5-3895-379-10) for not more than 30 seconds. Touch positive (+) probe of multimeter to terminal 4 (wire 307-OR). Touch negative (-) probe of multimeter to good ground. Measure voltage. Ensure propel control lever is in neutral position (TM 5-3895-379-10). Move positive (+) probe of multimeter to terminal 3 (wire 330-YL). Measure voltage. Turn engine start switch to OFF position (TM 5-3895-379-10). a. b. c. If 24 to 28 VDC are not measured at terminal 4 (wire 307-OR), go to Malfunction: NO POWER AT ENGINE START SWITCH. If 24 to 28 VDC are not measured at terminal 3 (wire 330-YL) and BRAKE fuse is good, notify supervisor. If 24 to 28 VDC are measured at terminals 3 and 4, go to next malfunction.
0032-12
TM 5-3895-379-23-1
0032
SCREW WASHER PANEL ASSEMBLY WASHER SCREW HARNESS CONNECTOR 3 5 TERMINALS 2
1 4
RELAY NEUTRAL START RELAY #1 OPERATOR STATION
86 87A 87 30 85
T0093SWR
Figure 8. Neutral Start Relay No. 1 Wiring.
0032-13
TM 5-3895-379-23-1
0032
MALFUNCTION Starter Relay Control wire (wire 306-GN) Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. Remove neutral start relay No. 1 from operators station (WP 0155). Set multimeter to measure ohms. Touch positive (+) probe of multimeter to terminal 1 (wire 306-GN) of harness connector. Touch negative (-) probe of multimeter to terminal 1 (wire 306-GN) of starter relay harness connector. Multimeter should measure zero ohms. If multimeter measures infinite ohms, repair or replace wire 306-GN and connectors (WP 0195).
WIRE 200-BK

T0092SWR
0032-14
TM 5-3895-379-23-1
0032
SCREW WASHER PANEL ASSEMBLY WASHER SCREW HARNESS CONNECTOR 3 TERMINALS 2
1 4 5
30
86 87A 87 85

T0091SWR
0032-15
TM 5-3895-379-23-1
0032
MALFUNCTION No Ground At Neutral Start Relay No. 1 or Relay Is Faulty. CORRECTIVE ACTION 1. 2. 3. Touch positive (+) probe of multimeter to terminal 2 (wire 200-BK) of harness connector. Touch negative (-) probe of multimeter to good ground. Multimeter should measure zero ohms. a. b. If multimeter measures infinite ohms, repair or replace wire 200-BK and connectors (WP 0195). If multimeter reads zero ohms, replace neutral start relay No. 1 (WP 0155).
SCREW WASHER PANEL ASSEMBLY WASHER SCREW HARNESS CONNECTOR 3 TERMINALS 2
1 4 5
30
86 87A 87 85

T0201SWR
0032-16
TM 5-3895-379-23-1
0032
MALFUNCTION No Power At Engine Start Switch. CORRECTIVE ACTION 1. 2. 3. 4. Remove two shoulder screws, washers, and vandal guard from box assembly. Remove three screws and washers and lift box assembly up from operator station. Touch positive (+) probe of multimeter to BAT terminal (wire 105-BR) of engine start switch. Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not present at BAT terminal (wire 105-BR), and KEY START fuse is good, repair or replace wiring and connectors to KEY START fuse holder (WP 0195).
START TERMINAL
WIRE 307-OR
BAT TERMINAL WIRE 105-BR INSTRUMENT PANEL RELAY TERMINAL
WIRE 306-GN
T0094SWR
0032-17
TM 5-3895-379-23-1
0032
MALFUNCTION Engine Start Switch Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. Push propel control lever forward (TM 5-3895-379-10) to prevent engine start-up. Touch positive (+) probe of multimeter to RELAY terminal (wire 306-GN) of engine start switch. Touch negative (-) probe of multimeter to good ground. Turn and hold engine start switch to START (full right) position (TM 5-3895-379-10) for not more than 30 seconds. Measure voltage. Move positive (+) probe of multimeter to START terminal (wire 307-OR) of engine start switch. Measure voltage. Turn engine start switch to OFF position (TM 5-3895-379-10). a. b. c. If 24 to 28 VDC are not present at RELAY terminal (wire 306-GN), replace engine start switch (WP 0166). If 24 to 28 VDC are not present at START terminal (wire 307-OR), replace engine start switch (WP 0166). If 24 to 28 VDC are present at RELAY and START terminals, repair or replace wiring (wire 103-YL or 307-OR) and connectors to engine start switch (WP 0195).
START TERMINAL
WIRE 307-OR
BAT TERMINAL WIRE 105-BR INSTRUMENT PANEL RELAY TERMINAL
WIRE 306-GN
T0202SWR
0032-18
TM 5-3895-379-23-1
0033
FIELD MAINTENANCE STARTER TURNS, BUT DOES NOT CRANK ENGINE
TROUBLESHOOTING PROCEDURE SYMPTOM STARTER TURNS, BUT DOES NOT CRANK ENGINE MALFUNCTION Starter or Flywheel Faulty. CORRECTIVE ACTION 1. 2. Remove starter (WP 0152). Inspect flywheel ring gear for looseness or missing teeth. a. b. If flywheel ring gear is not loose or missing teeth, replace starter (WP 0152). If flywheel ring gear is loose or missing teeth, replace flywheel (WP 0086).
END OF WORK PACKAGE
0033-1/2 blank
TM 5-3895-379-23-1
0034
FIELD MAINTENANCE STARTING AID SWITCH DOES NOT WORK
0034-1
TM 5-3895-379-23-1
0034
WARNING
Remove all jewelry such as rings, dog tags and bracelets. If jewelry contacts electrical connection, a direct short may occur resulting in injury or death and damage to equipment. SYMPTOM STARTING AID SWITCH DOES NOT WORK MALFUNCTION No Power At Starting Aid Switch. CORRECTIVE ACTION 1. 2. 3. 4. 5. Remove two shoulder screws, washers, and vandal guard from box assembly. Remove three screws and washers and lift box assembly up from operator station. Turn battery disconnect switch and engine start switch to ON position (TM 5-3895-379-10). Touch positive (+) probe of multimeter to terminal 2 (wire 148-WH). Touch negative (-) probe of multimeter to good ground. If 24-28 VDC are not measured at terminal 2 and START AID fuse is good, perform the following: (1) (2) (3) Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Repair or replace wiring and connectors to starting aid switch (WP 0195).
0034-2
TM 5-3895-379-23-1
0034

VANDAL GUARD WASHER TERMINAL 1 WIRE 376-GN
SHOULDER SCREW WASHER SCREW STARTING AID SWITCH
TERMINAL 2 WIRE 148-WH BOX ASSEMBLY

T0102SWR
Figure 1. Starting Aid Switch Wiring. MALFUNCTION Starting Aid Circuit Wiring or Switch Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. Move starting aid switch forward to start position (TM 5-3895-379-10). Set multimeter to measure VDC. Touch positive (+) probe of multimeter to terminal 1 (wire 376-GN). Touch negative (-) probe of multimeter to good ground. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). a. b. If 24 to 28 VDC are not measured at terminal 1, replace start aid switch (WP 0165). If 24 to 28 VDC are measured at terminal 1, perform the following: (1) (2) (3) Repair or replace wiring and connectors from starting aid switch to starting aid resistor (WP 0195). Install box assembly on operator station with three washers and screws. Install vandal guard on box assembly with two washers and shoulder screws.
0034-3
TM 5-3895-379-23-1
0034

VANDAL GUARD WASHER TERMINAL 1 WIRE 376-GN
SHOULDER SCREW WASHER SCREW STARTING AID SWITCH
TERMINAL 2 WIRE 148-WH BOX ASSEMBLY

T0103SWR
Figure 2. Starting Aid Switch Wiring. END OF WORK PACKAGE
0034-4
TM 5-3895-379-23-1
0035
FIELD MAINTENANCE VIBRATIONS PER MINUTE (VPM) TACHOMETER DOES NOT WORK
TROUBLESHOOTING PROCEDURE SYMPTOM VIBRATIONS PER MINUTE (VPM) TACHOMETER DOES NOT WORK MALFUNCTION Rear Vibration Sensor Faulty. CORRECTIVE ACTION 1. 2. Check adjustment of vibration sensor (WP 0184). Check for obvious signs of damage such as cracks, scrape marks on plate, or broken wires. a. b. c. If adjustment is OK, go to next malfunction. If adjustment is not OK, adjust vibration sensor (WP 0184). If vibration sensor is damaged, replace vibration sensor (WP 0184).
0035-1
TM 5-3895-379-23-1
0035
MALFUNCTION Rear Vibration Sensor Ground Fault. CORRECTIVE ACTION
WARNING
Remove all jewelry such as rings, dog tags and bracelets. If jewelry contacts electrical connection, a direct short may occur resulting in injury or death and damage to equipment. 1. 2. 3. 4. Disconnect vibration sensor connection from wiring harness connector. Set multimeter to measure ohms. Touch positive (+) probe of multimeter to harness connector (wire 200-BK). Touch negative (-) probe of multimeter to good ground. a. b. If infinite ohms are measured, repair or replace wire 200-BK and connectors to vibration sensor (WP 0195). If zero ohms are measured, go to next malfunction.
VIBRATION SENSOR WIRE 440-WH WIRE 200-BK HARNESS CONNECTOR
T0118SWR
Figure 1. Vibration Sensor Wiring.
0035-2
TM 5-3895-379-23-1
0035
MALFUNCTION Rear Vibration Sensor Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. 9. Set multimeter to measure VAC. Connect a jumper wire from terminal 1 (black wire) to frame of roller. Touch positive (+) probe of multimeter to terminal 2 (white wire). Touch negative (-) probe of multimeter to frame. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Have assistant start engine and turn vibratory system on for not more than 10 seconds (TM 5-3895-379-10). Multimeter should measure minimum 2.4 VAC peaks. Have assistant turn engine start switch to OFF position (TM 5-3895-379-10). Remove jumper wire. a. b. If minimum 2.4 VAC peaks are not measured, replace vibration sensor (WP 0184). If minimum 2.4 VAC peaks are measured, connect vibration sensor connector to wiring harness connector. Go to next malfunction.
123-WH
614-PU
200-BK
440-WH
T0119SWR
Figure 2. Vibrator Sensor Wiring.
0035-3
TM 5-3895-379-23-1
0035
MALFUNCTION Wire 440-RD To Vibration Per Minute (VPM) Tachometer Faulty. CORRECTIVE ACTION
NOTE
Wire 440 (part of instrument wiring harness) becomes wire 440-RD (part of main wiring harness) at connector (R1/P1). 1. 2. 3. 4. 5. 6. 7. Remove two shoulder screws, washers, and vandal guard from box assembly. Remove three screws and washers and lift box assembly up from operator station. Start engine and turn vibratory system on for not more than 10 seconds (TM 5-3895-379-10). Touch positive (+) probe of multimeter to terminal S (440-WH) of VPM tachometer. Touch negative (-) probe of multimeter to good ground. Multimeter should measure minimum of 2.4 VAC peaks. Turn engine start switch to OFF position (TM 5-3895-379-10). If minimum 2.4 VAC peaks are not measured at terminal S (wire 440-WH), repair or replace wire 440-WH/440-RD and connectors from VPM tachometer to speed sensor (WP 0195). MALFUNCTION No Power To Vibration Per Minute (VPM) Tachometer. CORRECTIVE ACTION 1. 2. 3. 4. Set multimeter to measure VDC. Turn engine start switch to ON position (TM 5-3895-379-10). Touch positive (+) probe of multimeter to terminal + (wire 123-WH) of VPM tachometer. Touch negative (-) probe of multimeter to good ground. a. b. If 24 to 28 VDC are not measured at terminal + (wire 123-WH) and GAUGES fuse is good, repair or replace wiring and connectors to GAUGES fuse holder (WP 0195). If 24 to 28 VDC are present at terminal + (wire 123-WH), replace VPM tachometer (WP 0170).
0035-4
TM 5-3895-379-23-1
0035
123-WH
614-PU
200-BK
440-WH
T0239SWR
Figure 3. Vibration Per Minute (VPM) Meter Wiring. END OF WORK PACKAGE
0035-5/6 blank
TM 5-3895-379-23-1
0036
FIELD MAINTENANCE WARNING AND INDICATOR LIGHTS DO NOT OPERATE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References WP 0155 References (cont.) WP 0171 WP 0177 WP 0180 WP 0195 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0036-1
TM 5-3895-379-23-1
0036
TROUBLESHOOTING PROCEDURE SYMPTOM WARNING AND INDICATOR LIGHTS DO NOT OPERATE MALFUNCTION Indicator Light Lamp Faulty. CORRECTIVE ACTION
WARNING
Remove all jewelry such as rings, dog tags and bracelets. If jewelry contacts electrical connection, a direct short may occur resulting in injury or death and damage to equipment. 1. 2. 3. 4. Remove two shoulder screws, washers, and vandal guard from box assembly. Remove three screws and washers and lift box assembly up from operator station. Turn lamp assembly caps clockwise and remove lamps. Check lamps for damage such as broken filaments or smoky condition. If lamps are damaged, perform the following: (1) (2) (3) Replace lamps with new parts and turn lamp assembly caps counterclockwise. Install box assembly on operator station with three washers and screws. Install vandal guard on box assembly with two washers and shoulder screws.
VANDAL GUARD WASHER
FUNCTIONAL INDICATOR LIGHT ASSEMBLY TERMINAL ORDER FEDCBA
SHOULDER SCREW WARNING LIGHTS ASSEMBLY
LAMP CAP WIRE 123-WH

T0096SWR
WASHER SCREW
Figure 1. Functional Indicator and Warning Light Assemblies.
0036-2
TM 5-3895-379-23-1
0036
MALFUNCTION Indicator Light Assemblies Faulty. CORRECTIVE ACTION 1. 2. 3. Remove wiring harness connector(s) from functional indicator light assembly or warning lights assembly. Set multimeter to diode check. Attach probes to light assemblies as noted below. If any diode checks are not OK, perform the following as needed: (1) (2) Replace functional indicator lights assembly (WP 0177). Replace warning lights assembly (WP 0180). Table 1. FUNCTIONAL INDICATOR LIGHTS ASSEMBLY Positive (+) Probe Terminal A Terminal B Terminal E Terminal F Negative (-) Probe Terminal C Terminal C Terminal C Terminal C Diode Checks. WARNING LIGHTS ASSEMBLY Positive (+) Probe Terminal B Terminal E Terminal A Terminal F Negative (-) Probe Terminal D Terminal D Terminal D Terminal D
VANDAL GUARD WASHER

T0179SWR
WASHER SCREW
0036-3
TM 5-3895-379-23-1
0036
MALFUNCTION Indicator Light Assemblies Internal Wiring Faulty. CORRECTIVE ACTION 1. 2. 3. Set multimeter to measure ohms. Attach probes to light assemblies as noted below. Multimeter should measure zero ohms. a. If any continuity check reads infinite, perform the following as needed: (1) (2) b. Replace functional indicator lights assembly (WP 0177). Replace warning lights assembly (WP 0180).
If all continuity checks are OK, connect wiring harness connector(s) and go to next malfunction. Table 2. Continuity Checks. WARNING LIGHTS ASSEMBLY Positive (+) Probe Terminal A Terminal B Terminal C Terminal E Terminal F Negative (-) Probe Terminal D Terminal D Terminal D Terminal D Terminal D
FUNCTIONAL INDICATOR LIGHTS ASSEMBLY Positive (+) Probe Terminal A Terminal B Terminal D Terminal E Terminal F Negative (-) Probe Terminal C Terminal C Terminal C Terminal C Terminal C
0036-4
TM 5-3895-379-23-1
0036
VANDAL GUARD WASHER

T0180SWR
WASHER SCREW
0036-5
TM 5-3895-379-23-1
0036
MALFUNCTION No Power To Indicator Light Assemblies. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Set multimeter to measure VDC. Touch positive (+) probe of multimeter to terminal C (wire 123-WH) of harness wiring light connector. Touch negative (-) probe of multimeter to good ground. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). a. b. If 24 to 28 VDC are not measured at terminal C (wire 123-WH) and GAUGES fuse is good, repair or replace wire 123-WH and connectors (WP 0195). If 24 to 28 VDC are measured at terminal C (wire 123-WH), connect connector to lights assembly and go to next malfunction.
VANDAL GUARD WASHER

T0097SWR
WASHER SCREW
Figure 4. Functional Indicator and Warning Light Assembly Wiring.
0036-6
TM 5-3895-379-23-1
0036
MALFUNCTION No Power To Functional Light Relay. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. Remove nine screws and washers and remove panel from operating station. Remove harness connector from functional light relay. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Touch positive (+) probe of multimeter to terminal 1 (wire 123-WH). Touch negative (-) probe of multimeter to good ground. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). If 24 to 28 VDC are not measured at terminal 1 (wire 123-WH) and GAUGES fuse is good, repair or replace wire 123-WH and connectors to GAUGES fuse holder (WP 0195).
SCREW WASHER RELAY 2 3 1 HARNESS CONNECTOR 4 5

T0098SWR
OPERATOR STATION
FUNCTIONAL LIGHT RELAY
Figure 5. Functional Light Relay Wiring.
0036-7
TM 5-3895-379-23-1
0036
MALFUNCTION Functional Light Relay Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Remove functional light relay from operator station (WP 0155). Set multimeter to measure ohms. Touch positive (+) probe of multimeter to terminal 85. Touch negative (-) probe of multimeter to terminal 86 of functional light relay. Multimeter should measure zero ohms. Touch positive (+) probe of multimeter to terminal 87A. Touch negative (-) probe of multimeter to terminal 30 of functional light relay. Multimeter should measure zero ohms. Move positive (+) probe of multimeter to terminal 87. Keep negative (-) probe of multimeter at terminal 30 of relay. Multimeter should measure infinite ohms. a. b. c. d.
SCREW WASHER
If multimeter does not measure zero ohms between terminals 85 and 86, replace functional light relay (WP 0155). If multimeter does not measure zero ohms between terminals 30 and 87A, replace functional light relay (WP 0155). If multimeter does not measure infinite ohms between terminals 30 and 87, replace functional light relay (WP 0155). If all continuity checks are OK, go to next malfunction.
PANEL ASSEMBLY

T0181SWR
OPERATOR STATION
0036-8
TM 5-3895-379-23-1
0036
MALFUNCTION No Ground At Functional Light Relay. CORRECTIVE ACTION 1. 2. 3. Touch positive (+) probe of multimeter to terminal 2 (wire 200-BK) of harness connector. Touch negative (-) probe of multimeter to operator station. Multimeter should measure zero ohms. If multimeter does not measure zero ohms, repair or replace wire 200-BK and connectors (WP 0195).

T0182SWR
OPERATOR STATION
0036-9
TM 5-3895-379-23-1
0036
MALFUNCTION No Power To Warning Light Relay. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. Remove nine screws and washers and remove panel from operator station. Remove harness connector from warning light relay. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Touch positive (+) probe of multimeter to terminal 1 (wire C931-OR). Touch negative (-) probe of multimeter to good ground. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). If 24 to 28 VDC are not measured at terminal 1 (wire C931-OR) and GAUGES fuse is good, repair or replace wire C931-OR (WP 0195).

T0099SWR
OPERATOR STATION
Figure 8. Warning Light Relay Wiring.
0036-10
TM 5-3895-379-23-1
0036
MALFUNCTION Warning Light Relay Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Remove warning light relay from operator station (WP 0155). Set multimeter to measure ohms. Touch positive (+) probe of multimeter to terminal 85. Touch negative (-) probe of multimeter to terminal 86 of warning light relay. Multimeter should measure zero ohms. Touch positive (+) probe of multimeter to terminal 87A. Touch negative (-) probe of multimeter to terminal 30 of warning light relay. Multimeter should measure zero ohms. Move positive (+) probe of multimeter to terminal 87. Keep negative (-) probe of multimeter at terminal 30 of warning light relay. Multimeter should measure infinite ohms. a. b. c. d.
SCREW WASHER
If multimeter does not measure zero ohms between terminals 85 and 86, replace warning light relay (WP 0155). If multimeter does not measure zero ohms between terminals 30 and 87A, replace warning light relay (WP 0155). If multimeter does not measure infinite ohms between terminals 30 and 87, replace warning light relay (WP 0155). If all continuity checks are OK, go to next malfunction.
PANEL ASSEMBLY

T0183SWR
OPERATOR STATION
0036-11
TM 5-3895-379-23-1
0036
MALFUNCTION No Ground At Warning Light Relay. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. Touch positive (+) probe of multimeter to terminal 2 (wire 200-BK) of harness connector. Touch negative (-) probe of multimeter to good ground. Multimeter should measure zero ohms. Move positive (+) of multimeter to terminal 4 (wire 200-BK) of harness connector. Touch negative (-) probe of multimeter to good ground. Multimeter should measure zero ohms. If multimeter does not measure zero ohms at both terminals 2 and 4, repair or replace wire 200-BK and connectors (WP 0195).

T0184SWR
OPERATOR STATION
0036-12
TM 5-3895-379-23-1
0036
MALFUNCTION Hourmeter Pressure Switch Circuit Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. Disconnect harness connector from hourmeter pressure switch connector. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Set multimeter to measure VDC. Touch positive (+) probe of multimeter to terminal 2 (wire 123-WH). Touch negative (-) probe of multimeter to good ground. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). If 24 to 28 VDC are not measured at terminal 2 (wire 123-WH), repair or replace wire 123 - WH and connectors (WP 0195).
HOURMETER PRESSURE SWITCH
HARNESS CONNECTOR WIRE 123-WH
PIN 2
PIN 1
T0100SWR
Figure 11. Hourmeter Wiring.
0036-13
TM 5-3895-379-23-1
0036
MALFUNCTION Hourmeter Pressure Switch Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. Connect a jumper wire from terminal 1 to terminal 2 of harness connector. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Observe warning and indicator lights for proper operation. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Remove jumper wire. a. b. If warning and indicator light operate, replace hourmeter pressure switch (WP 0171). If warning and indicator light do not operate, connect harness connector to hourmeter pressure switch connector, and go to next malfunction.
HOURMETER PRESSURE SWITCH
HARNESS CONNECTOR WIRE 123-WH
PIN 2
PIN 1
T0185SWR
Figure 12. Hourmeter Wiring.
0036-14
TM 5-3895-379-23-1
0036
MALFUNCTION No Power To Diode. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove four screws, washers, and cover from operator station. Remove diode from harness connector. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Set multimeter to measure VDC. Touch positive (+) probe of multimeter to input terminal (wire 400-GN). Touch negative (-) probe of multimeter to good ground. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). If 24 to 28 VDC are not measured at input terminal (wire 400-GN), repair or replace wire 400 - GN and connectors from diode to hourmeter pressure switch (WP 0195).
CONNECTOR
OPERATOR STATION ANODE SIDE CATHODE SIDE
WASHER SCREW DIODE
COVER
T0101SWR
Figure 13. Warning Alarm Diodes.
0036-15
TM 5-3895-379-23-1
0036
MALFUNCTION Diode Fault or Wire 938-BR Faulty. CORRECTIVE ACTION 1. 2. 3. 4. Set multimeter to diode check. Touch positive (+) probe of multimeter to cathode terminal. Touch negative (-) probe of multimeter to corresponding anode terminal. Repeat test for each set of terminals. a. b. If any diode checks are not OK, replace diode with new part. If diode checks are OK, repair or replace wire 938-BR and connectors (WP 0195).
CONNECTOR
OPERATOR STATION ANODE SIDE CATHODE SIDE
WASHER SCREW DIODE
COVER
T0186SWR
Figure 14. Warning Alarm Diodes. END OF WORK PACKAGE
0036-16
TM 5-3895-379-23-1
0037
FIELD MAINTENANCE WORK LIGHTS AND GAUGE LIGHTS DO NOT OPERATE
0037-1
TM 5-3895-379-23-1
0037
TROUBLESHOOTING PROCEDURE SYMPTOM WORK LIGHTS AND GAUGE LIGHTS DO NOT OPERATE MALFUNCTION No Power At Light Circuit Breaker. CORRECTIVE ACTION
WARNING
Remove all jewelry such as rings, dog tags and bracelets. If jewelry contacts electrical connection, a direct short may occur resulting in injury or death and damage to equipment. 1. 2. 3. 4. 5. 6. Remove nine screws and washers and remove panel from operator station. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Set multimeter to measure VDC. Touch positive (+) probe of multimeter to input terminal (wire 122-PU) of lights circuit breaker. Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured at input terminal (wire 112-PU), perform the following: (1) (2) (3) Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Repair or replace wire 112-PU and connectors from main relay to alternator circuit breaker (WP 0195).
0037-2
TM 5-3895-379-23-1
0037
SCREW WASHER PANEL ASSEMBLY WIRE 112-PU WASHER SCREW WIRE 114-GN
OPERATOR STATION
T0112SWR
Figure 1. Light Circuit Breaker Wiring.
0037-3
TM 5-3895-379-23-1
0037
MALFUNCTION Light Circuit Breaker Faulty. CORRECTIVE ACTION 1. 2. 3. Press circuit breaker button to reset. Touch positive (+) probe of multimeter to output terminal (wire 114-GN). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured at output terminal (wire 114-GN), perform the following: (1) (2) (3) Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Replace lights circuit breaker (WP 0173).
SCREW WASHER PANEL ASSEMBLY WIRE 112-PU WASHER SCREW WIRE 114-GN
OPERATOR STATION
T0221SWR
Figure 2. Light Circuit Breaker Wiring.
0037-4
TM 5-3895-379-23-1
0037
MALFUNCTION Work Light Control Switch Fault or Circuit Wiring Faulty. CORRECTIVE ACTION 1. 2. 3. 4. Touch positive (+) probe of multimeter to terminal B (wire 114-GR) of lights circuit breaker. Touch negative (-) probe of multimeter to good ground. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). a. If 24 to 28 VDC are not measured at terminal B (wire 114-GR), repair or replace wire 114 - GR and connectors from lights circuit breaker work light control switch (WP 0195). If 24 to 28 VDC are measured at input terminal B (wire 114-GR), replace work light control switch (WP 0162).
b.
TERMINAL B WIRE 114-GR WIRE 619-GN
WIRE 614-PU
WIRE 809-GN
T0113SWR
Figure 3. Work Light Control Switch Wiring. END OF WORK PACKAGE
0037-5/6 blank
TM 5-3895-379-23-1
0038
FIELD MAINTENANCE HYDRAULIC OIL PRESSURE IS LOW (WARNING LIGHT AND WARNING HORN ON)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References Volume 2, WP 0257 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0038-1
TM 5-3895-379-23-1
0038
TROUBLESHOOTING PROCEDURE SYMPTOM HYDRAULIC OIL PRESSURE IS LOW (WARNING LIGHT AND WARNING HORN ON) MALFUNCTION Hydraulic Oil Filter Indicator In Red Zone. CORRECTIVE ACTION
WARNING
When working on a running engine, provide shielding for exposed rotating parts. Tools, clothing or hands can get caught and cause injury. 1. 2. Open right-side door assembly (TM 5-3895-379-10). Check hydraulic oil filter indicator with engine running at high idle. a. b. If filter indicator is in red zone, replace filter (Volume 2, WP 0257). If filter indicator is not in red zone, notify supervisor.
FAN BLADE RED ZONE
WHITE FILTER INDICATOR (CB534B ONLY)
HYDRAULIC OIL FILTER INDICATOR

T0125SWR
Figure 1. Hydraulic Oil Filter Indicator. END OF WORK PACKAGE
0038-2
TM 5-3895-379-23-1
0039
FIELD MAINTENANCE HYDRAULIC OIL TEMPERATURE IS HIGH (WARNING LIGHT AND WARNING HORN ON)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References WP 0146 References (cont.) WP 0147 Volume 2, WP 0235 Volume 2, WP 0257 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0039-1
TM 5-3895-379-23-1
0039
TROUBLESHOOTING PROCEDURE SYMPTOM HYDRAULIC OIL TEMPERATURE IS HIGH (WARNING LIGHT AND WARNING HORN ON) MALFUNCTION Hydraulic Oil Filter Indicator In Red Zone. CORRECTIVE ACTION
WARNING
When working on a running engine, provide shielding for exposed rotating parts. Tools, clothing or hands can get caught and cause injury. 1. 2. Open right-side door assembly (TM 5-3895-379-10). Check hydraulic oil filter indicator with engine running at high idle. If filter indicator is in red zone, perform the following: (1) (2) Turn engine start switch to OFF position (TM 5-3895-379-10). Replace filter (Volume 2, WP 0257).
FAN BLADE RED ZONE
WHITE FILTER INDICATOR (CB534B ONLY)
HYDRAULIC OIL FILTER INDICATOR

T0178SWR
Figure 1. Hydraulic Oil Filter Indicator. MALFUNCTION V-belts Loose or Damaged. CORRECTIVE ACTION 1. Check fan V-belts for damage such as cracks to belt fiber, one or more cracks 1/8 inch in depth or 50% of belt thickness, splits, grease buildup, glazed sides, and peeling.
0039-2
TM 5-3895-379-23-1
0039
CORRECTIVE ACTION - Continued 2. 3. 4. Raise operator platform (Volume 2, WP 0235). Attach belt tension gauge to fan V-belts. Correct belt tension is 80 lb (36.3 kg). a. b. c. If fan V-belts are damaged, replace fan V-belts (WP 0147). If belt tension is 50 lb (22.8 kg) or less, adjust fan V-belt tension (WP 0147). If fan V-belts are not damaged or loose, remove belt tension gauge from fan V-belts. Go to next malfunction.
FAN V-BELTS ALTERNATOR BRACKET
FAN BLADE
FAN PULLEY
T0124SWR
Figure 2. Engine Fan Assembly. MALFUNCTION Fan Assembly and Guard Are Loose or Damaged. CORRECTIVE ACTION Check fan assembly and guard for looseness or damage such as cracked or missing fan blade(s), loose nuts and screws, bent or cracked fan pulley, or damage or wear resulting from extreme fan blade wobble. a. b. If fan assembly and guard are loose or damaged, tighten or replace loose or damaged parts (WP 0146). Lower operator platform (Volume 2, WP 0235). If fan assembly and guard are not loose or damaged, lower operator platform (Volume 2, WP 0235) and notify supervisor.
END OF WORK PACKAGE
0039-3/4 blank
TM 5-3895-379-23-1
0040
FIELD MAINTENANCE POWER STEERING PUMP MAKES NOISE AND STEERING CYLINDER RODS DO NOT MOVE SMOOTHLY
0040-1
TM 5-3895-379-23-1
0040
TROUBLESHOOTING PROCEDURE SYMPTOM POWER STEERING PUMP MAKES NOISE AND STEERING CYLINDER RODS DO NOT MOVE SMOOTHLY MALFUNCTION Power Steering Pump Leaks or Is Damaged. CORRECTIVE ACTION 1. 2. Open right-side door assembly (TM 5-3895-379-10). Check power steering pump for damage or leakage. If power steering pump is damaged or leaking, replace pump assembly (Volume 2, WP 0223).
POWER STEERING PUMP
T0126SWR
Figure 1. Power Steering Pump. END OF WORK PACKAGE
0040-2
TM 5-3895-379-23-1
0041
FIELD MAINTENANCE ROLLER DOES NOT TURN WHEN STEERING WHEEL IS TURNED
0041-1
TM 5-3895-379-23-1
0041
TROUBLESHOOTING PROCEDURE SYMPTOM ROLLER DOES NOT TURN WHEN STEERING WHEEL IS TURNED MALFUNCTION Power Steering Pump Leaks or Is Damaged. CORRECTIVE ACTION 1. 2. Open right-side door assembly (TM 5-3895-379-10). Check power steering pump for damage or leakage. If power steering pump is damaged or leaking, replace pump assembly (Volume 2, WP 0223).
POWER STEERING PUMP
T0177SWR
0041-2
TM 5-3895-379-23-1
0042
FIELD MAINTENANCE ROLLER TURNS SLOWLY IN BOTH DIRECTIONS
0042-1
TM 5-3895-379-23-1
0042
TROUBLESHOOTING PROCEDURE SYMPTOM ROLLER TURNS SLOWLY IN BOTH DIRECTIONS MALFUNCTION Power Steering Pump Leaks or Is Damaged. CORRECTIVE ACTION 1. 2. Open right-side door assembly (TM 5-3895-379-10). Check power steering pump for damage or leakage. If power steering pump is damaged or leaking, replace pump assembly (Volume 2, WP 0223).
POWER STEERING PUMP
M1062SWR
0042-2
TM 5-3895-379-23-1
0043
FIELD MAINTENANCE TOO MUCH FORCE IS NEEDED TO TURN STEERING WHEEL
0043-1
TM 5-3895-379-23-1
0043
TROUBLESHOOTING PROCEDURE SYMPTOM TOO MUCH FORCE IS NEEDED TO TURN STEERING WHEEL MALFUNCTION Power Steering Pump Leaks or Is Damaged. CORRECTIVE ACTION 1. 2. Open right-side door assembly (TM 5-3895-379-10). Check power steering pump for damage or leakage. If power steering pump is damaged or leaking, replace pump assembly (Volume 2, WP 0223).
POWER STEERING PUMP
T0163SWR
0043-2
TM 5-3895-379-23-1
0044
FIELD MAINTENANCE PARKING BRAKE DOES NOT DISENGAGE WHEN PARKING BRAKE SWITCH IS PULLED UP
0044-1
TM 5-3895-379-23-1
0044
TROUBLESHOOTING PROCEDURE SYMPTOM PARKING BRAKE DOES NOT DISENGAGE WHEN PARKING BRAKE SWITCH IS PULLED UP MALFUNCTION Brake Control Valve Faulty. CORRECTIVE ACTION
WARNING
Remove all jewelry such as rings, dog tags and bracelets. If jewelry contacts electrical connection a direct short may occur resulting in injury or death, and damage to equipment. Ensure that parking brake is engaged and propel control lever is in neutral position before turning engine start switch to ON position. If roller accidentally starts or rolls, injury or death to personnel may occur. 1. 2. 3. 4. 5. 6. Open left-side door assembly (TM 5-3895-379-10). Move propel speed switch into high (hare) position. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Place blade end of screwdriver approximately 1/4 inch (6 mm) from center hex nut on brake solenoid. Magnetic force should pull screwdriver to brake solenoid. a. b. If magnetic force pulls screwdriver to brake solenoid, replace brake control valve (WP 0216). If magnetic force does not pull screwdriver to brake solenoid, go to next malfunction.
0044-2
TM 5-3895-379-23-1
0044
BRAKE SOLENOID CONNECTOR
WIRE 200-BK TERMINAL 2
BRAKE SOLENOID
WIRE 777-PU HARNESS CONNECTOR TERMINAL 1
T0192SWR
Figure 1. Parking Brake Solenoid Wiring.
0044-3
TM 5-3895-379-23-1
0044
MALFUNCTION No Power To Brake Solenoid. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. Disconnect harness connector from brake control connector (wire 777-PU). Set multimeter to measure VDC. Touch positive (+) probe of multimeter to connector P20, pin 1 (wire 777-PU). Touch negative probe (-) of multimeter to good ground. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). a. b. If 24 to 28 VDC are measured at brake control connector, (wire 777-PU), replace brake control valve (WP 0216). If 24 to 28 VDC are not measured at brake control connector (wire 777-PU), close left-side door assembly (TM 5-3895-379-10) and go to next malfunction.
BRAKE SOLENOID CONNECTOR
BRAKE SOLENOID
WIRE 777-PU HARNESS CONNECTOR TERMINAL 1
T0130SWR
Figure 2. Parking Brake Solenoid Wiring.
0044-4
TM 5-3895-379-23-1
0044
MALFUNCTION No Power At Parking Brake Switch Terminal 3. CORRECTIVE ACTION 1. 2. 3. 4. 5. Remove nine screws and washers and remove panel from operator station. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Touch positive (+) probe of multimeter to terminal 3 (wire 155-PK). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured at terminal 3 (wire 155-PK) and BRAKE fuse is good, perform the following: (1) (2) (3)
Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Repair or replace wiring and connectors to BRAKE fuse holder (WP 0195).
PANEL ASSEMBLY PARKING BRAKE SWITCH
WIRE 155-PK TERMINAL 3 OPERATOR STATION
WIRE 765-BR TERMINAL 2

T0193SWR
Figure 3. Parking Brake Switch Wiring.
0044-5
TM 5-3895-379-23-1
0044
MALFUNCTION Parking Brake Switch Faulty. CORRECTIVE ACTION 1. 2. 3. Pull parking brake switch up. Touch positive (+) probe of multimeter to terminal 2 (wire 765-BR). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured at terminal 2 (wire 765-BR) and BRAKE fuse is good, perform the following: (1) (2) (3)
Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Replace parking brake switch (WP 0156).
PANEL ASSEMBLY PARKING BRAKE SWITCH
WIRE 765-BR TERMINAL 2

T0131SWR
Figure 4. Parking Brake Switch Wiring.
0044-6
TM 5-3895-379-23-1
0044
MALFUNCTION No Power To Brake Relay No. 1. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. Remove harness connector from brake relay No. 1. Pull parking brake switch up. Touch positive (+) probe of multimeter to terminal 1 (wire 765-BR). Touch negative (-) probe of multimeter to good ground. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). If 24 to 28 VDC are not measured at terminal 1 (wire 765-BR) and BRAKE fuse is good, repair or replace wiring and connectors from brake replay No. 1 to parking brake switch (WP 0195).
SCREW WASHER PANEL ASSEMBLY WASHER SCREW HARNESS CONNECTOR TERMINALS 2 3 1 4
RELAY BRAKE RELAY 1
OPERATOR STATION
T0132SWR
Figure 5. Brake Relay No. 1 Wiring.
0044-7
TM 5-3895-379-23-1
0044
MALFUNCTION Brake Relay No. 1 Coil Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. Remove brake relay No. 1 from operator station (WP 0155). Set multimeter to measure ohms. Touch positive (+) probe of multimeter to terminal 85. Touch negative (-) probe of multimeter to terminal 86 of brake relay No. 1. Multimeter should measure zero ohms. If multimeter does not measure zero ohms, replace brake relay No. 1 (WP 0155).
RELAY BRAKE RELAY 1
OPERATOR STATION
T0194SWR
Figure 6. Brake Relay 1 Wiring.
0044-8
TM 5-3895-379-23-1
0044
MALFUNCTION Brake Relay No. 1 Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. Touch positive (+) probe of multimeter to terminal 87A. Touch negative (-) probe of multimeter to terminal 30 of brake relay No. 1. Multimeter should measure zero ohms. Move positive (+) probe of multimeter to terminal 87. Keep negative (-) probe of multimeter at terminal 30 of brake relay No. 1. Multimeter should measure infinite ohms. a. b. If multimeter does not measure zero ohms between terminals 30 and 87A, replace brake relay No. 1 (WP 0155). If multimeter does not measure infinite ohms between terminals 1 and 4, replace brake relay No. 1 (WP 0155).
RELAY BRAKE RELAY 1
OPERATOR STATION
T0133SWR
Figure 7. Brake Relay No. 1 Wiring. END OF WORK PACKAGE
0044-9/10 blank
TM 5-3895-379-23-1
0045
FIELD MAINTENANCE PARKING BRAKE DOES NOT ENGAGE WHEN PARKING BRAKE SWITCH IS PUSHED DOWN
0045-1
TM 5-3895-379-23-1
0045
WARNING
Ensure that parking brake is engaged and propel control lever is in neutral position before turning engine start switch to ON position. If roller accidentally starts or rolls, injury or death to personnel may occur. SYMPTOM PARKING BRAKE DOES NOT ENGAGE WHEN PARKING BRAKE SWITCH IS PUSHED DOWN MALFUNCTION No Power At Parking Brake Switch. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. Remove nine screws and washers and remove panel from operator station. Push parking brake switch down. Touch positive (+) probe of multimeter to terminal 4 (wire 419-YL). Touch negative (-) probe of multimeter to good ground. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). If 24 to 28 VDC are not measured at terminal 4 (wire 419-YL), replace parking brake switch (WP 0156).
0045-2
TM 5-3895-379-23-1
0045

SCREW WASHER SCREW WASHER PANEL ASSEMBLY PARKING BRAKE SWITCH
WIRE 419-YL TERMINAL 4

T0134SWR
Figure 1. Parking Brake Switch Wiring. END OF WORK PACKAGE
0045-3/4 blank
TM 5-3895-379-23-1
0046
FIELD MAINTENANCE PROPEL MOTOR IS NOISY
TROUBLESHOOTING PROCEDURE SYMPTOM PROPEL MOTOR IS NOISY MALFUNCTION Hydraulic Fluid Low or Propel Motor Faulty. CORRECTIVE ACTION Check oil level in fuel/hydraulic tank (TM 5-3895-379-10). a. b. Add hydraulic oil if low (TM 5-3895-379-10). If oil level is found to be correct, replace propel motor (WP 0205).
END OF WORK PACKAGE
0046-1/2 blank
TM 5-3895-379-23-1
0047
FIELD MAINTENANCE PROPEL MOTOR LEAKS OIL
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References WP 0205 Volume 2, WP 0259 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
TROUBLESHOOTING PROCEDURE SYMPTOM PROPEL MOTOR LEAKS OIL MALFUNCTION Hydraulic Hose or Propel Motor Faulty. CORRECTIVE ACTION Check propel motor hydraulic hose and fittings. a. b. Tighten any hose and fittings found to be loose (Volume 2, WP 0259). Replace propel motor (WP 0205).
END OF WORK PACKAGE
0047-1/2 blank
TM 5-3895-379-23-1
0048
FIELD MAINTENANCE PROPEL SYSTEM DOES NOT CHANGE SPEEDS WHEN PROPEL SPEED SWITCH IS MOVED
0048-1
TM 5-3895-379-23-1
0048
TROUBLESHOOTING PROCEDURE SYMPTOM PROPEL SYSTEM DOES NOT CHANGE SPEEDS WHEN PROPEL SPEED SWITCH IS MOVED MALFUNCTION Propel Control Valve Faulty. CORRECTIVE ACTION
WARNING
Remove all jewelry such as rings, dog tags and bracelets. If jewelry contacts electrical connection a direct short may occur resulting in injury or death, and damage to equipment. Ensure that parking brake is engaged and propel control lever is in neutral position before turning engine start switch to ON position. If roller accidentally starts or rolls, injury or death to personnel may occur. 1. 2. 3. 4. 5. 6. Open left-side door assembly (TM 5-3895-379-10). Move propel speed switch into high (hare) position. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Place blade end of screwdriver approximately 1/4 in. (6 mm) from center of hex nut on shift solenoid. Magnetic force should pull screwdriver to shift solenoid. a. b. If magnetic force pulls screwdriver to shift solenoid, replace propel control valve (WP 0211). If magnetic force does not pull screwdriver to shift solenoid, go to next malfunction.
0048-2
TM 5-3895-379-23-1
0048
SHIFT SOLENOID SHIFT SOLENOID CONNECTOR
WIRE 200-BK PIN 2
WIRE 751-GN
PIN 1
T0225SWR
Figure 1. Shift Solenoid Wiring.
0048-3
TM 5-3895-379-23-1
0048
MALFUNCTION Brake Control Valve Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. Disconnect harness connector from brake control connector. Set multimeter to measure VDC. Touch positive (+) probe of multimeter to pin 1 (wire 751-GN). Touch negative (-) probe of multimeter to good ground. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). a. b. If 24 to 28 VDC are measured at wire 751-GN, replace brake control valve (WP 0216). If 24 to 28 VDC are not measured at wire 751-GN, close left-side door assembly (TM 5-3895-379-10) and go to next malfunction.
SHIFT SOLENOID SHIFT SOLENOID CONNECTOR
WIRE 200-BK PIN 2
WIRE 751-GN
PIN 1
T0127SWR
Figure 2. Shift Solenoid Wiring.
0048-4
TM 5-3895-379-23-1
0048
MALFUNCTION No Power To Propel Speed Switch. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. Remove nine screws and washers and remove panel from operator station. Move propel speed switch into high (hare) position. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Touch positive (+) probe of multimeter to (wire 155-PK). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured at wire 155-PK and BRAKE fuse is good, perform the following: (1) (2) (3) Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Repair or replace wiring and connectors to BRAKE fuse holder (WP 0195).
PROPEL SPEED RANGE SWITCH SCREW WASHER SCREW WASHER PANEL ASSEMBLY
WIRE 751-GN
PROPEL SPEED SWITCH OPERATOR STATION
WIRE 155-PK
T0128SWR
Figure 3. Propel Speed Switch Wiring.
0048-5
TM 5-3895-379-23-1
0048
MALFUNCTION Propel Speed Switch or Shift Solenoid Control Wire Faulty. CORRECTIVE ACTION 1. 2. 3. 4. Touch positive (+) probe of multimeter to wire 751-GN. Touch negative (-) probe of multimeter to good ground. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). a. b. If 24 to 28 VDC are not measured at wire 751-GN, replace propel speed switch (WP 0161). If 24 to 28 VDC are measured at wire 751-GN, repair or replace wire 751-GN and connectors from propel switch to brake control valve (WP 0195).
PROPEL SPEED RANGE SWITCH SCREW WASHER SCREW WASHER PANEL ASSEMBLY
WIRE 751-GN
PROPEL SPEED SWITCH OPERATOR STATION
WIRE 155-PK
T0129SWR
Figure 4. Propel Speed Switch Wiring. END OF WORK PACKAGE
0048-6
TM 5-3895-379-23-1
0049
FIELD MAINTENANCE PROPEL SYSTEM ENGAGES VERY QUICKLY WHEN MAKING A SHIFT
0049-1
TM 5-3895-379-23-1
0049
TROUBLESHOOTING PROCEDURE SYMPTOM PROPEL SYSTEM ENGAGES VERY QUICKLY WHEN MAKING A SHIFT MALFUNCTION Hydraulic Oil Filter Indicator In Red Zone. CORRECTIVE ACTION
WARNING
FAN BLADE
RED ZONE
WHITE FILTER INDICATOR (CB534B ONLY) HYDRAULIC OIL FILTER INDICATOR

T0170SWR
0049-2
TM 5-3895-379-23-1
0050
FIELD MAINTENANCE PROPEL SYSTEM ENGAGES VERY SLOWLY WHEN MAKING A SHIFT
0050-1
TM 5-3895-379-23-1
0050
TROUBLESHOOTING PROCEDURE SYMPTOM PROPEL SYSTEM ENGAGES VERY SLOWLY WHEN MAKING A SHIFT MALFUNCTION Hydraulic Oil Filter Indicator In Red Zone. CORRECTIVE ACTION
WARNING
FAN BLADE
RED ZONE

T0172SWR
0050-2
TM 5-3895-379-23-1
0051
FIELD MAINTENANCE PROPEL SYSTEM OPERATES IN FORWARD SPEEDS ONLY
TROUBLESHOOTING PROCEDURE SYMPTOM PROPEL SYSTEM OPERATES IN FORWARD SPEEDS ONLY MALFUNCTION Propel Control Lever Engagement Stops Out Of Adjustment. CORRECTIVE ACTION Adjust propel control lever (WP 0207) and (WP 0208). If fault is not corrected, perform the following as needed: (1) (2) (3) END OF WORK PACKAGE Replace propel control lever (WP 0206). Replace propel control valve (WP 0211). Replace propel pump assembly (WP 0203).
0051-1/2 blank
TM 5-3895-379-23-1
0052
FIELD MAINTENANCE PROPEL SYSTEM OPERATES IN REVERSE SPEEDS ONLY
TROUBLESHOOTING PROCEDURE SYMPTOM PROPEL SYSTEM OPERATES IN REVERSE SPEEDS ONLY MALFUNCTION Propel Control Lever Out Of Adjustment. CORRECTIVE ACTION Adjust propel control lever (WP 0207) and (WP 0208). If fault is not corrected, perform the following as needed: (1) (2) (3) END OF WORK PACKAGE Replace propel control lever (WP 0206). Replace propel control valve (WP 0211). Replace propel pump assembly (WP 0203).
0052-1/2 blank
TM 5-3895-379-23-1
0053
FIELD MAINTENANCE ROLLER WILL NOT MOVE WHEN PROPEL CONTROL LEVER IS OPERATED
0053-1
TM 5-3895-379-23-1
0053
TROUBLESHOOTING PROCEDURE SYMPTOM ROLLER WILL NOT MOVE WHEN PROPEL CONTROL LEVER IS OPERATED MALFUNCTION Hydraulic Oil Filter Indicator In Red Zone. CORRECTIVE ACTION
WARNING
FAN BLADE
RED ZONE

T0175SWR
0053-2
TM 5-3895-379-23-1
0054
FIELD MAINTENANCE NOISY VIBRATORY MOTOR
TROUBLESHOOTING PROCEDURE SYMPTOM NOISY VIBRATORY MOTOR MALFUNCTION Vibratory Motor Faulty. CORRECTIVE ACTION Remove and inspect vibratory motor (Volume 2, WP 0252). If vibratory mechanism is found to be damaged, replace motor (Volume 2, WP 0252). END OF WORK PACKAGE
0054-1/2 blank
TM 5-3895-379-23-1
0055
FIELD MAINTENANCE VIBRATION DOES NOT OCCUR WHILE AMPLITUDE SELECT SWITCH IS SET TO HIGH PITCH
0055-1
TM 5-3895-379-23-1
0055
TROUBLESHOOTING PROCEDURE SYMPTOM VIBRATION DOES NOT OCCUR WHILE AMPLITUDE SELECT SWITCH IS SET TO HIGH PITCH MALFUNCTION No Power To High Amplitude Solenoid. CORRECTIVE ACTION
WARNING
Remove all jewelry such as rings, dog tags and bracelets. If jewelry contacts electrical connection a direct short may occur resulting in injury or death, and damage to equipment. Ensure that parking brake is engaged and propel control lever is in neutral position before turning engine start switch to ON position. If roller accidentally starts or rolls, injury or death to personnel may occur. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Open left-side door assembly (TM 5-3895-379-10). Loosen screw and disconnect connector from high amplitude solenoid. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Set vibration control switch to manual (MAN) position and amplitude select switch to high pitch (push forward). Set multimeter to measure VDC. Touch positive (+) probe of multimeter to terminal 1 (wire C925-GN). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured at terminal 1 (wire C925-GN), press vibration on/off switch once and try again. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). a. b. If 24 to 28 VDC are measured at terminal 1 (wire C925-GN), connect connector to high amplitude solenoid and tighten screw. Notify supervisor. If 24 to 28 VDC are not measured at terminal 1 (wire C925-GN) and VIBE fuse is good, perform the following: (1) (2) Connect connector to high amplitude solenoid and tighten screw. Close left-side door assembly (TM 5-3895-379-10) and go to next malfunction.
0055-2
TM 5-3895-379-23-1
0055

CONNECTOR SCREW
TERMINAL 1
HIGH AMPLITUDE SOLENOID
T0144SWR
Figure 1. High Amplitude Solenoid Wiring.
0055-3
TM 5-3895-379-23-1
0055
MALFUNCTION No Power To Amplitude Select Switch. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. Remove nine screws and washers and remove panel from operator station. Set vibration control switch to manual (MAN) position. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Touch positive (+) probe of multimeter to terminal 2 (wire C933-GN). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured at terminal 2 (wire C933-GN), press vibration on/off switch once and try again. If 24 to 28 VDC are not measured at terminal 1 (wire C925-GN) and VIBE fuse is good, perform the following: (1) (2) (3) Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Repair or replace wire C933-GN and connectors to VIBE fuse holder (WP 0195).
PANEL ASSEMBLY SCREW WASHER WIRE C920-GN TERMINAL 3 WIRE C933-GN
WIRE B921-WH TERMINAL 1
TERMINAL 2 OPERATOR STATION WASHER SCREW
AMPLITUDE SELECT SWITCH

T0145SWR
Figure 2. Amplitude Select Switch Wiring.
0055-4
TM 5-3895-379-23-1
0055
MALFUNCTION Amplitude Select Switch or wires 920 or 921 Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. 9. Set amplitude select switch to high pitch (push forward). Touch positive (+) probe of multimeter to terminal 1 (wire B921-WH). Touch negative (-) probe of multimeter to good ground. Measure VDC. Set amplitude select switch to low pitch (pull back). Touch positive (+) probe of multimeter to terminal 3 (wire C920-GN). Touch negative (-) probe of multimeter to good ground. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). a. b. If 24 to 28 VDC are not measured at terminals 1 and 3, replace amplitude select switch (WP 0160). If 24 to 18 VDC are measured at terminals 1 and 3, repair or replace wiring and connectors from amplitude select switch (WP 0160).
PANEL ASSEMBLY SCREW WASHER WIRE C920-GN TERMINAL 3 WIRE C933-GN
WIRE B921-WH TERMINAL 1
TERMINAL 2 OPERATOR STATION WASHER SCREW
AMPLITUDE SELECT SWITCH

T0146SWR
Figure 3. Amplitude Select Switch Wiring. END OF WORK PACKAGE
0055-5/6 blank
TM 5-3895-379-23-1
0056
FIELD MAINTENANCE VIBRATION DOES NOT OCCUR WHILE AMPLITUDE SELECT SWITCH IS SET TO LOW PITCH
0056-1
TM 5-3895-379-23-1
0056
WARNING
Remove all jewelry such as rings, dog tags and bracelets. If jewelry contacts electrical connection a direct short may occur resulting in injury or death, and damage to equipment. Ensure that parking brake is engaged and propel control lever is in neutral position before turning engine start switch to ON position. If roller accidentally starts or rolls, injury or death to personnel may occur. SYMPTOM VIBRATION DOES NOT OCCUR WHILE AMPLITUDE SELECT SWITCH IS SET TO LOW PITCH MALFUNCTION No Power To Low Amplitude Solenoid. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Open left-side door assembly (TM 5-3895-379-10). Loosen screw and disconnect connector from low amplitude solenoid. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Set vibration control switch to manual (MAN) position and amplitude select switch to low pitch (pull back). Set multimeter to measure VDC. Touch positive (+) probe of multimeter to terminal 1 (wire C924-YL). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured at terminal 1 (wire C924-YL), press vibration on/off switch once and try again. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). a. b. If 24 to 28 VDC are measured at terminal 1 (wire C924-YL), connect connector to low amplitude solenoid and tighten screw. Notify supervisor. If 24 to 28 VDC are not measured at wire terminal 1 (wire C924-YL) and VIBE fuse is good, perform the following: (1) (2) Connect connector to low amplitude solenoid and tighten screw. Close left-side door assembly (TM 5-3895-379-10) and go to next malfunction.
0056-2
TM 5-3895-379-23-1
0056
SCREW CONNECTOR TERMINAL 1
HIGH AMPLITUDE SOLENOID
T0147SWR
Figure 1. Low Amplitude Solenoid Wiring.
0056-3
TM 5-3895-379-23-1
0056
MALFUNCTION No Power At Amplitude Select Switch Terminal 2. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. Remove nine screws and washers and remove panel from operator station. Set vibration control switch to manual (MAN) position. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Touch positive (+) probe of multimeter to terminal 2 (wire C933-GN). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured at terminal 2 (wire C933-GN), press vibration on/off switch once and try again. If 24 to 28 VDC are not measured at terminal 2 (wire C933-GN) and VIBE fuse is good, perform the following: (1) (2) (3)
SCREW WASHER
Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Repair or replace wire C933-GN and connectors to VIBE fuse holder (WP 0195).
PANEL ASSEMBLY
SCREW WASHER
WIRE C920-GN TERMINAL 3 WIRE C933-GN WIRE B921-WH TERMINAL 1 AMPLITUDE SELECT SWITCH
T0148SWR
OPERATOR STATION
TERMINAL 2
0056-4
TM 5-3895-379-23-1
0056
MALFUNCTION Amplitude Select Switch or Wires 920 or 921 Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. 9. Set amplitude select switch to high pitch (push forward). Touch positive (+) probe of multimeter to terminal 1 (wire B921-WH). Touch negative (-) probe of multimeter to good ground. Measure VDC. Set amplitude select switch to low pitch (pull back). Touch positive (+) probe of multimeter to terminal 3 (wire C920-GN). Touch negative (-) probe of multimeter to good ground. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). a. b. If 24 to 28 VDC are not measured at terminals 1 and 3, replace amplitude select switch (WP 0160). If 24 to 28 VDC are measured at terminals 1 and 3, repair or replace wiring and connectors from amplitude select switch (WP 0195).
PANEL ASSEMBLY
SCREW WASHER
SCREW WASHER
WIRE C920-GN TERMINAL 3 WIRE C933-GN WIRE B921-WH TERMINAL 1 AMPLITUDE SELECT SWITCH
T0149SWR
OPERATOR STATION
TERMINAL 2
0056-5/6 blank
TM 5-3895-379-23-1
0057
FIELD MAINTENANCE VIBRATION DOES NOT STOP WHEN TRAVEL STOPS
TROUBLESHOOTING PROCEDURE SYMPTOM VIBRATION DOES NOT STOP WHEN TRAVEL STOPS MALFUNCTION Propel Control Lever Engagement Stops Out Of Adjustment. CORRECTIVE ACTION Adjust propel control lever engagement stop (WP 0207). If symptom persists, replace propel control lever assembly (WP 0206). END OF WORK PACKAGE
0057-1/2 blank
TM 5-3895-379-23-1
0058
FIELD MAINTENANCE VIBRATION DOES NOT WORK IN FORWARD OR REVERSE TRAVEL
0058-1
TM 5-3895-379-23-1
0058
TROUBLESHOOTING PROCEDURE SYMPTOM VIBRATION DOES NOT WORK IN FORWARD OR REVERSE TRAVELVIBRATION DOES NOT WORK IN FORWARD OR REVERSE TRAVEL MALFUNCTION No Power To Rear Drum Solenoid. CORRECTIVE ACTION
WARNING
Ensure that parking brake is engaged and propel control lever is in neutral position before turning engine start switch to ON position. If roller accidentally starts or rolls, injury or death to personnel may occur. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Open left-side door assembly (TM 5-3895-379-10). Disconnect harness connector from rear drum solenoid connector. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Set drum select switch to rear position. Set vibration control switch to manual (MAN) position. Set multimeter to measure VDC. Touch positive (+) probe of multimeter to terminal 1 (wire C926-BU). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured at wire terminal 1 (wire C926-BU), press vibration on/off switch once and try again. a. If 24 to 28 VDC are measured at terminal 1 (wire C926-BU), perform the following: (1) (2) (3) b. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Connect harness connector to solenoid connector and notify supervisor.
If 24 to 28 VDC are not measured at terminal 1 (wire C926-BU) and VIBE fuse is good, perform the following: (1) (2) (3) Turn engine start switch to OFF position (TM 5-3895-379-10). Connect harness connector to solenoid connector. Close left-side door assembly (TM 5-3895-379-10) and go to next malfunction.
0058-2
TM 5-3895-379-23-1
0058
HARNESS CONNECTOR REAR DRUM SOLENOID CONNECTOR WIRE C926-BU REAR DRUM SOLENOID
TERMINAL 1
T0135SWR
Figure 1. Rear Drum Solenoid Wiring.
0058-3
TM 5-3895-379-23-1
0058
MALFUNCTION Vibration Push Switch Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. Remove vibration push switch (WP 0167). Touch positive (+) probe of multimeter to terminal. Touch negative (-) probe of multimeter to other terminal. Set multimeter to measure ohms. Press button of vibration push switch several times. a. b. If zero ohms followed by infinite ohms are not measured as button is pressed and pressed again, replace vibration push switch (WP 0167). If zero ohms followed by infinite ohms are measured as button is pressed and pressed again, go to next malfunction.
VIBRATION PUSH SWITCH WIRE 103-YL WIRE 932-YL
T0233SWR
Figure 2. Vibration Push Switch Wiring.
0058-4
TM 5-3895-379-23-1
0058
MALFUNCTION No Power To Vibration Push Switch. CORRECTIVE ACTION 1. 2. 3. 4. 5. Turn engine start switch to ON position (TM 5-3895-379-10). Touch positive (+) probe of multimeter to wire 103-YL. Touch negative (-) probe of multimeter to good ground. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). a. If 24 to 28 VDC are not measured at wire 103-YL and VIBE fuse is good, perform the following: (1) (2) b. Repair or replace wiring and connectors to VIBE fuse holder (WP 0195). Install vibration push switch (WP 0167).
If 24 to 28 VDC are measured at wire 103-YL, install vibration push switch (WP 0167) and go to next malfunction.
VIBRATION PUSH SWITCH WIRE 103-YL WIRE 932-YL
T0136SWR
Figure 3. Vibration Push Switch Wiring.
0058-5
TM 5-3895-379-23-1
0058
MALFUNCTION No Power To Drum Select Switch. CORRECTIVE ACTION 1. 2. 3. 4. 5. Remove nine screws and washers and remove panel from operator station. Turn engine start switch to ON position (TM 5-3895-379-10). Turn battery disconnect switch to ON position (TM 5-3895-379-10). Touch positive (+) probe of multimeter to terminal 5 (wire 103-YL). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured at terminal 5 (wire 103-YL) and VIBE fuse is good, perform the following: (1) (2) (3)
SCREW WASHER WIRE C926-BU TERMINAL 5 SCREW WASHER WIRE C927-PL TERMINAL 4
Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Repair or replace wiring and connectors to VIBE fuse holder (WP 0195).
PANEL ASSEMBLY WIRE 103-YL
DRUM SELECT SWITCH OPERATOR STATION
TERMINAL 6
T0137SWR
Figure 4. Drum Select Switch Wiring.
0058-6
TM 5-3895-379-23-1
0058
MALFUNCTION Drum Select Switch Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. Touch positive (+) probe of multimeter to terminal 4 (wire C926-BU). Touch negative (-) probe of multimeter to good ground. Pull drum select switch back to rear position to check rear vibratory circuit. Touch positive (+) probe of multimeter to terminal 6 (wire C927-PU). Touch negative (-) probe of multimeter to good ground Push drum select switch forward to front position to check front vibratory circuit. Touch positive (+) probe of multimeter to terminal 6 (wire C927-PU) and then to terminal 4 (wire C926-BU) while drum select switch is in center position to check vibratory circuit to both drums. a. If 24 to 28 VDC are not measured at terminal 4 (wire C926-BU) while drum select switch is pulled back to rear position, perform the following: (1) (2) (3) b. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Replace drum select switch (WP 0158).
If 24 to 28 VDC are not measured at terminal 6 (wire C927-PU) while drum select switch is pushed forward to front position, perform the following: (1) (2) (3) Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Replace drum select switch (WP 0158).
c.
If 24 to 28 VDC are measured at terminals 4 and 6 while drum select switch is in center position, perform the following: (1) (2) (3) Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Replace drum select switch (WP 0158).
d.
If all voltage output checks at drum select switch are OK, go to next malfunction.
0058-7
TM 5-3895-379-23-1
0058
MALFUNCTION No Power To Vibration Control Switch Terminal 2. CORRECTIVE ACTION 1. 2. 3. Touch positive (+) probe of multimeter to terminal 2 (wire C932-YL). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured at terminal 2 (wire C932-YL), press vibration on/off switch once and try again. If 24 to 28 VDC are not measured at terminal 2 (wire C932-YL), perform the following: (1) (2) (3) Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Repair or replace wire C932-YL and connectors (WP 0195).
PANEL ASSEMBLY SCREW WIRE C933-GN WASHER WASHER SCREW TERMINAL 3 WIRE C932-YL WIRE B934-BU TERMINAL 1 TERMINAL 2 VIBRATION CONTROL SWITCH OPERATOR STATION
T0232SWR
Figure 5. Vibration Control Switch Wiring.
0058-8
TM 5-3895-379-23-1
0058
MALFUNCTION Vibration Control Switch Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. Set vibration control switch to automatic (AUTO) position. Touch positive (+) probe of multimeter to terminal 1 (wire B934-BU). Touch negative (-) probe of multimeter to good ground. Measure VDC. Set vibration control switch to manual (MAN) position. Touch positive (+) probe of multimeter to terminal 3 (wire C933-GM). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured at terminals 1 and 3, perform the following: (1) (2) (3) Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Replace amplitude select switch (WP 0160).
T0138SWR
0058-9
TM 5-3895-379-23-1
0058
MALFUNCTION No Power To Amplitude Select Switch Terminal 2. CORRECTIVE ACTION 1. 2. 3. Touch positive (+) probe of multimeter to terminal 2 (wire C933-GN). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured at terminal 2 (wire C933-GN), press vibration on/off switch once and try again. If 24 to 28 VDC are not measured at terminals 2 (wire C933-GN), and VIBE fuse to good, perform the following: (1) (2) (3) Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Repair or replace wire C933-GN and connectors (WP 0195).
PANEL ASSEMBLY SCREW WIRE C920-GN WASHER WASHER SCREW TERMINAL 3 WIRE C933-GN WIRE B921-WH TERMINAL 1 TERMINAL 2 AMPLITUDE SELECT SWITCH OPERATOR STATION
T0139SWR
0058-10
TM 5-3895-379-23-1
0058
MALFUNCTION Amplitude Select Switch Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. 9. Set amplitude select switch to high pitch (push forward). Touch positive (+) probe of multimeter to terminal 1 (wire B921-WH). Touch negative (-) probe of multimeter to good ground. Measure VDC. Set amplitude select switch to low pitch (pull back). Touch positive (+) probe of multimeter to terminal 3 (wire B920-GN). Touch negative (-) probe of multimeter to good ground. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). a. b. If 24 to 28 VDC are not measured at both terminals 1 and 3, replace amplitude select switch (WP 0160). If 24 to 28 VDC are measured at terminals 1 and 3, repair or replace wiring and connectors from amplitude select switch (WP 0195).
T0234SWR
0058-11/12 blank
TM 5-3895-379-23-1
0059
FIELD MAINTENANCE VIBRATION FREQUENCY START-UP IS SLOW, TIME LAG AFTER TRAVEL STARTS IS EXCESSIVE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References Volume 2, WP 0250 References (cont.) Volume 2, WP 0251 Volume 2, WP 0254 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
TROUBLESHOOTING PROCEDURE SYMPTOM VIBRATION FREQUENCY START-UP IS SLOW, TIME LAG AFTER TRAVEL STARTS IS EXCESSIVE MALFUNCTION Vibration Control Solenoid or Vibration Cooling Control Valve Faulty. CORRECTIVE ACTION Perform hydraulic vibratory test and adjustment (Volume 2, WP 0250). If fault is not corrected, perform the following as needed: (1) (2) END OF WORK PACKAGE Replace vibratory control solenoid assembly (Volume 2, WP 0251). Replace vibratory cooling/control valve (Volume 2, WP 0254).
0059-1/2 blank
TM 5-3895-379-23-1
0060
FIELD MAINTENANCE VIBRATION OCCURS IN ONLY ONE DRUM
0060-1
TM 5-3895-379-23-1
0060
TROUBLESHOOTING PROCEDURE SYMPTOM VIBRATION OCCURS IN ONLY ONE DRUM MALFUNCTION No Power To Front or Rear Drum Solenoid. CORRECTIVE ACTION
WARNING
Remove all jewelry such as rings, dog tags and bracelets. If jewelry contacts electrical connection a direct short may occur resulting in injury or death, and damage to equipment. Ensure that parking brake is engaged and propel control lever is in neutral position before turning engine start switch to ON position. If roller accidentally starts or rolls, injury or death to personnel may occur. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Open left-side door assembly (TM 5-3895-379-10). If rear drum does not vibrate, disconnect harness connector from rear drum solenoid connector. If front drum does not vibrate, disconnect harness connector from front drum solenoid connector. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Set multimeter to measure VDC. Touch positive (+) probe of multimeter to terminal 1 (wire C923-BU for rear drum or C927-PU for front drum). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured at terminal 1 (wire C923-BU for rear drum or C927-PU for front drum), press vibration on/off switch once and try again. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). a. b. If 24 to 28 VDC are measured at terminal 1 (wire C923-BU for rear drum or C927-PU for front drum), connect harness connector to solenoid connector and notify supervisor. If 24 to 28 VDC are not measured at terminal 1 (wire C923-BU for rear drum or C927-PU for front drum) and VIBE fuse is good, connect harness connector to solenoid connector and go to next malfunction.
0060-2
TM 5-3895-379-23-1
0060

WIRE C927-PU HARNESS CONNECTORS WIRE C923-BU
FRONT DRUM SOLENOID
REAR DRUM SOLENOID
T0150SWR
Figure 1. Drum Solenoid Wiring.
0060-3
TM 5-3895-379-23-1
0060
MALFUNCTION No Power To Drum Select Switch Terminal 5. CORRECTIVE ACTION 1. 2. 3. 4. 5. Remove nine screws and washers and remove panel from operator station. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Touch positive (+) probe of multimeter to terminal 5 (wire 103-YL). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured at terminal 5 (wire 103-YL) and VIBE fuse is good, perform the following: (1) (2) (3)
Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Repair or replace wiring and connectors to VIBE fuse holder (WP 0195).
TERMINAL 6
T0151SWR
Figure 2. Drum Select Switch Wiring.
0060-4
TM 5-3895-379-23-1
0060
MALFUNCTION Drum Select Switch Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. Touch positive (+) probe of multimeter to terminal 4 (wire C926-BU). Touch negative (-) probe of multimeter to good ground. Pull drum select switch back to rear position to check rear vibratory circuit. Touch positive (+) probe of multimeter to terminal 6 (wire C927-PU). Touch negative (-) probe of multimeter to good ground. Push drum select switch forward to front position to check front vibratory circuit. Touch positive (+) probe of multimeter to terminal 6 (wire C927-PU), then to terminal 4 (wire C926 - BU) while drum select switch is in center position to check vibratory circuit to both drums. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). a. b. c. d.
8. 9.
If 24 to 28 VDC are not measured at terminal 4 (wire C926-BU) while drum select switch is pulled back to rear position, replace drum select switch (WP 0158). If 24 to 28 VDC are not measured at terminal 6 (wire C927-PU) while drum select switch is pushed forward to front position, replace drum select switch (WP 0158). If 24 to 28 VDC are measured at terminal 4 and 6 while drum select switch is in center position, replace drum select switch (WP 0158). If all voltage output checks at drum select switch are OK, notify supervisor.
TERMINAL 6
T0205SWR
Figure 3. Drum Select Switch Wiring. END OF WORK PACKAGE
0060-5/6 blank
TM 5-3895-379-23-1
0061
FIELD MAINTENANCE VIBRATION ONLY OCCURS WHILE VIBRATION CONTROL SWITCH IS SET TO AUTOMATIC MODE
0061-1
TM 5-3895-379-23-1
0061
TROUBLESHOOTING PROCEDURE SYMPTOM VIBRATION ONLY OCCURS WHILE VIBRATION CONTROL SWITCH IS SET TO AUTOMATIC MODE MALFUNCTION Propel Control Lever Engagement Stops Out Of Adjustment. CORRECTIVE ACTION Adjust propel control lever vibratory system engagement stops (WP 0207). If vibration still does not occur, go to next malfunction. MALFUNCTION No Power To Vibration Control Switch Terminal 2. CORRECTIVE ACTION
WARNING
Remove all jewelry such as rings, dog tags and bracelets. If jewelry contacts electrical connection a direct short may occur resulting in injury or death, and damage to equipment. Ensure that parking brake is engaged and propel control lever is in neutral position before turning engine start switch to ON position. If roller accidentally starts or rolls, injury or death to personnel may occur. 1. 2. 3. 4. 5. 6. 7. Remove nine screws and washers and remove panel from operator station. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Set multimeter to measure VDC. Touch positive (+) probe of multimeter to terminal 2 (wire C932-YL). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured at terminal 2 (wire C932-YL), press vibration on/off switch once and try again. If 24 to 28 VDC are still not measured at terminal 2 (wire C932-YL), perform the following: (1) (2) (3) Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Repair or replace wire C932-YL and connectors (WP 0195).
0061-2
TM 5-3895-379-23-1
0061
T0142SWR
0061-3
TM 5-3895-379-23-1
0061
MALFUNCTION Vibration Control Switch Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. Set vibration control switch to automatic (AUTO) position. Touch positive (+) probe of multimeter to terminal 1 (wire B934-BU). Touch negative (-) probe of multimeter to good ground. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). a. b. If 24 to 28 VDC are not measured at terminal 2 (wire B934-BU), replace vibration control switch (WP 0159). If 24 to 28 VDC are measured at terminal 1 (wire B934-BU), notify supervisor.
T0143SWR
Figure 2. Vibration Control Switch Wiring. END OF WORK PACKAGE
0061-4
TM 5-3895-379-23-1
0062
FIELD MAINTENANCE VIBRATION ONLY OCCURS WHILE VIBRATION CONTROL SWITCH IS SET TO MANUAL MODE
0062-1
TM 5-3895-379-23-1
0062
TROUBLESHOOTING PROCEDURE SYMPTOM VIBRATION ONLY OCCURS WHILE VIBRATION CONTROL SWITCH IS SET TO MANUAL MODE MALFUNCTION No Power To Vibration Control Switch Terminal 2. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. Remove nine screws and washers and remove panel from operator station. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Set multimeter to measure VDC. Touch positive (+) probe of multimeter to terminal 2 (wire C932-YL). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured at terminal 2 (wire C932-YL), press vibration on/off switch once and try again. If 24 to 28 VDC are not measured at terminal 2 (wire C932-YL), perform the following: (1) (2) (3) Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Repair or replace wire C932-YL and connectors (WP 0195).
T0140SWR
0062-2
TM 5-3895-379-23-1
0062
MALFUNCTION Vibration Control Switch Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. Set vibration control switch to automatic (AUTO) position. Touch positive (+) probe of multimeter to terminal 1 (wire B934-BU). Touch negative (-) probe of multimeter to good ground. Measure VDC. Set vibration control switch to manual (MAN) position. Touch positive (+) probe of multimeter to terminal 3 (wire C933-GN). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured at terminal 1 (wire B934-BU), perform the following: (1) (2) (3) Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Replace vibration control switch (WP 0159).
T0238SWR
0062-3
TM 5-3895-379-23-1
0062
MALFUNCTION No Power To Amplitude Select Switch Terminal 2. CORRECTIVE ACTION 1. 2. Touch positive (+) probe of multimeter to terminal 2 (wire C933-GN). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured at terminal 2 (wire C933-GN), perform the following: (1) (2) (3) Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Repair or replace wire C933-GN and connectors (WP 0195).
T0141SWR
0062-4
TM 5-3895-379-23-1
0062
MALFUNCTION Amplitude Select Switch or Wires 920 or 921 Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. 9. Set amplitude select switch to high pitch (push forward). Touch positive (+) probe of multimeter to terminal 1 (wire B921-WH). Touch negative (-) probe of multimeter to good ground. Measure VDC. Set amplitude select switch to low pitch (pull back). Touch positive (+) probe of multimeter to terminal 3 (wire C920-GN). Touch negative (-) probe of multimeter to good ground. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). a. b. If 24 to 28 VDC are not measured at terminals 1 and 3, replace amplitude select switch (WP 0160). If 24 to 28 VDC are measured at terminals 1 and 3, repair or replace wiring and connectors from amplitude select switch (WP 0195).
T0203SWR
0062-5/6 blank
TM 5-3895-379-23-1
0063
FIELD MAINTENANCE VIBRATION STOPS TOO SOON BEFORE TRAVEL STOPS
TROUBLESHOOTING PROCEDURE SYMPTOM VIBRATION STOPS TOO SOON BEFORE TRAVEL STOPS MALFUNCTION Propel Control Lever Engagement Stops Out Of Adjustment. CORRECTIVE ACTION Adjust propel control lever engagement stop (WP 0207). If symptom persists, replace propel control lever assembly (WP 0206). END OF WORK PACKAGE
0063-1/2 blank
TM 5-3895-379-23-1
0064
FIELD MAINTENANCE VIBRATORY SYSTEM ENGAGES HARSHLY
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References Volume 2, WP 0250 Volume 2, WP 0251 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
TROUBLESHOOTING PROCEDURE SYMPTOM VIBRATORY SYSTEM ENGAGES HARSHLY MALFUNCTION Hydraulic Vibrator Control Faulty. CORRECTIVE ACTION Perform hydraulic vibrator test and adjustment (Volume 2, WP 0250). If fault is not corrected, replace vibratory control solenoid assembly (Volume 2, WP 0251). END OF WORK PACKAGE
0064-1/2 blank
TM 5-3895-379-23-1
0065
FIELD MAINTENANCE NO SPRAY AT EITHER DRUM WHEN WATER SPRAY SWITCH IS IN INTERMITTENT SPRAY POSITION
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References WP 0155 References (cont.) WP 0157 WP 0163 WP 0195 Volume 2, WP 0270 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0065-1
TM 5-3895-379-23-1
0065
TROUBLESHOOTING PROCEDURE SYMPTOM NO SPRAY AT EITHER DRUM WHEN WATER SPRAY SWITCH IS IN INTERMITTENT SPRAY POSITION MALFUNCTION No Power At Water Spray Switch Terminal 2. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. Remove nine screws and washers and remove panel from operator station. Move water spray switch into intermittent spray (forward) position. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Touch positive (+) probe of multimeter to terminal 2 (wire 110-GN). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured at terminal 2 and WATER SPRAY fuse is good, perform the following: (1) (2) (3)
SCREW WASHER SCREW
Turn engine start switch to OFF position (TM 5-3895-379-10). Turn engine start switch to OFF position (TM 5-3895-379-10). Repair or replace wiring and connectors to WATER SPRAY fuse holder (WP 0195).
PANEL ASSEMBLY WIRE 936-GY TERMINAL 4 TERMINAL 1 TERMINAL 2 WATER SPRAY SWITCH WIRE 110-CB WIRE C935-PU
WASHER
OPERATOR STATION
T0235SWR
Figure 1. Water Spray Switch Wiring.
0065-2
TM 5-3895-379-23-1
0065
MALFUNCTION Water Spray Switch Faulty. CORRECTIVE ACTION 1. 2. 3. 4. To check front water spray pump, touch positive (+) probe of multimeter to terminal 1 (wire C935 - PU). Touch negative (-) probe of multimeter to operator station. To check rear water spray pump, touch positive (+) probe of multimeter to terminal 4 (wire C936 - GY). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured at terminals 1 and 4, perform the following: (1) (2) (3)
SCREW WASHER SCREW
Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Replace water spray switch (WP 0157).
PANEL ASSEMBLY WIRE 936-GY TERMINAL 4 TERMINAL 1 TERMINAL 2 WATER SPRAY SWITCH WIRE 110-CB WIRE C935-PU
WASHER
OPERATOR STATION
T0154SWR
0065-3
TM 5-3895-379-23-1
0065
MALFUNCTION Intermittent Water Spray Timer Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. Remove wire C937-WH from terminal 1 and wire 200-BK from terminal 2 of intermittent water spray timer. Set multimeter to measure ohms. Touch positive (+) probe of multimeter to terminal 1. Touch negative (-) probe of multimeter to good ground. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). a. b. If cycles of 15 seconds of zero ohms followed by 15 seconds of infinite ohms are not found, replace intermittent water spray timer (WP 0163). If cycles of 15 seconds of zero ohms followed by 15 seconds of infinite ohms are found, install wire C937-WH on terminal 1 and wire 200-BK on terminal 2 and go to next malfunction.
WIRE C936-GY WIRE 200-BK WIRE C937-WH
TERMINAL 1 TERMINAL 3 TERMINAL 2 VIEW FROM DRIVERS SEAT TIMER
T0155SWR
Figure 3. Intermittent Water Spray Timer Wiring.
0065-4
TM 5-3895-379-23-1
0065
MALFUNCTION Front or Rear Intermittent Relay Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. Remove harness connector from front or rear intermittent relay. Remove both connectors if water spray system on both drums is malfunctioning. Attach a jumper wire from terminal 1 to terminal 4. Move water spray switch into intermittent spray (forward) position. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). a. If water spray system operates at drum, perform the following: (1) (2) (3) b. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Replace relay (WP 0155).
If water spray does not operate at drum, connect relay connectors and install panel on operator station with nine screws and washers. Go to next malfunction.
SCREW WASHER
PANEL ASSEMBLY WASHER SCREW
2 3
5 HARNESS CONNECTOR RELAY
FRONT INTERMITTENT RELAY
REAR INTERMITTENT RELAY
OPERATOR STATION
T0156SWR
Figure 4. Front And Rear Intermittent Relay Wiring.
0065-5
TM 5-3895-379-23-1
0065
MALFUNCTION No Power To Front and Rear Water Spray Pumps Connectors. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. Remove four screws, washers, and cover from each bumper assembly. Disconnect pump connector from harness connector. To check front water spray pump connector, touch positive (+) probe of multimeter to harness connector, pin 1 (wire C922-BR). Touch negative (-) probe of multimeter to good ground. To check rear water spray pump connector, touch positive (+) probe of multimeter to harness connector, pin 1 (wire C923-OR). Touch negative (-) probe of multimeter to good ground. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). a. b. If 24 to 28 VDC are not measured at water spray pump connectors, replace water spray pump (Volume 2, WP 0270). If 24 to 28 VDC are not measured at water spray pump connectors, repair or replace wiring and connectors from water spray switch to water spray pumps (WP 0195).
HARNESS CONNECTOR TERMINAL 2
WIRE 200-BK
TERMINAL 1 WIRE C922-BR (FRONT) WIRE C923-OR (REAR) COVER WASHER SCREW
T0157SWR
PUMP CONNECTOR
FRONT SHOWN, REAR SIMILAR
Figure 5. Water Spray Pump Connector Wiring. END OF WORK PACKAGE
0065-6
TM 5-3895-379-23-1
0066
FIELD MAINTENANCE NOZZLE SPRAY PATTERN IS INCONSISTENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References Volume 2, WP 0267 Volume 2, WP 0274 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
TROUBLESHOOTING PROCEDURE SYMPTOM NOZZLE SPRAY PATTERN IS INCONSISTENT MALFUNCTION Water Spray Pipe Damaged. CORRECTIVE ACTION Clean and inspect water spray pipe assembly (Volume 2, WP 0267). If water spray pipe assembly is damaged, replace pipe assembly (Volume 2, WP 0267). MALFUNCTION Water Spray Check Valves Plugged. CORRECTIVE ACTION Clean and inspect water spray check valves (Volume 2, WP 0274). a. b. If water spray check valve is damaged, replace valve (Volume 2, WP 0274). If water spray check valve is not damaged, repeat Malfunction: Water spray pipe damaged.
END OF WORK PACKAGE
0066-1/2 blank
TM 5-3895-379-23-1
0067
FIELD MAINTENANCE SPRAY DOES NOT OCCUR IN EITHER DRUM WHEN WATER SPRAY SWITCH IS IN CONTINUOUS SPRAY POSITION
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References WP 0157 References (cont.) WP 0195 Volume 2, WP 0270 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0067-1
TM 5-3895-379-23-1
0067
TROUBLESHOOTING PROCEDURE SYMPTOM SPRAY DOES NOT OCCUR IN EITHER DRUM WHEN WATER SPRAY SWITCH IS IN CONTINUOUS SPRAY POSITION MALFUNCTION No Power To Water Spray Switch. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. Remove nine screws and washers and remove panel from operator station. Move water spray switch into continuous spray (full back) position. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Touch positive (+) probe of multimeter to terminal 2 (wire 110-GN). Touch negative (-) probe of multimeter to good ground. If 24 to 28 VDC are not measured at terminal 2 (wire 110-GN) and WATER SPRAY fuse is good, perform the following: (1) (2) (3)
SCREW WASHER WIRE C923-OR TERMINAL 2 SCREW WASHER TERMINAL 6 TERMINAL 3 WATER SPRAY SWITCH OPERATOR STATION WIRE C922-BR WIRE 110-GN
T0152SWR
Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Repair or replace wiring and connectors to water spray fuse holder (WP 0195).
PANEL ASSEMBLY
0067-2
TM 5-3895-379-23-1
0067
MALFUNCTION Water Spray Switch Faulty. CORRECTIVE ACTION 1. 2. 3. 4. Touch positive (+) probe of multimeter to terminal 3 (wire C922-BR). Touch negative (-) probe of multimeter to good ground. Touch positive (+) probe of multimeter to terminal 6 (wire C923-OR). Touch negative (-) probe of multimeter to good ground. a. If 24 to 28 VDC are not measured at terminals 3 and 6, perform the following: (1) (2) (3) b. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Replace water spray switch (WP 0157).
If 24 to 28 VDC are measured at terminals 3 and 6, install panel on operator station with nine screws and washers and go to next malfunction.
PANEL ASSEMBLY WIRE C923-OR TERMINAL 2 SCREW
SCREW WASHER
WASHER TERMINAL 6 TERMINAL 3 WATER SPRAY SWITCH OPERATOR STATION WIRE C922-BR WIRE 110-GN
T0222SWR
0067-3
TM 5-3895-379-23-1
0067
MALFUNCTION No Power To Water Spray Pump Connectors. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. Remove four screws, washers, and cover from each bumper assembly. Disconnect connector from harness connector. To check front water spray pump connector, touch positive (+) probe of multimeter to harness connector pin 1 (wire C922-BR). Touch negative (-) probe of multimeter to frame. To check rear water spray pump connector, touch positive (+) probe of multimeter to harness connector pin 1 (wire C923-OR). Touch negative (-) probe of multimeter to good ground. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). a. b. If 24 to 28 VDC are measured at water spray pump connectors, replace water spray pumps (Volume 2, WP 0270). If 24 to 28 VDC are not measured at water spray pump connectors, repair or replace wiring and connectors from water spray switch to water spray pumps (WP 0195).
WIRE 200-BK
TERMINAL 1 WIRE C922-BR (FRONT) WIRE C923-OR (REAR) COVER WASHER FRONT SHOWN, REAR SIMILAR SCREW
T0153SWR
PUMP CONNECTOR
Figure 3. Water Spray Pump Connector Wiring. END OF WORK PACKAGE
0067-4
TM 5-3895-379-23-1
0068
FIELD MAINTENANCE WATER CONSUMPTION UNEQUAL BETWEEN TANKS
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References WP 0067 Volume 2, WP 0267 References (cont.) Volume 2, WP 0270 Volume 2, WP 0272 Volume 2, WP 0273 Volume 2, WP 0274 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
TROUBLESHOOTING PROCEDURE SYMPTOM WATER CONSUMPTION UNEQUAL BETWEEN TANKS MALFUNCTION Water Spray Strainer Plugged. CORRECTIVE ACTION Clean and inspect water spray strainer assembly of tank which is fullest (Volume 2, WP 0272). If water spray strainer assembly or components are damaged, replace water spray assembly or components (Volume 2, WP 0272). MALFUNCTION Water Spray Check Valve Plugged. CORRECTIVE ACTION Clean and inspect water spray check valve (Volume 2, WP 0274). If water spray check valve is damaged, replace valve (Volume 2, WP 0274).
0068-1
TM 5-3895-379-23-1
0068
MALFUNCTION Water Spray Water Lines Pinched or Damaged. CORRECTIVE ACTION Check for pinched or damaged water lines. If water line(s) is pinched or damaged, replace water line(s) (Volume 2, WP 0273).
WATER LINES
T0161SWR
Figure 1. Water Spray System Water Lines. MALFUNCTION Water Spray Pump Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove four screws, washers, and cover from each bumper assembly. Loosen two hose clamps and disconnect input and output water lines from water spray pump. Attach a line from input side of pump to a 5 gal bucket full of clean water. Attach a line from output side of pump to a pressure gauge and plug cock. Open plug cock. Move water spray switch into continuous spray (full back) position. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Close plug cock slowly until pressure gauge reads 20 psi.
0068-2
TM 5-3895-379-23-1
0068
NOTE
Pump should discharge 1.5 gal in 60 seconds at 20 psi. 10. 11. 12. 13. 14. 15. Place an empty 5 gal bucket under plug cock for 60 seconds. Remove bucket from stream of water. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Measure amount of water collected in bucket. Remove plug cock, pressure gauge, and line. a. b. If 1 gal or less or water is collected, replace water spray pump (Volume 2, WP 0270). If 1.0 to 1.5 gal of water is collected, perform the following: (1) (2) (3) Install input and output water lines on water spray pump with two hose clamps. Install cover on bumper assembly with four washers and screws. Clean and inspect spray pipe assembly (Volume 2, WP 0267).
PRESSURE GAUGE
COVER
WATER SPRAY PUMP
PLUG COCK WASHER SCREW
OUTPUT
TO FULL BUCKET
T0162SWR
Figure 2. Water Spray Pump Test. END OF WORK PACKAGE
0068-3/4 blank
TM 5-3895-379-23-1
0069
FIELD MAINTENANCE WATER SPRAY OCCURS ON ONE DRUM ONLY
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References WP 0067 References (cont.) Volume 2, WP 0270 Volume 2, WP 0273 Volume 2, WP 0274 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0069-1
TM 5-3895-379-23-1
0069
TROUBLESHOOTING PROCEDURE SYMPTOM WATER SPRAY OCCURS ON ONE DRUM ONLY MALFUNCTION No Power At Nonfunctioning Water Spray Pump. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Remove four screws, washers, and cover from each bumper assembly. Move water spray switch into continuous spray (full back) position. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Disconnect pump connector from harness connector. To check front water spray pump connector, touch positive (+) probe of multimeter to harness connector, pin 1 (wire C922-BR). Touch negative (-) probe of multimeter to good ground. To check rear water spray pump connector, touch positive (+) probe of multimeter to pump connector, pin 1 (wire C923-OR). Touch negative (-) probe of multimeter to good ground. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). a. b. If 24 to 28 VDC are measured at water spray pump connectors, replace water spray pumps (Volume 2, WP 0270). If 24 to 28 VDC are not measured at water spray pump connectors, perform the following: (1) (2) Connect pump connector to harness connector. Install cover on bumper assembly with four washers and screws, and go to next malfunction.
0069-2
TM 5-3895-379-23-1
0069
WIRE 200-BK
TERMINAL 1 WIRE C922-BR (FRONT) WIRE C923-OR (REAR) COVER WASHER SCREW
T0158SWR
PUMP CONNECTOR
FRONT SHOWN, REAR SIMILAR
Figure 1. Water Spray Pump Connector Wiring. MALFUNCTION Water Spray Check Valve Plugged. CORRECTIVE ACTION Clean and inspect water spray check valve (Volume 2, WP 0274). a. b. If water spray check valve is damaged, replace valve (Volume 2, WP 0274). If water spray check valve is not damaged, go to next malfunction.
0069-3
TM 5-3895-379-23-1
0069
MALFUNCTION Water Spray Water Lines Pinched or Damaged. CORRECTIVE ACTION Check for pinched or damaged water lines. a. b. If water line(s) is pinched or damaged, replace water line(s) (Volume 2, WP 0273). If water line(s) is not pinched or damaged, go to Symptom: SPRAY DOES NOT OCCUR IN EITHER DRUM WHEN WATER SPRAY SWITCH IS IN CONTINUOUS SPRAY POSITION (WP 0067).
WATER LINES
T0159SWR
Figure 2. Water Spray System Waterlines. END OF WORK PACKAGE
0069-4
TM 5-3895-379-23-1
0070
FIELD MAINTENANCE WATER SPRAY PRESSURE IS LOW
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References Volume 2, WP 0267 References (cont.) Volume 2, WP 0270 Volume 2, WP 0273 Volume 2, WP 0274 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
TROUBLESHOOTING PROCEDURE SYMPTOM WATER SPRAY PRESSURE IS LOW MALFUNCTION Water Spray Check Valve Plugged. CORRECTIVE ACTION Clean and inspect water spray check valves (Volume 2, WP 0274). If water spray check valve is damaged, replace valve (Volume 2, WP 0274).
0070-1
TM 5-3895-379-23-1
0070
MALFUNCTION Water Spray Water Lines Pinched or Damaged. CORRECTIVE ACTION Check for pinched or damaged water lines. If water line(s) is pinched or damaged, replace water line(s) (Volume 2, WP 0273).
WATER LINES
T0166SWR
Figure 1. Water Spray System Water Lines. MALFUNCTION Water Spray Pump Faulty. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove four screws, washers, and cover from each bumper assembly. Loosen two hose clamps and disconnect input and output water lines from water spray pump. Attach a line from input side of pump to a 5 gal bucket full of clean water. Attach a line from output side of pump to a pressure gauge and plug cock. Open plug cock. Move water spray switch into continuous spray (full back) position. Turn battery disconnect switch to ON position (TM 5-3895-379-10). Turn engine start switch to ON position (TM 5-3895-379-10). Close plug cock slowly until pressure gauge reads 20 psi.
0070-2
TM 5-3895-379-23-1
0070
NOTE
Pump should discharge 1.5 gal in 60 seconds at 20 psi. 10. 11. 12. 13. 14. 15. Place an empty 5 gal bucket under plug cock for 60 seconds. Remove bucket from stream of water. Turn engine start switch to OFF position (TM 5-3895-379-10). Turn battery disconnect switch to OFF position (TM 5-3895-379-10). Measure amount of water collected in bucket. Remove plug cock, pressure gauge, and line. a. b. If 1 gal or less or water is collected, replace water spray pump (Volume 2, WP 0270). If 1.0 to 1.5 gal of water is collected, perform the following: (1) (2) (3) Install input and output water lines on water spray pump with two hose clamps. Install cover on bumper assembly with four washers and screws. Clean and inspect spray pipe assembly (Volume 2, WP 0267).
WATER SPRAY PUMP COVER INPUT PRESSURE GAUGE
PLUG COCK WASHER OUTPUT SCREW TO FULL BUCKET TO EMPTY BUCKET

T0160SWR
Figure 2. Water Spray Pump Test. END OF WORK PACKAGE
0070-3/4 blank
TM 5-3895-379-23-1
CHAPTER 3 PREVENTIVE MAINTENANCE INSTRUCTIONS FOR CB534B or CB534C ROLLER, MOTORIZED, VIBRATING TANDEM STEEL DRUMS NSN 3895-01-396-2822 AND 3895-01-502-4005
TM 5-3895-379-23-1
0071
FIELD MAINTENANCE PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
GENERAL To ensure that the CB534B and CB534C Rollers, Motorized, Vibrating Tandem Steel Drums are ready for operation at all times, they must be lubricated and inspected on a regular basis so that defects may be found before they result in damage, equipment failure, or injury. PMCS task contains systematic instructions on lubrications, inspections, adjustments, and corrections to be performed by Field Maintenance to keep the CB534B and CB534C in good operating condition and ready for their primary mission. For information on Corrosion Prevention and Control (CPC), refer to (WP 0001). EXPLANATION OF TABLE ENTRIES Item Number (Item No.) Column. Numbers in this column are for reference. When completing DA Form 2404 or DA Form 5988-E (Equipment Inspection and Maintenance Worksheet), include the item number for the check/service indicating a fault. Item numbers also appear in the order you must perform checks and services for the interval listed. Interval Column. This column tells you when you must perform the procedure in the procedure column. Intervals are based on calendar dates or hours.
NOTE
Operating hours information is sometimes given in addition to calendar intervals, perform these procedures at the interval reached first. Quarterly procedures must be performed once every three months. Semiannual procedures must be performed once every six months. Annual procedures must be performed once each year. Biennial procedures must be performed once every two years.
Man-Hours Column. This column indicates man-hours required to complete prescribed lubrication service. Item to Check/Service Column. This column identifies the item to be checked or serviced.
NOTE
The WARNINGs and CAUTIONs appearing in your PMCS table should always be observed. WARNINGs and CAUTIONs appear before applicable procedures. These WARNINGs and CAUTIONs must be observed to prevent injury to yourself and others or to prevent your equipment from being damaged. Procedure Column. This column gives the procedure you must perform to check or service the item listed in the Item to Check/Service column, to know if the equipment is ready or available for its intended mission or for operation. You must perform the procedures at the time stated in the interval column. GENERAL PMCS PROCEDURES Always perform PMCS in the same order so it gets to be a habit. Once you've had some practice, you'll spot anything wrong in a hurry. If any deficiency is discovered, perform the appropriate troubleshooting task in Chapter 2 of this manual. If any component or system is not serviceable, or if the given service does not correct the deficiency, notify your supervisor.
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GENERAL PMCS PROCEDURES - Continued Before performing preventive maintenance, read all the checks required for the applicable interval and prepare all tools needed to make all checks. Have several clean rags (Volume 2, WP 0288, Table 1, Item 60) handy. Perform ALL inspections at the applicable interval. Keep It Clean. Dirt, grease, oil, and debris get in the way and may cover up a serious problem. Clean as you work and as needed. Use detergent (Volume 2, WP 0288, Table 1, Item 17) and water when you clean. Rust and Corrosion. Check metal parts for rust and corrosion. If any bare metal or corrosion exists, clean and apply a light coat of lubricating oil (Volume 2, WP 0288, Table 1, Item 51, 52, 53). Report it to your supervisor. Bolts, Nuts, and Screws. Check bolts, nuts, and screws for obvious looseness, missing, bent, or broken condition. You can't try them all with a tool, but look for chipped paint, bare metal, or rust around bolt heads. If you find one you think is loose, tighten it. Welds. Look for loose or chipped paint, rust, or gaps where parts are welded together. If you find a bad weld, report it to your supervisor. Electric Wires and Connectors. Look for cracked or broken insulation, bare wires, and loose or broken connectors. Tighten loose connectors and ensure that the wires are in good condition. Hydraulic Hoses and Lines. Look for wear, damage, and signs of leaks. Ensure that clamps and fittings are tight. Wet spots indicate leaks, but a stain around a fitting or connector can also mean a leak. If a leak come from a loose fitting or connector, tighten it. If something is broken or worn out, correct if it authorized by the Maintenance Allocation Chart (Volume 2, WP 0287). If not authorized, notify your supervisor. FLUID LEAKAGE It is necessary for you to know how fluid leakage affects the status of the roller. Following are types/classes of leakage you need to know to be able to determine the status of the roller. Learn these leakage definitions and remember when in doubt, notify your supervisor. Equipment operation is allowed with minor leakage (Class I or II). Consideration must be given to fluid capacity in the item/system being checked/inspected. When in doubt, notify your supervisor. When operating with Class I or II leaks, continue to check fluid levels as required in the PMCS. Class III leaks should be reported immediately to your supervisor. Table 1. Leakage Definitions for PMCS. Class I Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops. Leakage of fluid great enough to form drops, but not enough to cause drops to drip from item being checked/ inspected. Leakage of fluid great enough to form drops that fall from item being checked/inspected.
Class II
Class III
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LUBRICATION ORDER Table 2. -Key-.
LOCATION
TEMPERATURE RANGE
LUBRICANT MIL SYMBOL (NATO CODE) SPECIFICIATION GAA M-10924 MIL-G-23827 EO SAE 30 MIL-PRF-2104
CAPACITY
INTERVAL
Operator station Above -25F (-32C) swivel, rotate lock, lubrication bearing and steering cylinder bearings Door assembly hinges and latches, toolbox hinges, operator platform hinges, radiator access door hinges Above -25F (-32C)
As required
As required
Front propel gear box Above -25F (-32C)
GO 75W MIL-PRF-2105 GO 80W/90 MIL-PRF-2105 GO 75W MIL-PRF-2105 GO 80W/90 MIL-PRF-2105 Synthetic Oil 4C6767
.8 gal (3.2 Liters)
After first 250 H or Q, then 1000 H or A
Above 0F (-18C)
Rear propel gear box Above -25F (-32C) to 0F (-18C) Above 0F (-18C)
.8 gal (3.2 Liters)
After first 250 H or Q, then 1000 H or A
Front and rear vibratory bearing reservoirs Hydraulic oil tank
Above -4F (-20C)
3.2 gal (12 Liters)
3000 H or 3 y BARS
Above 0F (-18C)
HYDO SAE 10W MIL-PRF-2104 EO OEA-30 MIL-L-46167 or MIL-PRF-46167 EO 15W 40 MIL-PRF-2104 EO SAE 10W MIL-PRF-2104 EO Sub-zero MIL-L-46167
-25F (-32C) to 0F (-18C)
15.5 gal (59 Liters) (CB534B) 14 gal (53 Liters) (CB534C)
A*
Engine crankcase
Above 32F (0C)
2.3 gal (9 Liters)
250 H** or Q
0F (-18C) to 32F (0C) -25F (-32C) to 0F (-18C)
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LUBRICATION ORDER - Continued Table 2. -Key- - Continued.
LOCATION
TEMPERATURE RANGE
LUBRICANT MIL SYMBOL (NATO CODE) SPECIFICIATION
CAPACITY
INTERVAL
*During warranty period, hydraulic oil and filter shall be changed at 1,000 hour intervals. After expiration of warranty, AOAP will be in effect for all active and reserve Army Fields and National Guard activities. AOAP hydraulic sampling will be taken annually.
**During warranty period, engine oil and filter shall be changed at 250 hour intervals. After expiration of warranty, AOAP will be in effect for all active and reserve Army Fields and National Guard activities. AOAP engine oil sampling will be taken at 250 hour intervals or quarterly, whichever comes first, for all active Army Fields. All reserve Army Fields and National Guard activities will take AOAP engine oil sampling at 500 hour intervals or semiannually, whichever comes first.
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LUBRICATION ORDER - Continued

LUBRICATION CHART Toolbox Hinge (See View A) Operator Station (2 Fittings) Under Platform (See View B) Operator Platform Hinges (See View C)
EO
GAA
EO
Radiator Access Door Hinge and Lever (See View M)
Hydraulic Oil Tank HYDO (See View D) EO Left Side Door Assembly Hinge (See View E) Left Side Door Assembly Latch (See View F)
Rotate Lock (See View L)
EO GAA EO
Front Vibratory Bearing Reservoir (See View K) Rear Vibratory Bearing Reservoir (See View K)
SO
GO
Front Propel Gearbox (See View H & J)
GAA
Left Steering Cylinder Bushings (2 Fittings) (See View G)
SO
GAA
Right Steering Cylinder Bushings (2 Fittings) (See View G)
EO
Engine Oil Filter (See View N)
Symbol
Frequency 250 H or Q
Method of Application Hand Oil Can
Right Side Door Assembly Latch (See View F)
EO
GAA
Articulation Bearing (Fittings) (See View O) Right Side Door Assembly Hinge (See View E)
1,000 H or A
Grease Gun
Rear Propel Gearbox (See View H & J)
GO
EO
2,000 H or A
Pump
I0022SWR
Figure 1.
Lubrication Chart.
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TOOLBOX HINGES EO HINGE LID
HASP
HINGE OPEN AND CLOSE LID AND LIFT AND DROP HASP WHILE APPLYING A FEW DROPS OF OIL TO HINGES
I0023SWR
Figure 2.
Item A.
OPERATOR STATION GAA LUBRICATE
LUBRICATE OPERATOR PLATFORM MUST BE RAISED

Figure 3. Item B.
I0024SWR
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OPERATOR PLATFORM HINGES EO OIL CAN POINTS
LEFT HINGE SHOWN RIGHT HINGE SIMILAR APPLY A FEW DROPS OF OIL AT THE TOP OF HINGES TO OIL CAN POINTS
I0025SWR
Figure 4.
Item C.
HYDRAULIC TANK HYDO ADD HYDRAULIC OIL
CHECK HYDRAULIC OIL LEVEL INSTRUCTIONS FOR DRAINING AND FILLING HYDRAULIC OIL TANK ARE FOUND IN WP 0037 00
I0026SWR
Figure 5.
Item D.
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LEFT- AND RIGHT-SIDE DOOR ASSEMBLY HINGES
EO
OIL CAN POINT
HINGE
RIGHT-SIDE DOOR ASSEMBLY SHOWN LEFT-SIDE DOOR ASSEMBLY SIMILAR APPLY A FEW DROPS OF OIL TO TOP OF HINGE WHILE OPENING AND CLOSING DOOR ASSEMBLY
I0027SWR
Figure 6.
Item E.
LEFT- AND RIGHT-SIDE DOOR ASSEMBLY LATCHES OIL CAN POINT EO
OIL CAN POINT OIL CAN POINT
RIGHT-SIDE DOOR ASSEMBLY SHOWN LEFT-SIDE DOOR ASSEMBLY SIMILAR APPLY A FEW DROPS OF OIL TO OIL CAN POINTS WHILE OPENING AND CLOSING DOOR ASSEMBLY
I0028SWR
Figure 7.
Item F.
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LEFT AND RIGHT STEERING CYLINDER BUSHINGS
GAA
LUBRICATE RIGHT-SIDE STEERING CYLINDER SHOWN LEFT-SIDE STEERING CYLINDER SIMILAR
I0029SWR
Figure 8.
Item G.
FRONT AND REAR PROPEL GEARBOXES (CB534B)
GO
CHECK LEVEL
FILL
FRONT PROPEL GEARBOX SHOWN REAR PROPEL GEARBOX SIMILAR INSTRUCTIONS FOR SERVICING FRONT AND REAR PROPEL GEARBOXES ARE FOUND IN WP 0116 00
I0030SWR
Figure 9.
Item H.
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FRONT AND REAR PROPEL GEARBOXES (CB534C)
GO CHECK LEVEL
FILL- DRAIN IS LOCATED 180 DEGREES OPPOSITE
FRONT PROPEL GEARBOX SHOWN, REAR PROPEL GEARBOX SIMILAR INSTRUCTIONS FOR SERVICING FRONT AND REAR PROPEL GEARBOXES ARE FOUND IN WP 0116 00
I0031SWR
Figure 10.
Item J.
FRONT AND REAR VIBRATORY BEARING RESERVOIRS
CHECK GO
LOCATED ON BOTH ENDS OF ROLLER
DRAIN AND FILL
INSTRUCTIONS FOR SERVICING FRONT AND REAR VIBRATORY BEARING RESERVOIRS ARE I0032SWR FOUND IN WP 0147 00
Figure 11. Item K.
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ROTATE LOCK
GAA
SHAFT BUSHING HANDLE LIFT HANDLE AND APPLY GREASE TO SHAFT OF ROTATE LOCK AT TOP OF BUSHING. RELEASE HANDLE.
I0033SWR
Figure 12.
Item L.
RADIATOR ACCESS DOOR HINGE AND LEVER
EO HINGE
ACCESS DOOR
LEVER
OIL CAN POINTS

I0034SWR
Figure 13.
Item M.
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ENGINE OIL AND FILTER CHECK OIL LEVEL EO
INSTRUCTIONS FOR ENGINE OIL SERVICES ARE FOUND IN ENGINE OIL SERVICE WORK PACKAGE I0035SWR
Figure 14.
Item N.
ARTICULATION BEARING
GO
LUBRICATE
LUBRICATE
I0036SWR
Figure 15. END OF WORK PACKAGE
Item O.
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FIELD MAINTENANCE PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (QUARTERLY)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Lubricating Oil, Engine, 15W40 Grade (Volume 2, WP 0288, Table 1, Item 29, 30, 31) Lubricating Oil, Gear, 80W-90 Grade (Volume 2, WP 0288, Table 1, Item 37, 38, 39) Personnel Required Horizontal Construction Engineer 12N Construction Equipment Repairer 91L References DA PAM 750-8 References (cont.) WP 0088 WP 0132 WP 0147 WP 0213 Volume 2, WP 0257 Equipment Condition Park roller. (TM 5-389-379-10) Drums chocked. (TM 5-389-379-10)
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Table 1. Preventive Maintenance Checks and Services (PMCS) (Quarterly) for CB534 Roller.
ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:
ITEM NO.
INTERVAL
MAN HOURS
PROCEDURE
NOTE
Review all WARNINGs, CAUTIONs, and NOTEs before performing Field PMCS on the DSWR. Unless otherwise indicated, perform all lubrication and preventive maintenance with roller parked on level ground, propel control lever in N (Neutral), parking brake applied, and engine shut down. Perform Operator PMCS prior to or in conjunction with Field Maintenance if: 1. There is a delay between daily operation of the roller and Field Maintenance PMCS. The regular operator is not assisting.
2.
Refer to DA Pam 750-8 for oil sampling requirements. Hardtime intervals for engine oil PMCS apply only during warranty period. After expiration of warranty, active and reserve Army Fields will send engine oil sample to an AOAP laboratory for analysis after 250 hours or quarterly, whichever comes first. National Guard activities will use 500 hours or semiannually, whichever comes first, as the prescribed interval. Intervals for sampling as well as draining and refilling lubricants may be changed by an AOAP laboratory.
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Table 1.
Preventive Maintenance Checks and Services (PMCS) (Quarterly) for CB534 Roller - Continued.
ITEM NO.
INTERVAL
MAN HOURS
PROCEDURE If AOAP laboratory support is not available, change engine oil and filter after 250 hours of operation. Perform quarterly tasks every three months or every 250 operating hours, whichever comes first.
1 2 3
Quarterly Quarterly Quarterly 1.5 Hours
Engine Oil Engine Oil Engine
Take engine oil sample from sampling valve Sample fails AOAP for AOAP analysis. analysis. Change oil and filter (TM 5-3895-379-10). For new roller, after three months or 250 operating hours, perform engine's first oil change, adjust low idle speed (WP 0132), and adjust valve lash (WP 0088). After operating a new roller for three months or 250 hours, change hydraulic oil filter (Volume 2, WP 0257).
Quarterly
0.5 Hours
Hydraulic Oil Filter
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Table 1.
ITEM TO BE CHECKED OR SERVICED Fan Belts EQUIPMENT NOT READY/ AVAILABLE IF: Belt is loose, missing, broken, greasy, peeling, glazed, cracked through to the belt fiber, has more than one crack (1/8 in. in depth or 50% of belt thickness), or has frays more than 2 in. long.
ITEM NO. 5
INTERVAL Quarterly
MAN HOURS
PROCEDURE Check fan V-belts for excessive wear and belt tightness. Replace or adjust accordingly. Replace belts as a set. Adjust belts as needed (WP 0147).
I0037SWR
Figure 1. Fan Belts.
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0072
Table 1.
ITEM NO.
INTERVAL
MAN HOURS
PROCEDURE
CAUTION
The drum drive gear reducer and the propel gearboxes generate a large amount of contaminants during the first three months, or 250 hours of operation. Oil sample taken from the gearboxes will generally show a high iron PPM count. This initial break-in wear is considered normal. If the initial three months or 250 hour oil change is not done, these contaminant particles will cause accelerated wear and can reduce the service life of the gearbox. Make every effort to complete the initial three month or 250 hour, and 12 month or 1000 hour gearbox oil changes to the rollers listed above. If the gearbox oil is changed before the initial quarterly or 250 hour interval, the oil should be sampled and changed again at 250 hours.
Quarterly
1.5 Hours
Front and Rear Propel Gearboxes (CB534B)
After operating a new roller for three months or 250 hours, whichever comes first, change propel gearbox oil (WP 0213).
PMCS Mandatory Replacement Parts List There are no replacement parts required for these PMCS procedures. END OF TASK END OF WORK PACKAGE
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FIELD MAINTENANCE PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (ANNUAL)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Lubricating Oil, Gear, 80W-90 Grade (Volume 2, WP 0288, Table 1, Item 37, 38, 39) Lubricating Oil MIL-L-2104 OE/, 10 Grade (Volume 2, WP 0288, Table 1, Item 51, 52, 53) Personnel Required Horizontal Construction Engineer 12N Construction Equipment Repairer 91L References DA PAM 750-8 References (cont.) WP 0118 WP 0124 WP 0135 WP 0190 WP 0192 WP 0213 Volume 2, WP 0235 Volume 2, WP 0256 Volume 2, WP 0257 Volume 2, WP 0262 Volume 2, WP 0263 Equipment Condition Park roller. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
Table 1.
Preventive Maintenance Checks and Services (PMCS) (Annual) for CB534 Roller.
ITEM NO. 1
INTERVAL Annual
MAN HOURS
PROCEDURE
Engine Air Intake Replace air cleaner primary and secondary System elements (WP 0118) every 12 months or 1,000 hours of operation, whichever comes first. 0.7 Hours Hydraulic Oil Change hydraulic oil (WP 0124) and filter (Volume 2, WP 0257) every 12 months or 1,000 hours of operation, whichever comes first. Change propel gearbox oil (WP 0213) every 12 months or 1,000 hours of operation, whichever comes first. Every 12 months or 1,000 hours of operation (whichever comes first), check for damage such as cracks or broken welds. Check attaching bolts for tightness. Ensure structural integrity: no compromising dents, holes, or bends. Cracks, broken welds, loose attaching bolts, compromising dents, holes, or bends are found.
Annual
Annual
1.5 Hours
Front and Rear Propel Gearboxes Rollover Protective Structure (ROPS)
Annual
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Table 1.
Preventive Maintenance Checks and Services (PMCS) (Annual) for CB534 Roller - Continued.
ITEM TO BE CHECKED OR SERVICED Platform EQUIPMENT NOT READY/ AVAILABLE IF: Cracks, bad welds, or missing bolts are found.
ITEM NO. 5
INTERVAL Annual
MAN HOURS
PROCEDURE Every 12 months or 1,000 hours of operation (whichever comes first), raise platform assembly (Volume 2, WP 0235). Check platform hinges for cracks, welds, and missing bolts. If rust is present, wipe away with wire brush or abrasive material and repaint.
HINGE BOLTS ROPS
PLATFORM HINGE
I0038SWR
Figure 1. 6 Annual Batteries
Platform.
Every 12 months or 1,000 hours of Worn or damaged battery operation (whichever comes first), inspect/ cables. service batteries (WP 0190). Check battery cables for wear or damage (WP 0192).
Annual
0.5 Hours
Vibratory Bearing Change vibratory bearing reservoir oil Reservoirs (Volume 2, WP 0262) every 12 months or 1,000 hours of operation, whichever comes first. Drum Scrapers Check scraper every 12 months or 1,000 Scraper is damaged or hours of operation (whichever comes first), cannot be adjusted. and replace if damaged or worn beyond adjustment (Volume 2, WP 0263). Drain and flush system Damaged or broken water spray system parts found. (TM 5-3895-379-10) every 12 months or 1,000 hours of operation, whichever comes first. Check for damaged parts. Replace or service damaged parts. Pressure test radiator (WP 0135) every 12 Radiator fails pressure test. months or 1,000 hours of operation, whichever comes first. Replace radiator cap as needed.
Annual
Annual
Water Spray System
10
Annual
Radiator
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Table 1.
Preventive Maintenance Checks and Services (PMCS) (Annual) for CB534 Roller - Continued.
ITEM TO BE CHECKED OR SERVICED Fuel Tank EQUIPMENT NOT READY/ AVAILABLE IF:
ITEM NO. 11
INTERVAL Annual
MAN HOURS
PROCEDURE Drain tank and flush out sediment (WP 0124) every 12 months or 1,000 hours of operation, whichever comes first.
12
Annual
Hydraulic Oil
NOTE
Refer to DA Pam 750-8 for sampling requirements. After expiration of warranty, active and reserve Army Fields and National Guard activities will send a hydraulic oil sample to an AOAP laboratory for analysis once a year. Intervals for sampling as well as draining and refilling lubricants may be changed by an AOAP laboratory. If AOAP laboratory support is not available, change hydraulic oil and filter (Volume 2, WP 0257) after 12 months or 1,000 hours of operation, whichever comes first.
Take hydraulic oil sample for AOAP analysis (Volume 2, WP 0256).
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0074
FIELD MAINTENANCE PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (BIENNIAL)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Antifreeze: Permanent, Ethylene Glycol, Inhibited (Volume 2, WP 0288, Table 1, Item 5, 6, 7) Lubricating Oil, Gear, 80W-90 Grade (Volume 2, WP 0288, Table 1, Item 37, 38, 39) Personnel Required Construction Equipment Repairer 91L (2) References WP 0088 References (cont.) WP 0101 WP 0139 Equipment Condition Park roller. (TM 5-389-379-10) Drums chocked. (TM 5-389-379-10)
Table 1.
Preventive Maintenance Checks and Services (PMCS) (Biennial) for CB534 Roller.
ITEM TO BE CHECKED OR SERVICED Engine Engine Crankcase Breather Tube Radiator EQUIPMENT NOT READY/ AVAILABLE IF:
ITEM NO. 1 2
INTERVAL Biennial Biennial
PROCEDURE Adjust valve lash (WP 0088) every 24 months or 1,000 operating hours, whichever comes first. Remove and clean breather tube (WP 0101) every 12 months or 2,000 operating hours, whichever comes first.
Biennial
Change coolant (WP 0139) every 24 months or 2,000 Class III leaks or operating hours, whichever comes first. Inspect for leaks excessive corrosion found. or loose hoses. Check for excessive corrosion. Every 24 months or 2,000 operating hours (whichever Damaged parts found. comes first), thoroughly clean water spray system lines, valves, drain cocks, spray bars, water tanks, screens, and nozzles. Check for damaged parts. Replace any damaged parts. 1. Check and service water spray system (TM 5-3895-379-10). 2. Check and service water spray screen (TM 5-3895-379-10). 3. Check and service water spray nozzles (TM 5-3895-379-10).
Biennial
Water Spray System
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CHAPTER 4 MAINTENANCE INSTRUCTIONS FOR CB534B or CB534C ROLLER, MOTORIZED, VIBRATING TANDEM STEEL DRUMS NSN 3895-01-396-2822 AND 3895-01-502-4005
TM 5-3895-379-23-1
0075
FIELD MAINTENANCE SERVICE UPON RECEIPT
INITIAL SETUP: Materials/Parts Cleaning Compound, Solvent (Volume 2, WP 0288, Table 1, Item 13, 14, 15) Personnel Required Construction Equipment Repairer 91L References DA PAM 750-8 DD Form 1397 References (cont.) DD Form 5986-E SF 361 SF Form 364 WP 0071 WP 0072 Equipment Condition Park roller. (TM 5-389-379-10) Drums chocked. (TM 5-389-379-10)
GENERAL 1. 2. When a used or reconditioned CB534B or CB534C Roller is first received, determine whether it has been properly prepared for service and is in condition to perform its mission. Follow the inspection and servicing instructions that follow.
END OF TASK INSPECTION INSTRUCTIONS 1. 2. Read and follow all precautions and instructions on DD Form 1397. Remove all packing and shipping material, such as tape, tie downs, protective covers, and shipping seals.
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. 3. 4. Clean any exposed metal parts coated with rust preventive compound. Use cleaning compound, solvent. Inspect the equipment for damage incurred during shipment. If the equipment has been damaged, report the damage on SF 361, Transportation Discrepancy Report. Check the equipment against the packing slip to see if the shipment is complete. Report all discrepancies in accordance with applicable service instructions (e.g., for Army instructions, see DA PAM 750-8). Check to see whether the equipment has been modified. Check equipment against packing slip to ensure that shipment is complete. Report any discrepancies on SF Form 364.
5.
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INSPECTION INSTRUCTIONS - Continued 6. 7. Clean all external surfaces as needed. Touch up any paint scratches. Remove all Basic Issue Item (BII), Additional Authorization List (AAL), and Components of End Item (COEI) equipment and stow in accordance with TM 5-3895-379-10.
END OF TASK SERVICING INSTRUCTIONS 1. 2. Service roller in accordance with PMCS instructions in TM 5-3895-379-10 and PMCS instructions in this manual (WP 0071) and (WP 0072). Schedule the next PMCS on DA Form 5986-E. Refer to TM 5-3893-379-10 and perform functional checks of all major roller systems to ensure roller is ready for operation. Remove all warning tags.
END OF TASK END OF WORK PACKAGE
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0076
FIELD MAINTENANCE ENGINE, TURBO, DIESEL TESTS
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gage, Compression (Volume 2, WP 0289, Table 1, Item 11) Test Set, Electronic Systems (Volume 2, WP 0289, Table 1, Item 37) Personnel Required Construction Equipment Repairer 91L Equipment Condition Valve lash is set correctly. (WP 0088) Equipment Condition (cont.) Fuel injector nozzles removed. (WP 0109) or (WP 0110) Fuel shut-off valves in off position. (WP 0116) Battery fully charged. (WP 0190)
CYLINDER COMPRESSION TEST
NOTE
Cylinder compression test is used to compare each cylinder of engine. Document each individual cylinder test result as test is performed on each cylinder. 1. Install compression gauge into injector hole (Figure 1, Item 1).
M0001SWR
Figure 1.
Cylinder Compression Test.
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CYLINDER COMPRESSION TEST - Continued
NOTE
When performing compression test, one or more cylinders vary more than 51 psi (350 kPa), cylinder and related components may need repair. 2. 3. Operate starter motor and crank engine until the maximum pressure is indicated on the compression gauge. Repeat Steps (1) and (2) for all cylinders.
END OF TASK FOLLOW-ON MAINTENANCE Install fuel injector nozzles. (WP 0109) or (WP 0110) END OF TASK END OF WORK PACKAGE
0076-2
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FIELD MAINTENANCE ENGINE OIL SERVICE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (Volume 2, WP 0289, Table 1, Item 23) Materials/Parts Lubricating Oil, Engine, 15W40 Grade (Volume 2, WP 0288, Table 1, Item 29, 30, 31) Filter, Oil (Volume 2, WP 0290, Table 1, Item 106) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 13 and 15 References (cont.) WP 0071 WP 0072 Equipment Condition Engine off. (TM 5-3895-379-10) Battery disconnect switch in OFF position. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Right-side door assembly opened. (TM 5-3895-379-10)
0077-1
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0077
DRAIN/FILTER REMOVAL
WARNING
Do not drain engine oil while engine is hot, injury may result. Prolonged contact with lubricating oil, MIL-PRF-2105, may cause a 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 many cause injury.
CAUTION
Drain the crankcase with the 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 crankcase or oil pan and cannot be removed by draining the oil. Failure to follow this recommendation procedure can result in waste particles being recirculated through the engine lubrication system with the new oil. 1. 2. Place container under oil pan drain valve (Figure 1, Item 1) and open valve by turning valve to counterclockwise. After engine oil has drained, close oil pan drain valve (Figure 1, Item 1) by turning valve to full clockwise.
0077-2
TM 5-3895-379-23-1
0077
DRAIN/FILTER REMOVAL - Continued
1 CLOSE
OPEN
M0002SWR
Figure 1.
Engine Oil Drain.
0077-3
TM 5-3895-379-23-1
0077
DRAIN/FILTER REMOVAL - Continued 3. Remove oil filter (Figure 2, Item 3) with seal (Figure 2, Item 2) from oil filter assembly (Figure 2, Item 1).
2 3
REMOVE
INSTALL
M0003SWR
Figure 2. Engine Oil Filter Removal. 4. Dispose of drained oil and filter in accordance with local regulations.
END OF TASK
0077-4
TM 5-3895-379-23-1
0077
FILL/FILTER INSTALLATION 1. Clean the gasket mating surface of the oil filter assembly (Figure 3, Item 1). Ensure all of the old filter gasket is removed.
NOTE
Refer to Lubrication Chart in (WP 0071) to determine correct grade of oil. 2. 3. Fill the oil filter (Figure 3, Item 3) with clean engine oil. Apply a light coating of clean engine oil to the seal (Figure 3, Item 2) of new oil filter (Figure 3, Item 3).
CAUTION
Tighten the oil filter element by hand only. Do not use a filter wrench to install the filter. 4. Install new oil filter (Figure 3, Item 3) with seal (Figure 3, Item 2) on oil filter assembly (Figure 3, Item 1). When the gasket contacts the oil filter assembly, tighten filter 3/4 turn more.
2 3
REMOVE
Figure 3.
INSTALL
M1253SWR
Engine Oil Filter Installation.
0077-5
TM 5-3895-379-23-1
0077
FILL/FILTER INSTALLATION - Continued
CAUTION
Do not overfill crankcase with engine oil or serious engine damage will occur. 5. 6. 7. Remove filler cap (Figure 4, Item 1) and seal (Figure 4, Item 3) from filler assembly (Figure 4, Item 2) by turning filler cap clockwise. Add oil according to Lubrication Instructions (WP 0071) and (WP 0072). Install seal (Figure 4, Item 3) and filler (Figure 4, Item 1) on filler assembly (Figure 4, Item 2).
INSTALL REMOVE 1
3 2
M0004SWR
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Check engine oil level. (TM 5-3895-379-10)
Engine Oil Fill.
Start engine and check for leaks. (TM 5-3895-379-10) Close right-side door assembly. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0077-6
TM 5-3895-379-23-1
0078
FIELD MAINTENANCE ENGINE ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Engine Stand, Minimum Capacity 2,000 lb (907 kg) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Lifting Device, Minimum Capacity 2,000 lb (907 kg) Plate, Automotive, Individual (Volume 2, WP 0289, Table 1, Item 25) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 2, WP 0288, Table 1, Item 12) Lubricating Oil MIL-L-2104 OE/, 10 Grade (Volume 2, WP 0288, Table 1, Item 51, 52, 53) Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Wooden Blocks Personnel Required Construction Equipment Repairer 91L (3) References TM 5-3895-379-23P, Figure 1 Equipment Condition Operator platform assembly raised. (Volume 2, WP 0235) Fan and fan guard removed. (WP 0146) Air cleaner removed. (WP 0118) Service meter removed (CB534B Roller). (WP 0169) NATO connector removed. (WP 0193) Fuel shut-off valves in the OFF position. (WP 0125) Hydraulic tank drained. (WP 0124) Radiator drained. (WP 0139) Muffler removed. (WP 0134) Battery disconnect switch removed. (WP 0191)
0078-1
TM 5-3895-379-23-1
0078
REMOVAL
WARNING
Check coolant level only after engine has been stopped and fill cap and radiator are cool enough to touch with bare hand. Remove fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent injury. 1. Position wooden blocks (Figure 1, Item 1) under each steering cylinder mounting (Figure 1, Item 2).
1
M0005SWR
Figure 1. Engine Assembly Removal.
0078-2
TM 5-3895-379-23-1
0078
REMOVAL - Continued 2. Remove two bolts (Figure 2, Item 1), nuts (Figure 2, Item 3), and clamp (Figure 2, Item 4) from brace assembly (Figure 2, Item 2).
2 1
4 3
M0006SWR
Figure 2.
Engine Assembly Removal.
0078-3
TM 5-3895-379-23-1
0078
REMOVAL - Continued 3. Remove bolt (Figure 3, Item 2) and clamp (Figure 3, Item 3) from fuel hose assembly (Figure 3, Item 4) on brace assembly (Figure 3, Item 1).
WARNING
The weight of the brace assembly is 60 lb (27 kg). Use an assistant to aid in removal to prevent possible injury. 4. Remove seven bolts (Figure 3, Item 5), nuts (Figure 3, Item 6), washers (Figure 3, Item 7), and brace assembly (Figure 3, Item 1).
2, 3, 4
5, 6, 7
M0007SWR
0078-4
TM 5-3895-379-23-1
0078
REMOVAL - Continued 5. Disconnect hydraulic hoses (Figure 4, Items 1 and 2) from vibratory control valve (Figure 4, Item 3).
1
M0008SWR
Figure 4. 6.
Disconnect hydraulic hose (Figure 5, Item 2) from vibratory control valve (Figure 5, Item 1).
2
Figure 5.
1
M0009SWR
0078-5
TM 5-3895-379-23-1
0078
REMOVAL - Continued 7. Disconnect hydraulic hoses (Figure 6, Items 2 and 3) from vibratory control valve (Figure 6, Item 1).
1 3
M0010SWR
Figure 6. Engine Assembly Removal. 8. Disconnect hydraulic hoses (Figure 7, Items 2 and 3) from propel control valve (Figure 7, Item 1).
1 3
2
M0011SWR
0078-6
TM 5-3895-379-23-1
0078
REMOVAL - Continued 9. Disconnect hydraulic hoses (Figure 8, Items 1 and 3) from propel control valve (Figure 8, Item 2).
M0012SWR
Figure 8. 10.
Disconnect hydraulic hoses (Figure 9, Items 1, 2, and 4) from propel control valve (Figure 9, Item 3).
1 2
M0013SWR
Figure 9.
0078-7
TM 5-3895-379-23-1
0078
REMOVAL - Continued 11. Disconnect hydraulic hose (Figure 10, Item 1) from propel control valve (Figure 10, Item 2).
M0014SWR
Figure 10. Engine Assembly Removal. 12. Disconnect hydraulic hoses (Figure 11, Items 1 and 3) from hydraulic tank (Figure 11, Item 2).
1 2
M0015SWR
0078-8
TM 5-3895-379-23-1
0078
REMOVAL - Continued 13. 14. Disconnect hydraulic hoses (Figure 12, Items 1 and 3) from hydraulic tank (Figure 12, Item 2). Remove bolt (Figure 12, Item 4) and clip (Figure 12, Item 5) securing hydraulic hose (Figure 12, Item 1) to hydraulic tank (Figure 12, Item 2).
2 1 2
4, 5 3
M0016SWR
Figure 12.
0078-9
TM 5-3895-379-23-1
0078
REMOVAL - Continued
WARNING
DO NOT smoke or permit any open flame in area of machine while you are servicing 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 injury, death or damage to roller. Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing. 15. 16. 17. For the CB534B Roller, disconnect fuel lines (Figure 13, Items 5 and 6) from fuel shut-off valves (Figure 13, Item 1). For the CB534C Roller, disconnect fuel lines (Figure 13, Items 5 and 6) from fuel tank fittings (Figure 13, Item 2). Remove bolt (Figure 13, Item 3) and clamp (Figure 13, Item 4) securing fuel lines (Figure 13, Items 5 and 6).
1, 2
3, 4
M0017SWR
Figure 13. Engine Assembly Removal. 18. 19. 20. Disconnect fuel hose (Figure 14, Item 1) from fuel/water separator head (Figure 14, Item 2). Remove bolt (Figure 14, Item 5) and clamp (Figure 14, Item 6) securing two fuel hoses. Move hoses aside. Remove bolt (Figure 14, Item 3) and clamp (Figure 14, Item 4) securing three hoses. Move hoses aside.
0078-10
TM 5-3895-379-23-1
0078
REMOVAL - Continued
1 2
3, 4
5, 6
M0018SWR
Figure 14. 21.
Disconnect steering hydraulic hoses (Figure 15, Items 1 and 2).
M0019SWR
Figure 15.
0078-11
TM 5-3895-379-23-1
0078
REMOVAL - Continued 22. 23. Remove two bolts (Figure 16, Item 1), washers (Figure 16, Item 2), clamps (Figure 16, Item 3), and battery cable (Figure 16, Item 8) from frame. Move cable aside. Remove two bolts (Figure 16, Item 4), washers (Figure 16, Item 5), and bracket (Figure 16, Item 6) securing hoses to engine mount (Figure 16, Item 7). Move hoses aside.
1, 2, 3 8 4, 5, 6
7
Figure 16. Engine Assembly Removal. 24.
M0020SWR
Disconnect steering hydraulic hoses (Figure 17, Items 2 and 3) from steering pump (Figure 17, Item 1).
0078-12
TM 5-3895-379-23-1
0078
REMOVAL - Continued
1
M0021SWR
Figure 17. 25. 26.
Disconnect electrical wires (Figure 18, Items 4 and 5) from fuel level sending unit (Figure 18, Item 1). Cut cable ties securing wiring harness (Figure 18, Item 3) to fuel/hydraulic tank (Figure 18, Item 2). Move harness aside.
4, 5
M0022SWR
Figure 18.
0078-13
TM 5-3895-379-23-1
0078
REMOVAL - Continued 27. 28. 29. Disconnect wiring harness (Figure 19, Item 1) from hydraulic oil temperature switch (Figure 19, Item 2). Move harness aside. Remove two bolts (Figure 19, Item 3), washers (Figure 19, Item 4), and starter relay (Figure 19, Item 5) from frame. Cut cable ties securing starter relay (Figure 19, Item 5) and wiring harness (Figure 19, Item 6). Move harness aside.
3, 4, 5
1, 2
M0023SWR
Figure 19. Engine Assembly Removal. 30. 31. 32. 33. Remove bolt (Figure 20, Item 3) and three screws (Figure 20, Item 2) securing electrical connector (Figure 20, Item 1) to frame. Separate electrical connector (Figure 20, Item 1), by disconnecting connector halves. Disconnect electrical connector (Figure 20, Item 4). Remove nut (Figure 20, Item 5) and washer (Figure 20, Item 6) securing ground wire (Figure 20, Item 7) to frame.
0078-14
TM 5-3895-379-23-1
0078
REMOVAL - Continued
5, 6, 7
M0024SWR
Figure 20. 34.
Remove bolt (Figure 21, Item 1) and washer (Figure 21, Item 2) securing engine ground wire (Figure 21, Item 3) to frame.
1, 2
M0025SWR
Figure 21.
0078-15
TM 5-3895-379-23-1
0078
REMOVAL - Continued
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
Weight of the engine, radiator, and pump unit is 1,600 lb (726 kg). 35. Attach lifting sling to overhead lift and the two engine lifting brackets (Figure 22, Items 1 and 2).
M0026SWR
0078-16
TM 5-3895-379-23-1
0078
REMOVAL - Continued 36. 37. Carefully check that all hydraulic hoses, fuel hoses, and electrical connections and harnesses have been disconnected. Remove the four engine mount bolts (Figure 23, Item 1), nuts (Figure 23, Item 2), and washers (Figure 23, Item 3) holding the engine, radiator, and hydraulic pumps to roller frame.
1, 2, 3
M0027SWR
Figure 23. 38.
Remove engine, radiator, and hydraulic pumps from the roller frame.
END OF TASK
0078-17
TM 5-3895-379-23-1
0078
INSTALLATION
WARNING
NOTE
Weight of the engine, radiator, and pump unit is 1,600 lb (726 kg). 1. Attach sling to overhead lift and two engine lifting brackets (Figure 24, Items 1 and 2).
M0028SWR
Figure 24. Engine Assembly Installation. 2. 3. Carefully check that all hydraulic hoses, fuel hoses, and electrical connections and harnesses are clear prior to installation. Position engine, radiator, and hydraulic pumps from the roller frame.
0078-18
TM 5-3895-379-23-1
0078
INSTALLATION - Continued 4. Install four engine mount bolts (Figure 25, Item 1), washers (Figure 25, Item 2), and nuts (Figure 25, Item 3).
1, 2, 3
M0029SWR
Figure 25. 5.
Engine Assembly Installation.
Connect engine ground wire (Figure 26, Item 3) to frame with bolt (Figure 26, Item 1) and washer (Figure 26, Item 2).
1, 2
M0030SWR
Figure 26.
0078-19
TM 5-3895-379-23-1
0078
INSTALLATION - Continued 6. 7. 8. 9. Connect ground wire (Figure 27, Item 7) to frame with nut (Figure 27, Item 5) and washer (Figure 27, Item 6). Connect electrical connector (Figure 27, Item 1). Connect electrical connector (Figure 27, Item 4) by joining the connector halves. Install electrical connector (Figure 27, Item 4) with bolt (Figure 27, Item 3) and three screws (Figure 27, Item 2).
5, 6, 7
M0031SWR
Figure 27. Engine Assembly Installation.
0078-20
TM 5-3895-379-23-1
0078
INSTALLATION - Continued 10. 11. 12. Connect wiring harness (Figure 28, Item 1) to hydraulic oil temperature switch (Figure 28, Item 2). Install starter relay (Figure 28, Item 5) to frame with two bolts (Figure 28, Item 3) and washers (Figure 28, Item 4). Using cable ties, secure starter relay harness (Figure 28, Item 6).
3, 4, 5
1, 2
M0032SWR
Figure 28.
0078-21
TM 5-3895-379-23-1
0078
INSTALLATION - Continued 13. 14. Connect electrical wires (Figure 29, Items 4 and 5) to fuel level sending unit (Figure 29, Item 1). Using cable ties, secure wiring harness (Figure 29, Item 3) to fuel/hydraulic tank (Figure 29, Item 2).
4, 5
M0033SWR
Figure 29. Engine Assembly Installation. 15. Connect hydraulic hoses (Figure 30, Items 2 and 3) to steering pump (Figure 30, Item 1).
1
M0034SWR
0078-22
TM 5-3895-379-23-1
0078
INSTALLATION - Continued 16. 17. Attach bracket (Figure 31, Item 6) and hoses to engine mount (Figure 31, Item 7) with two bolts (Figure 31, Item 4) and washers (Figure 31, Item 5). Attach battery cable (Figure 31, Item 8) to frame with two bolts (Figure 31, Item 1), washers (Figure 31, Item 2), and clamp (Figure 31, Item 3).
1, 2, 3 8 4, 5, 6
7
Figure 31. 18. Engine Assembly Installation.
M0035SWR
Connect steering hydraulic hoses (Figure 32, Items 1 and 2).
M0036SWR
Figure 32.
0078-23
TM 5-3895-379-23-1
0078
INSTALLATION - Continued
WARNING
DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing damage to roller and injury or death. 19. 20. 21. Connect fuel hose (Figure 33, Item 1) to fuel/water separator head (Figure 33, Item 2). Attach two fuel hoses with bolt (Figure 33, Item 5) and clamp (Figure 33, Item 6). Install bolt (Figure 33, Item 3) and clamp (Figure 33, Item 4).
1 2
3, 4
5, 6
M0037SWR
0078-24
TM 5-3895-379-23-1
0078
INSTALLATION - Continued 22. 23. 24. Attach fuel lines (Figure 34, Items 5 and 6) with bolt (Figure 34, Item 3) and clamp (Figure 34, Item 4). For the CB534B Roller, connect fuel lines (Figure 34, Items 5 and 6) to fuel shut-off valves (Figure 34, Item 1). For the CB534C Roller, connect fuel lines (Figure 34, Items 5 and 6) to fuel tank fittings (Figure 34, Item 2).
1, 2
3, 4
M0038SWR
Figure 34. 25. 26.
Connect hydraulic hoses (Figure 35, Items 1 and 3) to hydraulic tank (Figure 35, Item 2). Attach hydraulic hose (Figure 35, Item 1) to hydraulic tank (Figure 35, Item 2) with bolt (Figure 35, Item 4) and clip (Figure 35, Item 5).
2 1 2
4, 5 3
M0039SWR
Figure 35.
0078-25
TM 5-3895-379-23-1
0078
INSTALLATION - Continued 27. Connect hydraulic hoses (Figure 36, Items 1 and 3) to hydraulic tank (Figure 36, Item 2).
1 2
M0040SWR
Figure 36. Engine Assembly Installation. 28. Connect hydraulic hose (Figure 37, Item 1) to propel control valve (Figure 37, Item 2).
M0041SWR
0078-26
TM 5-3895-379-23-1
0078
INSTALLATION - Continued 29. Connect hydraulic hoses (Figure 38, Items 1, 2, and 4) to propel control valve (Figure 38, Item 3).
1 2
M0042SWR
Figure 38. 30.
Connect hydraulic hoses (Figure 39, Items 1 and 3) to propel control valve (Figure 39, Item 2).
M0043SWR
Figure 39.
0078-27
TM 5-3895-379-23-1
0078
INSTALLATION - Continued 31. Connect hydraulic hoses (Figure 40, Items 2 and 3) to propel control valve (Figure 40, Item 1).
1 3
2
Figure 40. Engine Assembly Installation. 32.
M0044SWR
Connect hydraulic hoses (Figure 41, Items 2 and 3) to vibratory control valve (Figure 41, Item 1).
1 3
M0045SWR
0078-28
TM 5-3895-379-23-1
0078
INSTALLATION - Continued 33. Connect hydraulic hose (Figure 42, Item 2) to vibratory control valve (Figure 42, Item 1).
2
Figure 42. 34.
1
M0046SWR
Connect hydraulic hoses (Figure 43, Items 1 and 2) to vibratory control valve (Figure 43, Item 3).
1
M0047SWR
Figure 43.
0078-29
TM 5-3895-379-23-1
0078
WARNING
The weight of the brace assembly is 60 lb (27 kg). Use an assistant to aid in installation to prevent possible injury. 35. 36. Install brace assembly (Figure 44, Item 1) with seven bolts (Figure 44, Item 5), washers (Figure 44, Item 7), and nuts (Figure 44, Item 6). Install fuel hose assembly (Figure 44, Item 4) on brace assembly (Figure 44, Item 1) with bolt (Figure 44, Item 2) and clamp (Figure 44, Item 3).
2, 3, 4
5, 6, 7
M0048SWR
0078-30
TM 5-3895-379-23-1
0078
INSTALLATION - Continued 37. Install clamp (Figure 45, Item 4) on brace assembly (Figure 45, Item 2) with two bolts (Figure 45, Item 1) and nuts (Figure 45, Item 3).
2 1
4 3
M0049SWR
Figure 45. 38.
Remove two wooden blocks (Figure 46, Item 1) from under each steering cylinder mount (Figure 46, Item 2).
1
M0050SWR
Figure 46. END OF TASK
0078-31
TM 5-3895-379-23-1
0078
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Install fan assembly and fan guard. (WP 0146) Install air cleaner assembly. (WP 0118) Install NATO connector. (WP 0193) Install battery disconnect switch. (WP 0191) Install service meter (CB534B Roller). (WP 0169) Install muffler. (WP 0134) Fill hydraulic tank. (WP 0124) Fill radiator. (WP 0139) Turn fuel shut-off valves to the ON position. (WP 0125) Prime fuel system. (WP 0128) Lower operator platform assembly. (Volume 2, WP 0235) Start engine and check for leaks and proper operation. (TM 5-3895-379-10)
0078-32
TM 5-3895-379-23-1
0079
FIELD MAINTENANCE ENGINE LIFTING PLATES REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 1 Equipment Condition Engine off. (TM 5-3895-379-10) Equipment Condition (cont.) Operator platform assembly raised. (Volume 2, WP 0235)
0079-1
TM 5-3895-379-23-1
0079
REMOVAL
WARNING
Use caution and allow engine to cool before removal of component. Failure to follow this warning may cause injury.
NOTE
Engine lifting plates are replaced the same way for CB534B and CB534C Rollers except where noted. CB534B Roller is shown. 1. Remove two screws (Figure 1, Item 3) and left engine lifting plate (Figure 1, Item 2) from cylinder head (Figure 1, Item 1).
2 3
LEFT ENGINE LIFTING PLATE

M0051SWR
Figure 1. Engine Lifting Plates Removal. 2. For CB534B Roller, remove nut (Figure 2, Item 12), washer (Figure 2, Item 3), washer (Figure 2, Item 4), bolt (Figure 2, Item 2), washer (Figure 2, Item 3), washer (Figure 2, Item 4), and grommet (Figure 2, Item 5) from radiator bracket (Figure 2, Item 1). For CB534B Roller, remove three screws (Figure 2, Item 10), washers (Figure 2, Item 11), clip (Figure 2, Item 9), and right engine lifting bracket (Figure 2, Item 13) from cylinder head (Figure 2, Item 6). For CB534C Roller, remove two screws (Figure 2, Item 8) and right engine lifting bracket (Figure 2, Item 7) from cylinder head (Figure 2, Item 6).
3. 4.
0079-2
TM 5-3895-379-23-1
0079
REMOVAL - Continued
2 1 3 4 5 13 4 3 12 6 7 6
11 10 9 CB534B ROLLER RIGHT ENGINE LIFTING BRACKET 8 CB534C ROLLER RIGHT ENGINE LIFTING BRACKET
M0052SWR
Engine Lifting Plates Removal.
0079-3
TM 5-3895-379-23-1
0079
INSTALLATION 1. 2. For CB534C Roller only, install right engine lifting bracket (Figure 3, Item 7) and two screws (Figure 3, Item 8) to cylinder head (Figure 3, Item 6). For CB534B Roller only, install right engine lifting bracket (Figure 3, Item 13) and clip (Figure 3, Item 9) on cylinder head (Figure 3, Item 6) with three washers (Figure 3, Item 11) and screws (Figure 3, Item 10). Tighten screws to 33-47 lb-ft (45-64 Nm). For CB534B Roller only, attach lifting bracket (Figure 3, Item 13) to radiator bracket (Figure 3, Item 1) with grommet (Figure 3, Item 5), washer (Figure 3, Item 4), washer (Figure 3, Item 3), bolt (Figure 3, Item 2), washer (Figure 3, Item 4), washer (Figure 3, Item 3), and nut (Figure 3, Item 12). Tighten nut to 33-47 lb-ft (45-64 Nm).
3.
2 1 3 4 5 13 4 3 12 6 7 6
11 10 9 CB534B ROLLER RIGHT ENGINE LIFTING BRACKET 8 CB534C ROLLER RIGHT ENGINE LIFTING BRACKET
M1130SWR
Figure 3. Engine Lifting Plates Installation.
0079-4
TM 5-3895-379-23-1
0079
INSTALLATION - Continued 4. Install left engine lifting plate (Figure 4, Item 2) on cylinder head (Figure 4, Item 1) with two screws (Figure 4, Item 3). Tighten screws to 33-47 lb-ft (45-64 Nm).
1
2 3
LEFT ENGINE LIFTING PLATE

M0053SWR
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE
Engine Lifting Plates Installation.
Lower operator platform assembly. (Volume 2, WP 0235) END OF TASK END OF WORK PACKAGE
0079-5/6 blank
TM 5-3895-379-23-1
0080
FIELD MAINTENANCE FRONT ENGINE MOUNT REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Lifting Device, Minimum Capacity 2,000 lb (907 kg) Wrench, Torque, 50-250 ft-lb (Volume 2, WP 0289, Table 1, Item 43) Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figure 1 Equipment Condition Engine off. (TM 5-3895-379-10) Operator platform assembly raised. (Volume 2, WP 0235) Hydraulic oil cooler removed. (Volume 2, WP 0260)
0080-1
TM 5-3895-379-23-1
0080
REMOVAL
WARNING
NOTE
Front engine mount is replaced the same way for CB534B and CB534C Rollers, except where noted. CB534B Roller is shown. 1. 2. For CB534B Roller only, remove nut (Figure 1, Item 8), washer (Figure 1, Item 3), clip (Figure 1, Item 9), screw (Figure 1, Item 2), and washer (Figure 1, Item 3) from upper cross brace (Figure 1, Item 10). Remove four nuts (Figure 1, Item 7), washers (Figure 1, Item 4), two clips (Figure 1, Item 6), upper cross brace (Figure 1, Item 10), four screws (Figure 1, Item 1), and washers (Figure 1, Item 4) from upper frame assembly (Figure 1, Item 5).
1 4
2 3
1 4
4 7 10 9 8 3 7 4 6 5
M0054SWR
Figure 1. Front Engine Mount Removal.
0080-2
TM 5-3895-379-23-1
0080
REMOVAL - Continued
WARNING
NOTE
Engine weighs 2,000 lb (907 kg). 3. Attach lifting device to right engine lifting bracket (Figure 2, Item 1).
CB534C ROLLER RIGHT ENGINE LIFTING BRACKET CB534B ROLLER RIGHT ENGINE LIFTING BRACKET
Figure 2. Front Engine Mount Removal.
M0055SWR
0080-3
TM 5-3895-379-23-1
0080
REMOVAL - Continued
NOTE
Sleeves may stay with mount assembly. 4. Remove two nuts (Figure 3, Item 6), washers (Figure 3, Item 5), bolts (Figure 3, Item 1), washers (Figure 3, Item 2), and spacer sleeves (Figure 3, Item 7) from front engine mount (Figure 3, Item 11) and frame assembly (Figure 3, Item 4). With assistance, use a lifting device to raise engine (Figure 3, Item 8) until there is space between resilient mount (Figure 3, Item 3) and front engine mount (Figure 3, Item 11) or frame assembly (Figure 3, Item 4).
5.
WARNING
Do not place fingers between engine mount and frame assembly. Shifting engine may cause injury. 6. Remove four screws (Figure 3, Item 10), washers (Figure 3, Item 9), front engine mount (Figure 3, Item 11), two resilient mounts (Figure 3, Item 3), and remaining spacer sleeves (Figure 3, Item 7) from engine (Figure 3, Item 8) and frame assembly (Figure 3, Item 4).
0080-4
TM 5-3895-379-23-1
0080
REMOVAL - Continued
2 3 11 10 9 8 7 4 3 5 6
M0056SWR
Front Engine Mount Removal.
0080-5
TM 5-3895-379-23-1
0080
INSTALLATION 1. Install front engine mount (Figure 4, Item 11) on engine (Figure 4, Item 8) with four washers (Figure 4, Item 9) and screws (Figure 4, Item 10). Tighten screws to 145-205 lb-ft (197-278 Nm).
WARNING
Do not place fingers between engine mount and frame assembly. Shifting engine may cause injury. 2. 3. Position two resilient mounts (Figure 4, Item 3) between front engine mount (Figure 4, Item 11) and frame assembly (Figure 4, Item 4). Install two spacer sleeves (Figure 4, Item 7), washers (Figure 4, Item 2), bolts (Figure 4, Item 1), washers (Figure 4, Item 5), and nuts (Figure 4, Item 6) in front engine mount (Figure 4, Item 11) and frame assembly (Figure 4, Item 4). DO NOT tighten nuts.
WARNING
NOTE
Engine weighs 2,000 lb (907 kg). 4. 5. With assistance, use a lifting device to lower engine (Figure 4, Item 8). Tighten nuts (Figure 4, Item 6) to 145-205 lb-ft (197-278 Nm).
0080-6
TM 5-3895-379-23-1
0080
1
2 3 11 10 9 8 7 4 3 5 6
M1303SWR
Figure 4. 6.
Front Engine Mount Installation.
Remove lifting device from front engine bracket (Figure 5, Item 1).
1 1
CB534C ROLLER RIGHT ENGINE LIFTING BRACKET CB534B ROLLER RIGHT ENGINE LIFTING BRACKET
M0057SWR
Figure 5.
Front Engine Mount Installation.
0080-7
TM 5-3895-379-23-1
0080
INSTALLATION - Continued 7. Install upper cross brace (Figure 6, Item 10) on upper frame assembly (Figure 6, Item 5) with four washers (Figure 6, Item 4), screws (Figure 6, Item 1), two clips (Figure 6, Item 6), four washers (Figure 6, Item 4), and nuts (Figure 6, Item 7). For CB534B Roller, install clip (Figure 6, Item 9) on upper cross brace (Figure 6, Item 10) with washer (Figure 6, Item 3), screw (Figure 6, Item 2), washer (Figure 6, Item 3), and nut (Figure 6, Item 8).
8.
1 4
2 3
1 4
4 7 10 9 8 3 7 4 6 5
M0058SWR
Figure 6. Front Engine Mount Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Install hydraulic oil cooler. (Volume 2, WP 0260) Lower operator platform. (Volume 2, WP 0235) Start engine and check for leaks. (TM 5-3895-379-10)
0080-8
TM 5-3895-379-23-1
0081
FIELD MAINTENANCE REAR ENGINE MOUNT REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Lifting Device, Minimum Capacity 2,000 lb (907 kg) Wrench, Torque, 50-250 ft-lb (Volume 2, WP 0289, Table 1, Item 43) Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figure 1 Equipment Condition Engine off. (TM 5-3895-379-10) Operator platform assembly raised. (Volume 2, WP 0235)
0081-1
TM 5-3895-379-23-1
0081
REMOVAL
WARNING
NOTE
Left and right engine mounts are replaced the same way. Left engine mount is shown. 1. 2. For CB534B Roller, remove nut (Figure 1, Item 8), washer (Figure 1, Item 3), clip (Figure 1, Item 9), screw (Figure 1, Item 2), and washer (Figure 1, Item 3) from upper cross brace (Figure 1, Item 10). Remove four nuts (Figure 1, Item 7), washers (Figure 1, Item 4), two clips (Figure 1, Item 6), upper cross brace (Figure 1, Item 10), four screws (Figure 1, Item 1), and washers (Figure 1, Item 4) from upper frame assembly (Figure 1, Item 5).
1 2 3 1 4
10
I0059SWR
Figure 1. Rear Engine Mount Removal.
0081-2
TM 5-3895-379-23-1
0081
REMOVAL - Continued
WARNING
NOTE
Engine weighs 2,000 lb (907 kg). 3. Attach lifting device to rear engine lifting plate (Figure 2, Item 1).
M0060SWR
Figure 2.
Rear Engine Mount Removal.
0081-3
TM 5-3895-379-23-1
0081
REMOVAL - Continued 4. Remove two screws (Figure 3, Item 2), washers (Figure 3, Item 1), and hose assembly mounting bracket (Figure 3, Item 4) from left rear engine mount (Figure 3, Item 3).
1 2
M0061SWR
Figure 3. Rear Engine Mount Removal. 5. Remove two nuts (Figure 4, Item 5), washers (Figure 4, Item 4), bolts (Figure 4, Item 1), washers (Figure 4, Item 7), and spacer sleeves (Figure 4, Item 6) from two rear engine mounts (Figure 4, Item 2) and frame assembly (Figure 4, Item 3).
4 5
M0062SWR
Figure 4. Rear Engine Mount Removal.
0081-4
TM 5-3895-379-23-1
0081
REMOVAL - Continued 6. With assistance, use lifting device to raise engine (Figure 5, Item 3) until there is a space between resilient mounts (Figure 5, Item 4) and rear engine mounts (Figure 5, Item 1) or frame assembly (Figure 5, Item 2).
WARNING
Do not place fingers between engine mount and frame assembly. Shifting engine may cause injury. 7. Remove eight bolts (Figure 5, Item 6), washers (Figure 5, Item 7), two rear engine mounts (Figure 5, Item 1), two resilient mounts (Figure 5, Item 4), and remaining spacer sleeves (Figure 5, Item 5) from engine (Figure 5, Item 3) and frame assembly (Figure 5, Item 2).
7 6
2 4 5 4
M0063SWR
Rear Engine Mount Removal.
0081-5
TM 5-3895-379-23-1
0081
INSTALLATION 1. Install two rear engine mounts (Figure 6, Item 1) on engine (Figure 6, Item 3) with eight washers (Figure 6, Item 6) and bolts (Figure 6, Item 5). Tighten bolts to 60-90 lb-ft (80-120 Nm).
WARNING
NOTE
Engine weighs 2,000 lb (907 kg). 2. 3. Position two resilient mounts (Figure 6, Item 4) between two rear engine mounts (Figure 6, Item 1) and frame assembly (Figure 6, Item 2). With assistance, use lifting device to lower engine (Figure 6, Item 3).
6 5
2 4 3
4
M1129SWR
Figure 6. Rear Engine Mount Installation. 4. Install two spacer sleeves (Figure 7, Item 6), washers (Figure 7, Item 7), bolts (Figure 7, Item 1), washers (Figure 7, Item 4), and nuts (Figure 7, Item 5) in two rear engine mounts (Figure 7, Item 2) and frame assembly (Figure 7, Item 3). Tighten nuts (Figure 7, Item 5) to 145-205 lb-ft (197-278 Nm).
5.
0081-6
TM 5-3895-379-23-1
0081
4 5
M1128SWR
Figure 7. 6.
Rear Engine Mount Installation.
Install hose assembly mounting bracket (Figure 8, Item 4) to left-rear engine mount (Figure 8, Item 3) with two washers (Figure 8, Item 1) and bolts (Figure 8, Item 2).
1 2
M0064SWR
Figure 8.
0081-7
TM 5-3895-379-23-1
0081
INSTALLATION - Continued 7. Remove lifting device from rear engine lifting plate (Figure 9, Item 1).
1
M0065SWR
Figure 9. Rear Engine Mount Installation. 8. Install upper cross brace (Figure 10, Item 10) on upper frame assembly (Figure 10, Item 5) with four washers (Figure 10, Item 4), screws (Figure 10, Item 1), two clips (Figure 10, Item 6), four washers (Figure 10, Item 4), and nuts (Figure 10, Item 7). For CB534B Roller, install clip (Figure 10, Item 9) on upper cross brace (Figure 10, Item 10) with washer (Figure 10, Item 3), screw (Figure 10, Item 2), washer (Figure 10, Item 3), and nut (Figure 10, Item 8).
1 2 3 1 4
9.
10
I0066SWR
0081-8
TM 5-3895-379-23-1
0081
FOLLOW-ON MAINTENANCE 1. 2. Lower operator platform. (Volume 2, WP 0235) Start engine and check for proper operation. (TM 5-3895-379-10)
0081-9/10 blank
TM 5-3895-379-23-1
0082
FIELD MAINTENANCE CYLINDER HEAD REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Beam, Hoisting (Volume 2, WP 0289, Table 1, Item 2) Lifting Device, Minimum Capacity 90 lb (41 kg) Stand Subassembly, Maintenance, Automotive Engine (Volume 2, WP 0289, Table 1, Item 35) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Lubricating Oil, General Purpose (Volume 2, WP 0288, Table 1, Item 40, 41, 42, 43, 44, 45, 46, 47) Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Gasket (Volume 2, WP 0290, Table 1, Item 60) Qty: 1 Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figures 2 and 3 Equipment Condition Engine off. (TM 5-3895-379-10) Operator platform assembly raised. (Volume 2, WP 0235) Radiator drained. (WP 0139) Battery cables disconnected. (WP 0192) Fuel filter base removed. (WP 0127) Fuel injector nozzles removed. (WP 0109) or (WP 0110) Intake manifold removed. (WP 0105) Exhaust manifold removed. (WP 0106) or (WP 0107) Thermostat housing removed. (WP 0142) or (WP 0143) Rocker arm assembly removed. (WP 0090)
0082-1
TM 5-3895-379-23-1
0082
REMOVAL
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
Cylinder head weighs 90 lb (41 kg). Tag and mark the short, medium, and long head bolts during removal. 1. Remove, evenly and gradually, 22 head bolts (Figure 1, Item 1) from cylinder head (Figure 1, Item 2) in reverse of sequence.
1 2
M 18 L 19 M 9
M 8 M 1
M 2 M 3
M 13 14 L
M 20 S 21 S 22
M 10 S 11 12 S
M 7 S 6 5 S
M 4 S 17
15 M S 18
M0067SWR
Figure 1.
Cylinder Head Removal.
NOTE
Do not use pry bar to separate cylinder head from cylinder block. Place cylinder head on a surface that will not damage cylinder head face. 2. With assistance, attach lifting device to cylinder head (Figure 2, Item 2). Lift cylinder head straight up and off cylinder block (Figure 2, Item 1).
0082-2
TM 5-3895-379-23-1
0082
REMOVAL - Continued
1 2
M0068SWR
Figure 2. 3.
Remove cylinder head gasket (Figure 3, Item 1) from cylinder block (Figure 3, Item 2). Discard gasket.
1 2
M0069SWR
0082-3
TM 5-3895-379-23-1
0082
CLEANING Clean top of cylinder block (Figure 4, Item 1) and bottom of cylinder head (Figure 4, Item 2). END OF TASK INSPECTION 1. 2. Inspect cylinder head (Figure 4, Item 2) for cracks, damage, and warpage. Replace cylinder head if damaged. Inspect cylinder head bolts for damage, distortion, and reduction in threads. Replace head bolts if damaged.
1 2
M1125SWR
Figure 4. END OF TASK INSTALLATION
Cylinder Head Cleaning and Inspection.
NOTE
Note location of dowels on each end of cylinder block. Dowels hold cylinder head gasket in place while cylinder head is installed. Be sure to locate "FRONT TOP," stamped on gasket, for correct installation. Do not use any sealant or gasket compound on cylinder head gasket. 1. Install new cylinder head gasket (Figure 5, Item 1) to cylinder block (Figure 5, Item 2).
0082-4
TM 5-3895-379-23-1
0082
1 2
M1126SWR
Figure 5. 2.
Cylinder Head Installation.
Place guide bolts in positions 15 and 20 as numbered in sequence illustration.
NOTE
Weight of cylinder head is 90 lb (41 kg). 3. With assistance, use a lifting device and lower cylinder head (Figure 6, Item 2) onto cylinder block (Figure 6, Item 1).
1 2
M1127SWR
Figure 6.
0082-5
TM 5-3895-379-23-1
0082
NOTE
Lubricate bolt threads with clean engine oil before assembly. 4. 5. 6. Tighten 22 head bolts (Figure 7, Item 1), evenly and gradually, in numbered sequence to 80 lb-ft (108 Nm). Again tighten 22 head bolts (Figure 7, Item 1), evenly and gradually, in numbered sequence to 80 lb-ft (108 Nm) to ensure proper torque. Tighten all head bolts and nuts in number sequence as follows: a. b. c. Short bolts (S) 150 degrees further (2.5 flats). Medium length bolts (M) 180 degrees further (3.0 flats). Long bolts (L) 210 degrees further (3.5 flats).
1 2
M 18 L 19 M 9
M 8 M 1
M 2 M 3
M 13 14 L
M 20 S 21 S 22
M 10 S 11 12 S
M 7 S 6 5 S
M 4 S 17
15 M S 18
M1061SWR
Figure 7. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. 9.
Install rocker arm and push rods. (WP 0090) Install thermostat housing. (WP 0142) or (WP 0143) Install exhaust manifold. (WP 0106) or (WP 0107) Install intake manifold. (WP 0105) Install fuel filter base. (WP 0127) Install fuel injector nozzles. (WP 0109) or (WP 0110) Fill radiator. (WP 0139) Connect battery cables. (WP 0192) Lower operator platform assembly. (Volume 2, WP 0235)
0082-6
TM 5-3895-379-23-1
0082
FOLLOW-ON MAINTENANCE - Continued 10. Start engine and check for leaks and proper operation. (TM 5-3895-379-10)
0082-7/8 blank
TM 5-3895-379-23-1
0083
FIELD MAINTENANCE CRANKSHAFT PULLEY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Goggles (Volume 2, WP 0289, Table 1, Item 13) Puller Kit, Universal (Volume 2, WP 0289, Table 1, Item 27) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Cleaning Compound, Solvent (Volume 2, WP 0288, Table 1, Item 13, 14, 15) Detergent, GP Liquid (Volume 2, WP 0288, Table 1, Item 17) Lubricating Oil, Engine, 15W40 Grade (Volume 2, WP 0288, Table 1, Item 29, 30, 31) Materials/Parts (cont.) Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Sealing Compound (Volume 2, WP 0288, Table 1, Item 61) Personnel Required Construction Equipment Repairer 91L Equipment Condition Radiator removed. (WP 0136) V-belts removed. (WP 0147)
0083-1
TM 5-3895-379-23-1
0083
REMOVAL
NOTE
Some engines have water immersion seal on front cover. Front of seal has a flexible lip. Plastic mandrel supplied with seal must be installed in seal when crankshaft pulley is removed. This ensures lip maintains correct shape. It may be necessary to keep crankshaft from rotating when removing bolts. Use appropriate tool. 1. Remove three bolts (Figure 1, Item 2) and counterbalance weight (Figure 1, Item 3) from end of crankshaft (Figure 1, Item 5).
NOTE
It may be necessary to use a puller to remove crankshaft pulley. 2. Remove crankshaft pulley (Figure 1, Item 4) from engine (Figure 1, Item 1).
1 5 4 3 2
M0070SWR
Figure 1. Crankshaft Pulley Removal. END OF TASK CLEANING
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. Clean removed parts with detergent. Dry parts with compressed air. END OF TASK
0083-2
TM 5-3895-379-23-1
0083
INSPECTION 1. 2. 3. Inspect counter-balance weight and crankshaft pulley for cracks or other damage. Replace if damaged. Inspect wear of pulley grooves. Replace pulley if worn. Inspect to ensure plastic mandrel and seal lip maintains the correct shape, if supplied.
END OF TASK INSTALLATION 1. 2. Apply a coat of lubricating oil to exposed surface of crankshaft end (Figure 2, Item 5). If supplied, remove plastic mandrel from seal, if required.
NOTE
Position counterbalance weight to align holes with crankshaft end. Apply sealing compound to threads of bolts. It may be necessary to keep crankshaft from rotating when installing bolts. 3. 4. Position crankshaft pulley (Figure 2, Item 4) on crankshaft end (Figure 2, Item 5). Install counterbalance weight (Figure 2, Item 3) and three bolts (Figure 2, Item 2). Tighten bolt to 85 lb-ft (115 Nm).
1 5 4 3 2
M0071SWR
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install alternator V-belts. (WP 0147) Install radiator. (WP 0136)
Crankshaft Pulley Installation.
0083-3/4 blank
TM 5-3895-379-23-1
0084
FIELD MAINTENANCE CRANKSHAFT FRONT OIL SEAL REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Drill Bit Set Standard (Volume 2, WP 0289, Table 1, Item 6) Drill, Hand (Volume 2, WP 0289, Table 1, Item 7) Installer, Cover (Volume 2, WP 0289, Table 1, Item 20) Puller Kit, Universal (Volume 2, WP 0289, Table 1, Item 27) Materials/Parts Gasket (Volume 2, WP 0290, Table 1, Item 82) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 10 Equipment Condition Crankshaft pulley removed. (WP 0083)
REMOVAL
CAUTION
Make sure main lip is used to remove crankshaft front oil seal. Do not damage edge of oil seal housing. 1. 2. Drill three holes evenly spaced in crankshaft front oil seal (Figure 1, Item 1). Position slide hammer puller in holes and remove gasket (Figure 1, Item 1) from oil seal housing (Figure 1, Item 2).
1 2
M0072SWR
Crankshaft Front Oil Seal Removal.
0084-1
TM 5-3895-379-23-1
0084
CLEANING Clean oil seal housing. END OF TASK INSPECTION Inspect for any damage to oil seal housing and front of engine block. END OF TASK INSTALLATION
CAUTION
Make sure spring loaded lip of oil seal is facing towards inside of timing case cover and is square to bore of seal housing.
NOTE
Lubricate oil seal and crankshaft pulley area that contacts new oil seal with clean engine oil. Using front seal installer, install new gasket (Figure 2, Item 1) in oil seal housing (Figure 2, Item 2).
1 2
M1124SWR
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE Install crankshaft pulley. (WP 0083) END OF TASK END OF WORK PACKAGE
Crankshaft Front Oil Seal Installation.
0084-2
TM 5-3895-379-23-1
0085
FIELD MAINTENANCE CRANKSHAFT REAR OIL SEAL REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Bushing Driver Set (Volume 2, WP 0289, Table 1, Item 4) Inserter, Seal (Volume 2, WP 0289, Table 1, Item 17) Inserter, Seal (Volume 2, WP 0289, Table 1, Item 18) Wrench, Torque, 0-300 in-lb (Volume 2, WP 0289, Table 1, Item 41) Materials/Parts Gasket (Volume 2, WP 0290, Table 1, Item 49) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 2 Equipment Condition Flywheel removed. (WP 0086) Flywheel housing removed. (WP 0087)
0085-1
TM 5-3895-379-23-1
0085
REMOVAL
NOTE
Removal and installation procedures are the same for the CB534B and CB534C Rollers. The CB534C Roller shown has a 14-bolt housing assembly. The CB534B Roller has a 10-bolt housing. 1. 2. Remove 12 bolts (Figure 1, Item 1), two socket head bolts (Figure 1, Item 6), and washers (Figure 1, Item 7) from housing assembly (Figure 1, Item 2). Remove crankshaft rear oil seal (Figure 1, Item 4), gasket (Figure 1, Item 3), and housing assembly (Figure 1, Item 2) from cylinder block dowels (Figure 1, Item 5). Discard gasket.
2 5 4 3
6, 7
M0073SWR
Figure 1. END OF TASK CLEANING
Crankshaft Rear Oil Seal Removal.
Ensure all parts and surfaces of the engine block are clean and free of oil, grease, and dirt. END OF TASK INSPECTION Inspect all parts and surfaces for damage and cracks. Replace as required. END OF TASK
0085-2
TM 5-3895-379-23-1
0085
INSTALLATION
NOTE
The crankshaft rear seal is lubricated by the manufacturer. Do not lubricate seal or crankshaft flange prior to installation. 1. Using seal installer (Figure 2, Item 2) and suitable press, install crankshaft rear seal (Figure 2, Item 3) into housing assembly (Figure 2, Item 1).
1 2 3
M0074SWR
Figure 2. 2. 3. 4.
Crankshaft Rear Oil Seal Installation.
Position seal installer (Figure 3, Item 5) onto crankshaft flange. Install new gasket (Figure 3, Item 2) to cylinder block dowels (Figure 3, Item 4). Install housing (Figure 3, Item 1) and new oil seal (Figure 3, Item 3) as an assembly on the two cylinder block dowels (Figure 3, Item 4). Remove seal installer (Figure 3, Item 5).
1 4 3 2
3
M0075SWR
Figure 3.
0085-3
TM 5-3895-379-23-1
0085
NOTE
If installing M8 bolts, tighten two bolts to 160 lb-in. (18 Nm). If installing M6 bolts, tighten two bolts to 116 lb-in. (13 Nm). 5. Install 12 bolts (Figure 4, Item 1), two washers (Figure 4, Item 3), and socket head bolts (Figure 4, Item 2) in housing (Figure 4, Item 4). Tighten eight bolts to 192 lb-in. (22 Nm).
M1114SWR
4
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install flywheel housing. (WP 0087) Install flywheel. (WP 0086)
2, 3
0085-4
TM 5-3895-379-23-1
0086
FIELD MAINTENANCE FLYWHEEL ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Beam, Hoisting (Volume 2, WP 0289, Table 1, Item 2) Bracket, Mounting (Volume 2, WP 0289, Table 1, Item 3) Guide Bolts, 1/2 x 4 x 30 Lifting Device, Minimum Capacity 120 lb (54 kg) Pin, Straight, Threaded (Volume 2, WP 0289, Table 1, Item 24) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figure 5 Equipment Condition Starter assembly removed. (WP 0152) Vibratory and propel pumps removed. (WP 0203)
0086-1
TM 5-3895-379-23-1
0086
REMOVAL
WARNING
NOTE
Weight of flywheel assembly is 120 lb (54 kg). 1. Remove two bolts (Figure 1, Item 1) and washers (Figure 1, Item 2) from flywheel assembly (Figure 1, Item 3).
1, 2
M0076SWR
Figure 1. Flywheel Assembly Removal. 2. Install two guide bolts (Figure 2, Item 2) through flywheel assembly (Figure 2, Item 1) to crankshaft (Figure 2, Item 3).
0086-2
TM 5-3895-379-23-1
0086
REMOVAL - Continued
3
M0077SWR
Figure 2. 3. 4. 5. 6. 7.
Flywheel Assembly Removal.
Install link bracket (Figure 3, Item 3) to flywheel assembly (Figure 3, Item 2). Attach lifting device to link bracket (Figure 3, Item 3). Remove remaining six bolts (Figure 3, Item 4) and washers (Figure 3, Item 5) from flywheel assembly (Figure 3, Item 2). With assistance, use lifting device to remove flywheel assembly (Figure 3, Item 2) from flywheel housing (Figure 3, Item 1). Remove guide bolts (Figure 3, Item 7) from crankshaft (Figure 3, Item 6).
7
4, 5
M0078SWR
Flywheel Assembly Removal.
0086-3
TM 5-3895-379-23-1
0086
INSTALLATION
WARNING
NOTE
If flywheel ring rear teeth are damaged, replace flywheel assembly. Weight of flywheel assembly is 120 lb (54 kg). 1. Install two guide bolts (Figure 4, Item 1) to crankshaft (Figure 4, Item 2).
1
2
M1122SWR
Figure 4. Flywheel Assembly Installation. 2. 3. 4. 5. 6. 7. Install link bracket (Figure 5, Item 3) to flywheel assembly (Figure 5, Item 2). Attach lifting device to link bracket (Figure 5, Item 3) and flywheel assembly (Figure 5, Item 2). With assistance, lift flywheel assembly (Figure 5, Item 2) into flywheel housing (Figure 5, Item 1). Install six washers (Figure 5, Item 5) and bolts (Figure 5, Item 4) into flywheel assembly (Figure 5, Item 2) and crankshaft (Figure 5, Item 6). Tighten bolts to 77 lb-ft (104 Nm). Remove lifting device and link bracket (Figure 5, Item 3) from flywheel assembly (Figure 5, Item 2). Remove guide bolts (Figure 5, Item 7) from flywheel assembly (Figure 5, Item 2).
0086-4
TM 5-3895-379-23-1
0086
1 2 3
4, 5
M1123SWR
Figure 5. 8.
Flywheel Assembly Installation.
Install remaining two washers (Figure 6, Item 2) and bolts (Figure 6, Item 1) into flywheel (Figure 6, Item 3) and crankshaft (Figure 6, Item 4). Tighten bolts to 77 lb-ft (104 Nm).
1, 2
M1121SWR
Flywheel Assembly Installation.
0086-5
TM 5-3895-379-23-1
0086
FOLLOW-ON MAINTENANCE 1. 2. Install starter assembly. (WP 0152) Install vibratory and propel pumps. (WP 0203)
0086-6
TM 5-3895-379-23-1
0087
FIELD MAINTENANCE FLYWHEEL HOUSING REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Lifting Device, Minimum Capacity 70 lb (32 kg) Link (Volume 2, WP 0289, Table 1, Item 22) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Gasket (Volume 2, WP 0290, Table 1, Item 54) Qty: 1 Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figure 6 Equipment Condition Engine assembly removed. (WP 0078) Starter removed. (WP 0152) Flywheel assembly removed. (WP 0086)
0087-1
TM 5-3895-379-23-1
0087
REMOVAL
WARNING
NOTE
Weight of flywheel housing is 70 lb (32 kg). 1. 2. Set engine on flat level surface and support engine forward of flywheel housing. Remove two mounting bolts (Figure 1, Item 1) on top of flywheel housing (Figure 1, Item 2).
1 2
M0079SWR
Figure 1. Flywheel Housing Removal.
0087-2
TM 5-3895-379-23-1
0087
REMOVAL - Continued 3. 4. Attach two link brackets (Figure 2, Item 1) and lifting device to support flywheel housing (Figure 2, Item 4). Remove six mounting bolts (Figure 2, Item 3) that attach flywheel housing (Figure 2, Item 4) to cylinder block.
NOTE
If necessary, use a soft hammer to separate flywheel housing from its doweled location. 5. With assistance, remove flywheel housing (Figure 2, Item 4) away from engine (Figure 2, Item 2).
1 2 3 4
M0080SWR
Flywheel Housing Removal.
0087-3
TM 5-3895-379-23-1
0087
INSTALLATION
NOTE
Make sure rear face of cylinder block housing is clean and undamaged. Verify dowels are undamaged. If equipped with felt seal to rear flange of oil pan, replace felt seal during installation procedure. Weight of flywheel housing is 70 lb (32 kg). 1. 2. Attach two link brackets (Figure 3, Item 1) and lifting device and support flywheel housing (Figure 3, Item 3). With assistance, lift and position flywheel housing (Figure 3, Item 3) on dowels attached to cylinder block. Ensure holes are aligned.
NOTE
For aluminum flywheel housings, bolt torque is 52 lb-ft (71 Nm). For cast iron flywheel housing, bolt torques are as follows: Cast iron flywheel housing with M10 bolt: 33 lb-ft (45 Nm); Cast iron flywheel housing with M12 bolts stamped 8.8: 55 lb-ft (75 Nm); Cast iron flywheel housing with M12 bolts stamped 10.9: 85 lb-ft (115 Nm). 3. Install six mounting bolts (Figure 3, Item 2) that attach the flywheel housing (Figure 3, Item 3) to cylinder block.
1 2 3
M1172SWR
Figure 3. Flywheel Housing Installation.
0087-4
TM 5-3895-379-23-1
0087
INSTALLATION - Continued 4. Install two mounting bolts (Figure 4, Item 1) on top of flywheel housing (Figure 4, Item 2).
1 2
M0081SWR
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Install flywheel assembly. (WP 0086) Install starter motor. (WP 0152) Install engine assembly. (WP 0078)
Flywheel Housing Installation.
0087-5/6 blank
TM 5-3895-379-23-1
0088
FIELD MAINTENANCE VALVE LASH (CLEARANCE) ADJUSTMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Personnel Required Construction Equipment Repairer 91L Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Valve mechanism cover removed. (WP 0101)
ADJUSTMENT 1. Valve lash is measured between top of valve stem and rocker arm lever. With engine hot or cold, correct clearances are 0.008 in. (0.20 mm) for inlet valves and 0.018 in. (0.45 mm) for exhaust valves.
NOTE
No. 1 cylinder is at front of engine. To set valve lash for respective cylinders, perform the following steps: 2. No. 1 Cylinder: Rotate crankshaft in direction of engine rotation until inlet valve of No. 4 cylinder has just opened and No. 4 exhaust valve has not completely closed. Check clearances of inlet and exhaust valve for No. 1 cylinder and adjust as necessary. No. 3 Cylinder: Rotate crankshaft in direction of engine rotation until inlet valve of No. 2 cylinder has just opened and No. 2 exhaust valve has not completely closed. Check clearances of inlet and exhaust valve for No. 3 cylinder and adjust as necessary. No. 4 Cylinder: Rotate crankshaft in direction of engine rotation until inlet valve of No. 1 cylinder has just opened and No. 1 exhaust valve has not completely closed. Check clearances of inlet and exhaust valve for No. 4 cylinder and adjust as necessary. No. 2 Cylinder: Rotate crankshaft in direction of engine rotation until inlet valve of No. 3 cylinder has just opened and No. 3 exhaust valve has not completely closed. Check clearances of inlet and exhaust valve for No. 2 cylinder and adjust as necessary.
3.
4.
5.
END OF TASK
0088-1
TM 5-3895-379-23-1
0088
FOLLOW-ON MAINTENANCE 1. 2. Install valve mechanism cover. (WP 0101) Start engine and check for proper operation. (TM 5-3895-379-10)
0088-2
TM 5-3895-379-23-1
0089
FIELD MAINTENANCE ROCKER SHAFT ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Lubricating Oil, Engine, 15W40 Grade (Volume 2, WP 0288, Table 1, Item 29, 30, 31) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 9 WP 0088 Equipment Condition Valve mechanism cover removed. (WP 0101)
0089-1
TM 5-3895-379-23-1
0089
REMOVAL
NOTE
It is not necessary to remove the oil supply tube in order to remove rocker shaft assembly. Begin removal of rocker arm assembly starting at the end brackets and moving toward the center. If pushrods are removed, tag and mark for installation. 1. 2. 3. Remove three nuts (Figure 1, Item 1) and bolts (Figure 1, Item 4) from rocker shaft assembly (Figure 1, Item 2). Remove rocker arm assembly (Figure 1, Item 2). If required, remove oil seal (Figure 1, Item 3) from oil supply passage in cylinder head (Figure 1, Item 5). Discard oil seal.
M0082SWR
5
Figure 1. Rocker Shaft Assembly Removal. END OF TASK INSTALLATION
NOTE
Make sure all oil holes in rocker shaft and in rocker levers are not clogged or plugged prior to assembly procedure. When installing, make sure bolt and oil supply connection are correctly positioned on rocker shaft. Lubricate all components with clean engine oil before and after installation. 1. If removed, install new oil seal (Figure 2, Item 3) in oil supply passage in cylinder head (Figure 2, Item 5).
0089-2
TM 5-3895-379-23-1
0089
NOTE
If removed, ensure pushrods are installed in original location and seated correctly on valve lifters. Ensure pushrods are seated properly under individual rocker arms and rocker arm assembly sits evenly on cylinder head. Ensure adjustment screws are properly seated in ends of pushrods. It may be necessary to loosen adjustment screws to help prevent bent valves or pushrods during installation. 2. Position rocker arm assembly (Figure 2, Item 2) on cylinder head (Figure 2, Item 5).
NOTE
Start from the center and tighten nuts and bolts outward. Alternately tighten the nuts and bolts. On aluminum bracket, tighten nuts and bolts to 30 lb-ft (41 Nm). On cast iron or steel brackets, tighten nuts and bolts to 55 lb-ft (75 Nm). 3. Install three bolts (Figure 2, Item 4) and nuts (Figure 2, Item 1) on rocker arm assembly (Figure 2, Item 2).
M0083SWR
5
Figure 2. 4. Adjust valve lash (WP 0088). Rocker Shaft Assembly Installation.
END OF TASK FOLLOW-ON MAINTENANCE Install valve mechanism cover. (WP 0101) END OF TASK END OF WORK PACKAGE
0089-3/4 blank
TM 5-3895-379-23-1
0090
FIELD MAINTENANCE ROCKER ARM ASSEMBLY REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Lubricating Oil, Engine, 15W40 Grade (Volume 2, WP 0288, Table 1, Item 29, 30, 31) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Ring, Retaining (Volume 2, WP 0290, Table 1, Item 97) Qty: 2 Washer, Flat (Volume 2, WP 0290, Table 1, Item 95) Qty: 2 Personnel Required Construction Equipment Repairer 91L Equipment Condition Rocker shaft assembly removed. (WP 0089)
0090-1
TM 5-3895-379-23-1
0090
DISASSEMBLY
NOTE
Tag and mark each component to ensure correct assembly. 1. 2. 3. 4. 5. 6. Remove two retaining rings (Figure 1, Item 1) and washers (Figure 1, Item 2) from each end of rocker arm (Figure 1, Item 3). Discard retaining rings and washers. Slide components off each end of rocker shaft assembly. Remove end rocker arm (Figure 1, Item 3) from rocker shaft (Figure 1, Item 10). Remove remaining rocker arms (Figure 1, Item 3), rocker shaft brackets (Figure 1, Item 4), springs (Figure 1, Item 5), and washers (Figure 1, Item 6) from rocker shaft (Figure 1, Item 10). Remove rocker arm bushing (Figure 1, Item 7) from rocker shaft (Figure 1, Item 10). If necessary, remove bolt (Figure 1, Item 9) and oil supply connection (Figure 1, Item 8) from rocker shaft (Figure 1, Item 10).
1 2
M0084SWR
10
Figure 1. Rocker Arm Disassembly. END OF TASK
0090-2
TM 5-3895-379-23-1
0090
ASSEMBLY
NOTE
Make sure all oil holes in rocker shaft and in rocker levers are not clogged or plugged before beginning assembly procedure. When assembling, make sure bolt and oil supply connection are correctly positioned on rocker shaft. Lubricate all components with clean engine oil before beginning assembly procedure. 1. If removed, install oil supply connection (Figure 2, Item 8) and bolt (Figure 2, Item 9) on rocker shaft (Figure 2, Item 10).
NOTE
Bushings may require reaming to fit. Ream new arm bushing to a clearance of 0.0024 +/0.0012 in. (0.06 +/- 0.03 mm). 2. Install arm bushing (Figure 2, Item 7) on rocker shaft (Figure 2, Item 10).
NOTE
Install each of the components in the correct order onto rocker shaft. Ensure bolts and connectors are correctly positioned on rocker shaft. 3. 4. Install remaining washers (Figure 2, Item 6), springs (Figure 2, Item 5), rocker shaft brackets (Figure 2, Item 4), and rocker arms (Figure 2, Item 3) on rocker shaft (Figure 2, Item 10). Install two new washers (Figure 2, Item 2) and new retaining rings (Figure 2, Item 1) each end of rocker arm (Figure 2, Item 3).
1 2
M0086SWR
10
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE Install rocker shaft assembly. (WP 0089) END OF TASK END OF WORK PACKAGE
Rocker Arm Assembly.
0090-3/4 blank
TM 5-3895-379-23-1
0091
FIELD MAINTENANCE IDLER GEAR AND HUB REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Bushing Driver Set (Volume 2, WP 0289, Table 1, Item 4) Puller Kit, Universal (Volume 2, WP 0289, Table 1, Item 27) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Bushing (Volume 2, WP 0290, Table 1, Item 96) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 10 Equipment Condition Timing gear case cover removed. (WP 0092)
0091-1
TM 5-3895-379-23-1
0091
REMOVAL
NOTE
Idler gear marks may not be in mesh with other three gears due to different speed of rotation of idler gear. 1. 2. Align timing marks on crankshaft gear (Figure 1, Item 6), camshaft gear (Figure 1, Item 7), fuel injector pump gear (Figure 1, Item 5), and idler gear (Figure 1, Item 4). Remove three bolts (Figure 1, Item 2) and retaining plate (Figure 1, Item 3) from idler gear (Figure 1, Item 4).
NOTE
Use puller to remove idler gear. 3. Remove idler gear (Figure 1, Item 4) from front of cylinder block (Figure 1, Item 1).
1 2 3 4
M0087SWR
Figure 1.
Idler Gear and Hub Removal.
CAUTION
Do not turn crankshaft while idler gear is off engine.
NOTE
Drive gear of fuel injection pump may turn counterclockwise when idler gear is removed. Drive gear of fuel injection pump may have to be turned clockwise to align timing marks before installing idler gear. Remove bushings with puller or roller off front face of one bushing and remove with driver and press. 4. If necessary, remove two-piece bushings (Figure 2, Item 2) from idler gear (Figure 2, Item 1).
0091-2
TM 5-3895-379-23-1
0091
REMOVAL - Continued
1 2
M0088SWR
Figure 2.
NOTE
Prior to removal of idler gear hub, ensure oil hole is marked with an (X) at top. 5. Remove idler gear hub (Figure 3, Item 1) from cylinder block (Figure 3, Item 2).
1 2
M0089SWR
(X)
0091-3
TM 5-3895-379-23-1
0091
INSTALLATION
NOTE
When hub is installed, make sure oil hole marked (X) is at top. 1. Install idler gear hub (Figure 4, Item 1) on cylinder block (Figure 4, Item 2).
1 2
M1113SWR
(X)
Figure 4. Idler Gear and Hub Installation. 2. If removed, install two piece bushings (Figure 5, Item 2) on idler gear (Figure 5, Item 1). To install bushings on idler gear: a. b. Press in new bushings. Machine bores to correct tolerance for clearance on hub. Specification for clearance of bushings on hub is 0.0023 - 0.0047 in. (0.058 - 0.119 mm). Specification for inside of flanged bushings (tilted in position) is 1.998 - 2.0007 in. (50.80 - 50.82 mm). Machine faces of bushings to get correct end play clearance of gear. Specification for width of gear and split bushing assembly (tilted in position) is 1.186 - 1.187 in. (30.12 - 30.15 mm). Specification for end play of gear is 0.004 - 0.008 in. (0.10 - 0.20 mm).
c.
3.
Install idler gear (Figure 5, Item 1) on gear hub (Figure 4, Item 1) front of cylinder block (Figure 4, Item 2).
0091-4
TM 5-3895-379-23-1
0091
1 2
M1112SWR
Figure 5.
Idler Gear and Hub Installation.
0091-5
TM 5-3895-379-23-1
0091
NOTE
Drive gear of fuel injection pump may have to be turned clockwise to align timing marks before installing idler gear. Ensure timing marks on crankshaft gear, camshaft gear, and idler gear are aligned after installation of idler gear. 4. Install retaining plate (Figure 6, Item 3) and three bolts (Figure 6, Item 2) on idler gear (Figure 6, Item 4). Tighten bolts to a torque of 33 lb-ft (45 Nm).
NOTE
Idler gear end play is between 0.004 to 0.008 in. (0.10 to 0.20 mm). 5. Check idler gear (Figure 6, Item 4) end play. Replace idler gear if out of tolerance.
NOTE
Idler and camshaft gear end play must have a minimum backlash of 0.003 (0.08 mm). 6. Check timing between camshaft gear (Figure 6, Item 7) and idler gear (Figure 6, Item 4). Replace idler gear if out of tolerance.
1 2 3 4
M0090SWR
Figure 6. Idler Gear and Hub Installation. END OF TASK FOLLOW-ON MAINTENANCE Install timing gear case cover. (WP 0092) END OF TASK END OF WORK PACKAGE
0091-6
TM 5-3895-379-23-1
0092
FIELD MAINTENANCE TIMING GEAR CASE COVER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Aligning Tool, Rotating Members (Volume 2, WP 0289, Table 1, Item 1) Cover Guide (Volume 2, WP 0289, Table 1, Item 5) Wrench, Torque, 0-300 in-lb (Volume 2, WP 0289, Table 1, Item 41) Materials/Parts Gasket (Volume 2, WP 0290, Table 1, Item 48) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 10 Equipment Condition Operator platform assembly raised. (Volume 2, WP 0235) Fan drive pulley removed. (WP 0145) Crankshaft pulley removed. (WP 0083) Water pump removed. (WP 0144) Alternator removed. (WP 0148)
REMOVAL 1. 2. Remove 17 bolts (Figure 1, Item 5) and two nuts (Figure 1, Item 1). Remove timing gear case cover (Figure 1, Item 2) and gasket (Figure 1, Item 3). Discard gasket.
M0091SWR
5
2, 3, 4
Timing Gear Case Cover Removal.
0092-1
TM 5-3895-379-23-1
0092
INSTALLATION 1. 2. 3. Clean all faces of mating components. Install new gasket (Figure 2, Item 3) and timing case cover (Figure 2, Item 2) to timing case (Figure 2, Item 4). Install two bolts (Figure 2, Item 5) loosely to hold gasket (Figure 2, Item 3) and timing case cover (Figure 2, Item 2) in position.
M1299SWR
2, 3, 4
Figure 2. Timing Gear Case Cover Installation. 4. Use front cover alignment tool and crankshaft pulley bolts (Figure 3, Item 1) to centralize timing case cover (Figure 3, Item 2).
M0092SWR
Figure 3. Timing Gear Case Cover Installation.
0092-2
TM 5-3895-379-23-1
0092
CAUTION
Position of timing gear case cover is critical. If cover is not centered, backlash between fuel pump gear and water pump gear could be affected. This could result in damage to fuel injection pump. 5. Install 17 cover bolts (Figure 4, Item 5) and two nuts (Figure 4, Item 1). Tighten bolts to 192 lb-in. (22 Nm).
M1054SWR
5
Figure 4. 6. Remove front cover alignment tool.
2, 3, 4
Timing Gear Cover Installation.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Install alternator. (WP 0148) Install water pump. (WP 0144) Install crankshaft pulley. (WP 0083) Install fan drive pulley. (WP 0145) Lower operator platform assembly. (Volume 2, WP 0235)
0092-3/4 blank
TM 5-3895-379-23-1
0093
FIELD MAINTENANCE OIL PAN REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Goggles (Volume 2, WP 0289, Table 1, Item 13) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Adhesive, Gasket Cement (Volume 2, WP 0288, Table 1, Item 3) Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Gasket (Volume 2, WP 0290, Table 1, Item 132) Qty: 1 O-ring (Volume 2, WP 0290, Table 1, Item 94) Qty: 1 Materials/Parts (cont.) O-ring (Volume 2, WP 0290, Table 1, Item 108) Qty: 1 Gasket (Volume 2, WP 0290, Table 1, Item 54) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 6 and 14 Equipment Condition Engine off. (TM 5-3895-3790-10) Gauge rod (dipstick) tube assembly removed. (WP 0099) Engine oil drained. (WP 0077)
0093-1
TM 5-3895-379-23-1
0093
REMOVAL
WARNING
NOTE
Oil pan is replaced the same way for CB534B and CB534C Rollers. CB534B Roller is shown. 1. 2. 3. Remove four bolts (Figure 1, Item 3) from oil pan (Figure 1, Item 5). Remove six bolts (Figure 1, Item 4) from oil pan (Figure 1, Item 5). Remove 12 screws (Figure 1, Item 6), breather tube bracket (Figure 1, Item 7), oil pan (Figure 1, Item 5), and gasket (Figure 1, Item 2) from engine (Figure 1, Item 1). Discard gasket.
1 2
4 5 7 6
M0093SWR
Figure 1.
Oil Pan Removal.
0093-2
TM 5-3895-379-23-1
0093
REMOVAL - Continued 4. 5. 6. 7. Remove plug (Figure 2, Item 2) and O-ring (Figure 2, Item 3) from oil pan (Figure 2, Item 7). Discard O-ring. Remove insert (Figure 2, Item 1) and plug (Figure 2, Item 8) from oil pan (Figure 2, Item 7). Remove drain valve (Figure 2, Item 6) and O-ring (Figure 2, Item 5) from oil pan (Figure 2, Item 7). Discard O-ring. Remove gasket (Figure 2, Item 4) from oil pan (Figure 2, Item 7). Discard seal.
1 8
2 3 4
2 3 5 6
7
M0094SWR
Oil Pan Removal.
0093-3
TM 5-3895-379-23-1
0093
INSTALLATION
WARNING
Adhesive causes immediate bonding on contact with eyes, skin or clothing and also gives off harmful vapors. Wear protective goggles and use in well-ventilated area. If adhesive gets in eyes, try to keep eyes open; flush eyes with water for 15 minutes and get immediate medical attention. 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 sealing compound gets on skin or clothing, wash immediately with soap and water.
NOTE
Ensure mating surfaces are clean. 1. Install new gasket (Figure 3, Item 4) on oil pan (Figure 3, Item 7) using gasket cement.
CAUTION
Ensure drain valve is in the closed (full right) position after installation. Failure to follow this caution may cause damage to equipment. 2. 3. 4. Install new O-ring (Figure 3, Item 5) and drain valve (Figure 3, Item 6) on oil pan (Figure 3, Item 7). Place drain valve in closed position. Install plug (Figure 3, Item 8) and insert (Figure 3, Item 1) on oil pan (Figure 3, Item 7). Install new O-ring (Figure 3, Item 3) and plug (Figure 3, Item 2) on oil pan (Figure 3, Item 7).
1 8
2 3 4
2 3 5 6
7
M1120SWR
Figure 3.
Oil Pan Installation.
0093-4
TM 5-3895-379-23-1
0093
INSTALLATION - Continued 5. 6. 7. Install gasket (Figure 4, Item 3), breather tube bracket (Figure 4, Item 8), and oil pan (Figure 4, Item 6) on engine (Figure 4, Item 2) with 12 screws (Figure 4, Item 7). Tighten screws to 15-25 lb-ft (20-34 Nm). Install six bolts (Figure 4, Item 5) on oil pan (Figure 4, Item 6). Tighten bolts to 15-25 lb-ft (20-34 Nm). Install four bolts (Figure 4, Item 4) on oil pan (Figure 4, Item 6). Tighten bolts to 15-25 lb-ft (20-34 Nm).
2 1 3
OPEN 4 CLOSE
5 6 8 7
M0095SWR
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3.
Oil Pan Installation.
Install gauge rod (dipstick) tube assembly. (WP 0099) Fill engine with oil. (WP 0077) Operate roller and check for leaks. (TM 5-3895-379-10)
0093-5/6 blank
TM 5-3895-379-23-1
0094
FIELD MAINTENANCE ENGINE OIL PUMP REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 50-250 ft-lb (Volume 2, WP 0289, Table 1, Item 43) Materials/Parts Sealing Compound, Loctite 271 (Volume 2, WP 0288, Table 1, Item 62) Gasket (Volume 2, WP 0290, Table 1, Item 50) Qty: 2 O-ring (Volume 2, WP 0290, Table 1, Item 33) Qty: 2 Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figure 11 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Oil pan removed. (WP 0093)
0094-1
TM 5-3895-379-23-1
0094
REMOVAL
NOTE
The engine oil pump is mounted to No. 1 main bearing cap. Use a torque wrench extension to reach No. 1 bearing cap. 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove two bolts (Figure 1, Item 6) and No. 1 main bearing cap (Figure 1, Item 13) from engine block (Figure 1, Item 3). Remove two bolts (Figure 1, Item 1) from strainer (Figure 1, Item 8) and suction pipe (Figure 1, Item 11) from engine oil pump (Figure 1, Item 15). Remove bolt (Figure 1, Item 9) from engine oil pump support bracket (Figure 1, Item 10). Remove strainer (Figure 1, Item 8), suction pipe (Figure 1, Item 11), and gasket (Figure 1, Item 14) from roller. Discard gasket. Remove two bolts (Figure 1, Item 2) from engine oil relief valve (Figure 1, Item 12). Remove bolt (Figure 1, Item 7) from engine oil relief valve (Figure 1, Item 12). Remove engine oil relief valve (Figure 1, Item 12) from engine block (Figure 1, Item 3). Disconnect oil tube (Figure 1, Item 4) from engine oil relief valve (Figure 1, Item 12) and remove two O-rings (Figure 1, Item 5) from oil tube (Figure 1, Item 4). Discard O-rings. Remove engine oil pump (Figure 1, Item 15) from engine block (Figure 1, Item 3).
1 2 3 4, 5 6 7 8 9
M0096SWR
15
14
13
12
11
10
Figure 1. Engine Oil Pump Removal. END OF TASK INSTALLATION
CAUTION
Use a feeler gauge to check and insure that there is a minimum of 0.003 inch (0.08 mm) backlash between engine oil pump gear and idler gear. 1. 2. Fill engine oil pump (Figure 2, Item 15) with clean engine oil. Install engine oil pump (Figure 2, Item 15) on engine.
0094-2
TM 5-3895-379-23-1
0094
INSTALLATION - Continued 3. 4. 5. 6. 7. 8. 9. 10. Install two new O-rings (Figure 2, Item 5) on oil tube (Figure 2, Item 4) and connect oil tube (Figure 2, Item 4) to oil relief valve (Figure 2, Item 12). Install engine oil relief valve (Figure 2, Item 12) on engine. Install bolt (Figure 2, Item 7) on engine oil relief valve (Figure 2, Item 12) and engine block (Figure 2, Item 3). Install two bolts (Figure 2, Item 2) to engine oil relief valve (Figure 2, Item 12) and engine oil pump (Figure 2, Item 15). Install new gasket (Figure 2, Item 14), suction pipe (Figure 2, Item 11), and strainer (Figure 2, Item 8) on roller. Install bolt (Figure 2, Item 9) on oil pump support bracket (Figure 2, Item 10). Install two bolts (Figure 2, Item 1) on strainer (Figure 2, Item 8) and suction pipe (Figure 2, Item 11). Install No. 1 main bearing cap (Figure 2, Item 13) and two bolts (Figure 2, Item 6) on engine block (Figure 2, Item 3). Tighten bolts to 195 lb-ft (264 Nm).
2 1 3 4, 5 6 7 8 9
15
14
13
12
11
10
M1101SWR
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install oil pan. (WP 0093) Fill engine with oil. (WP 0077)
Engine Oil Pump Installation.
Start engine and check for leaks and proper operation. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0094-3/4 blank
TM 5-3895-379-23-1
0095
FIELD MAINTENANCE ENGINE OIL COOLER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Goggles (Volume 2, WP 0289, Table 1, Item 13) Materials/Parts Cleaning Compound, Solvent (Volume 2, WP 0288, Table 1, Item 13, 14, 15) Cloth, Cleaning (Volume 2, WP 0288, Table 1, Item 16) Lubricating Oil, Engine, 15W40 Grade (Volume 2, WP 0288, Table 1, Item 29, 30, 31) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Gasket (Volume 2, WP 0290, Table 1, Item 100) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 15 Equipment Condition Engine coolant drained. (WP 0139) Engine oil drained. (WP 0077) Right-side door assembly opened. (TM 5-3895-379-10)
0095-1
TM 5-3895-379-23-1
0095
REMOVAL
NOTE
Tag and mark hoses to aid in installation. Oil cooler is replaced the same way for CB534B and CB534C Rollers except where noted. Inspect all hoses, lines, and fittings for cracks, bends, nicks, dents, stripped treads, and cuts. Replace all damaged parts. 1. 2. Loosen two clamps (Figure 1, Item 3) and remove hose assemblies (Figure 1, Items 4 and 5) from oil cooler (Figure 1, Item 8). Remove connector (Figure 1, Item 6).
NOTE
On CB534B Roller, item 7 is a ring. On CB534C Roller, item 7 is a washer. 3. 4. 5. Remove connector ring (Figure 1, Item 7) or washer (Figure 1, Item 7). Discard ring or washer. Remove oil cooler (Figure 1, Item 8), gasket (Figure 1, Item 9), and rubber housing bushing (Figure 1, Item 2) from oil filter head assembly (Figure 1, Item 1). Remove gasket (Figure 1, Item 9) from oil cooler (Figure 1, Item 8). Discard gasket.
4 5 3 3 1 2
6 7 8 9
M0097SWR
Figure 1. Engine Oil Cooler Removal. END OF TASK
0095-2
TM 5-3895-379-23-1
0095
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. 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. 1. 2. 3. Clean all metal parts with cleaning compound, solvent. Use cleaning cloth or compressed air to dry all metal parts. Check oil cooler and connector for nicks and cracks that could cause leakage. Check for stripped threads. Replace any damaged parts.
END OF TASK
0095-3
TM 5-3895-379-23-1
0095
INSTALLATION 1. 2. Apply a light coat of lubricating oil to new gasket (Figure 2, Item 9) and rubber brushing (Figure 2, Item 2) and install gasket and rubber bushing on oil cooler (Figure 2, Item 8). Position oil cooler (Figure 2, Item 8) on oil filter head assembly (Figure 2, Item 1).
NOTE
On CB534B Roller, Item 7 is a ring. On CB534C Roller, Item 7 is a washer. 3. 4. 5. Install new connector ring or washer (Figure 2, Item 7) on oil cooler (Figure 2, Item 8). Install connector (Figure 2, Item 6). Install hose assemblies (Figure 2, Items 4 and 5) on oil cooler (Figure 2, Item 8) and tighten two clamps (Figure 2, Item 3).
4 5 3 3 1 2
6 7 8 9
M1212SWR
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4.
Engine Oil Cooler Installation.
Close right-side door assembly. (TM 5-3895-379-10) Fill cooling system to proper level. (WP 0139) Fill engine with oil. (WP 0077) Start engine and check for leaks. (TM 5-3895-379-10)
0095-4
TM 5-3895-379-23-1
0096
FIELD MAINTENANCE ENGINE OIL COOLER LINES AND FITTINGS REPLACEMENT (CB534B)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 15 Equipment Condition Engine off. (TM 5-3895-379-10) Coolant system drained. (WP 0139) Operator platform assembly raised. (Volume 2, WP 0235)
REMOVAL 1. 2. 3. Loosen nut (Figure 1, Item 4) and remove tube (Figure 1, Item 5) from elbow (Figure 1, Item 2). Remove compression sleeve (Figure 1, Item 3) and nut (Figure 1, Item 4) from hose (Figure 1, Item 5). Remove elbow (Figure 1, Item 2) from connector (Figure 1, Item 1).
1 2 3 4 5
M0098SWR
Figure 1. Engine Oil Cooler Lines and Fittings Removal.
0096-1
TM 5-3895-379-23-1
0096
REMOVAL - Continued 4. 5. Remove screw (Figure 2, Item 2), clamp (Figure 2, Item 1), and tube (Figure 2, Item 3) from bracket (Figure 2, Item 4). Remove clamp (Figure 2, Item 1) from tube (Figure 2, Item 3).
4 3
M0099SWR
Figure 2. Engine Oil Cooler Lines and Fittings Removal. 6. 7. 8. 9. 10. 11. 12. 13. Loosen clamp (Figure 3, Item 9) and remove tube (Figure 3, Item 1) from hose (Figure 3, Item 8). Remove clamp (Figure 3, Item 9) from hose (Figure 3, Item 8). Loosen clamp (Figure 3, Item 7) and remove hose (Figure 3, Item 8) from oil cooler assembly (Figure 3, Item 6). Remove clamp (Figure 3, Item 7) from hose (Figure 3, Item 8). Loosen clamp (Figure 3, Item 5) and remove hose (Figure 3, Item 2) from oil cooler assembly (Figure 3, Item 6). Remove clamp (Figure 3, Item 5) from hose (Figure 3, Item 2). Loosen clamp (Figure 3, Item 3) and remove hose (Figure 3, Item 2) from hose (Figure 3, Item 4). Remove clamp (Figure 3, Item 3) from hose (Figure 3, Item 2).
0096-2
TM 5-3895-379-23-1
0096
REMOVAL - Continued
1 9 2 8 7 3 4
6
M0100SWR
Figure 3. Engine Oil Cooler Lines and Fittings Removal. END OF TASK
0096-3
TM 5-3895-379-23-1
0096
INSTALLATION 1. 2. Place clamp (Figure 4, Item 5) on tube (Figure 4, Item 4). Install hose (Figure 4, Item 4), clamp (Figure 4, Item 5), and throttle cable bracket (Figure 4, Item 2) on engine block (Figure 4, Item 3) with two washers (Figure 4, Item 1) and screws (Figure 4, Item 6). Tighten screws to 15-25 lb-ft (20-34 Nm).
1 4 2 4
5
M0101SWR
Figure 4. Engine Oil Cooler Lines and Fittings Installation. 3. 4. 5. 6. Place clamp (Figure 5, Item 4) on hose (Figure 5, Item 5). Install hose (Figure 5, Item 5) on tube (Figure 5, Item 3) and tighten clamp (Figure 5, Item 4). Place clamp (Figure 5, Item 1) on hose (Figure 5, Item 5). Install hose (Figure 5, Item 5) on adapter (Figure 5, Item 2) and tighten clamp (Figure 5, Item 1).
0096-4
TM 5-3895-379-23-1
0096
3
M0102SWR
Figure 5. Engine Oil Cooler Lines and Fittings Installation. 7. 8. 9. 10. 11. 12. 13. 14. Place clamp (Figure 6, Item 3) on hose (Figure 6, Item 2). Install hose (Figure 6, Item 2) on hose (Figure 6, Item 4) and tighten clamp (Figure 6, Item 3). Place clamp (Figure 6, Item 5) on hose (Figure 6, Item 2). Install hose (Figure 6, Item 2) on oil cooler assembly (Figure 6, Item 6) and tighten clamp (Figure 6, Item 5). Place clamp (Figure 6, Item 7) on hose (Figure 6, Item 8). Install hose (Figure 6, Item 8) on oil cooler assembly (Figure 6, Item 6) and tighten clamp (Figure 6, Item 7). Place clamp (Figure 6, Item 9) on hose (Figure 6, Item 8). Install hose (Figure 6, Item 1) in hose (Figure 6, Item 8) and tighten clamp (Figure 6, Item 9).
1 9 2 8 7 3 4
6
M0103SWR
Figure 6. Engine Oil Cooler Lines and Fittings Installation.
0096-5
TM 5-3895-379-23-1
0096
INSTALLATION - Continued 15. 16. Place clamp (Figure 7, Item 1) on hose (Figure 7, Item 3). Install clamp (Figure 7, Item 1) and hose (Figure 7, Item 3) on bracket (Figure 7, Item 4) with screw (Figure 7, Item 2). Tighten screw to 15-25 lb-ft (20-34 Nm).
1 2
3
M0104SWR
Figure 7. Engine Oil Cooler Lines and Fittings Installation. 17. 18. 19. Install adapter (Figure 8, Item 2) on connector (Figure 8, Item 1). Place nut (Figure 8, Item 4) and compression sleeve (Figure 8, Item 3) on hose (Figure 8, Item 5). Install hose (Figure 8, Item 5) on adapter (Figure 8, Item 2) and tighten nut (Figure 8, Item 4).
1 2
3 4 5
M0105SWR
Figure 8. Engine Oil Cooler Lines and Fittings Installation. END OF TASK
0096-6
TM 5-3895-379-23-1
0096
FOLLOW-ON MAINTENANCE 1. 2. 3. Lower operator platform assembly. (Volume 2, WP 0235) Fill coolant system. (WP 0139) Start engine and check for leaks. (TM 5-3895-379-10)
0096-7/8 blank
TM 5-3895-379-23-1
0097
FIELD MAINTENANCE ENGINE OIL COOLER LINES AND FITTINGS REPLACEMENT (CB534C)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 15 Equipment Condition Engine off. (TM 5-3895-379-10) Coolant system drained. (WP 0139) Operator platform assembly raised. (Volume 2, WP 0235)
0097-1
TM 5-3895-379-23-1
0097
REMOVAL
WARNING
Oil is very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury. 1. 2. Loosen clamp (Figure 1, Item 2) and remove hose (Figure 1, Item 3) from elbow (Figure 1, Item 1). Remove clamp (Figure 1, Item 2) from hose (Figure 1, Item 3).
2 3
M0106SWR
0097-2
TM 5-3895-379-23-1
0097
REMOVAL - Continued 3. 4. Remove bolt (Figure 2, Item 2) and fastener (Figure 2, Item 1) from mounting bracket (Figure 2, Item 4). Remove fastener (Figure 2, Item 1) from hose (Figure 2, Item 3).
4 3
M0107SWR
Figure 2. Engine Oil Cooler Lines and Fittings Removal. 5. 6. 7. 8. Loosen clamp (Figure 3, Item 5) and remove hose (Figure 3, Item 1) from oil cooler assembly (Figure 3, Item 4). Remove clamp (Figure 3, Item 5) from hose (Figure 3, Item 1). Loosen clamp (Figure 3, Item 3) and remove hose (Figure 3, Item 2) from oil cooler assembly (Figure 3, Item 4). Remove clamp (Figure 3, Item 3) from hose (Figure 3, Item 2).
2 1
3 5
4
M0108SWR
0097-3
TM 5-3895-379-23-1
0097
REMOVAL - Continued 9. 10. Loosen clamp (Figure 4, Item 1) and remove hose (Figure 4, Item 3) from adapter (Figure 4, Item 2). Remove clamp (Figure 4, Item 1) from hose (Figure 4, Item 3).
2 1
3
M0109SWR
Figure 4. Engine Oil Cooler Lines and Fittings Removal. END OF TASK INSTALLATION 1. 2. Place clamp (Figure 5, Item 1) on hose (Figure 5, Item 3). Install hose (Figure 5, Item 3) on adapter (Figure 5, Item 2) and tighten clamp (Figure 5, Item 1).
2 1
3
M1282SWR
0097-4
TM 5-3895-379-23-1
0097
INSTALLATION - Continued 3. 4. 5. 6. Place clamp (Figure 6, Item 3) on hose (Figure 6, Item 2). Install hose (Figure 6, Item 2) on oil cooler assembly (Figure 6, Item 4) and tighten clamp (Figure 6, Item 3). Place clamp (Figure 6, Item 5) on hose (Figure 6, Item 1). Install hose (Figure 6, Item 1) on oil cooler assembly (Figure 6, Item 4) and tighten clamp (Figure 6, Item 5).
2 1
3 5
4
M1281SWR
Figure 6. Engine Oil Cooler Lines and Fittings Installation. 7. 8. Install fastener (Figure 7, Item 1) on hose (Figure 7, Item 3). Install fastener (Figure 7, Item 1) on mounting bracket (Figure 7, Item 4) with bolt (Figure 7, Item 2). Tighten bolt to 15-25 lb-ft (20-34 Nm).
4 3
M0110SWR
0097-5
TM 5-3895-379-23-1
0097
INSTALLATION - Continued 9. 10. Place clamp (Figure 8, Item 2) on hose (Figure 8, Item 3). Install hose (Figure 8, Item 3) on elbow (Figure 8, Item 1) and tighten clamp (Figure 8, Item 2).
2 3
M0111SWR
Figure 8. Engine Oil Cooler Lines and Fittings Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Lower operator platform assembly. (Volume 2, WP 0235) Fill cooling system to proper level. (WP 0139) Refill oil. (WP 0077) Start engine and check for leaks. (TM 5-3895-379-10)
0097-6
TM 5-3895-379-23-1
0098
FIELD MAINTENANCE ENGINE OIL SAMPLING VALVE AND FITTINGS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (Volume 2, WP 0289, Table 1, Item 23) Wrench, Torque, 0-300 in-lb (Volume 2, WP 0289, Table 1, Item 41) Materials/Parts Lubricating Oil MIL-L-2104 OE/, 30 Grade (Volume 2, WP 0288, Table 1, Item 54, 55) Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Sealing Compound, Loctite 271 (Volume 2, WP 0288, Table 1, Item 62) O-ring (Volume 2, WP 0290, Table 1, Item 120) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 15 Equipment Condition Engine off. (TM 5-3895-379-10) Engine oil drained. (WP 0077)
0098-1
TM 5-3895-379-23-1
0098
REMOVAL 1. Remove engine oil sampling valve drain cap (Figure 1, Item 1) from engine oil sampling valve (Figure 1, Item 2).
NOTE
Use drain pan to catch any oil that may drain from engine oil sampling valve. Dispose of oil IAW local policy and ordinances. Ensure all spills are cleaned up. 2. 3. 4. 5. 6. 7. Place drain pan with 1 qt (0.9 Liter) minimum capacity under engine oil sampling valve (Figure 1, Item 2). Turn and hold knurled knob (Figure 1, Item 10) in direction of arrow and allow remainder of engine oil to drain. Disconnect hourmeter pressure switch connector (Figure 1, Item 6) from connector (Figure 1, Item 7). Remove hourmeter pressure switch (Figure 1, Item 5) from tee (Figure 1, Item 4). Loosen locking nut (Figure 1, Item 9) on engine oil sampling valve (Figure 1, Item 2) and remove engine oil sampling valve from connector (Figure 1, Item 8). Remove O-ring (Figure 1, Item 3) from engine oil sampling valve (Figure 1, Item 2). Discard O-ring.
NOTE
Replace any damaged parts. 8. Remove connector (Figure 1, Item 8) from tee (Figure 1, Item 4).
5 3 2 1 4 6 7
10
8
M0112SWR
Figure 1.
Engine Oil Sampling Valve and Fittings Removal.
0098-2
TM 5-3895-379-23-1
0098
REMOVAL - Continued 9. 10. 11. Remove plug (Figure 2, Item 1) from tee (Figure 2, Item 2). Remove tee (Figure 2, Item 2) and connector (Figure 2, Item 3) from oil filter head assembly (Figure 2, Item 4). Remove connector (Figure 2, Item 3) from tee (Figure 2, Item 2).
1 2 3
4
Figure 2. END OF TASK INSTALLATION 1. 2.
M0113SWR
Engine Oil Sampling Valve and Fittings Removal.
Apply sealing compound to threads of connector (Figure 3, Item 3) and install connector and tee (Figure 3, Item 2) to oil filter head assembly (Figure 3, Item 4). Apply sealing compound to threads of plug (Figure 3, Item 1) and install in tee (Figure 3, Item 2).
1 2 3
4
Figure 3.
M1240SWR
Engine Oil Sampling Valve and Fittings Installation.
0098-3
TM 5-3895-379-23-1
0098
INSTALLATION - Continued 3. 4. Apply sealing compound to threads of connector (Figure 4, Item 8) and install in tee (Figure 4, Item 4). Coat new O-ring (Figure 4, Item 3) with oil and install on engine oil sampling valve (Figure 4, Item 2).
NOTE
When installing engine oil sampling valve, position drain of valve downward to ease in collection of sample. 5. 6. 7. 8. Apply sealing compound to threads of engine oil sampling valve (Figure 4, Item 2) and install on connector (Figure 4, Item 8). Tighten locking nut (Figure 4, Item 9). Install hourmeter pressure switch (Figure 4, Item 5) on tee (Figure 4, Item 4) and tighten to 60-108 lb-in. (7-12 Nm). Connect hourmeter pressure switch connector (Figure 4, Item 6) to connector (Figure 4, Item 7). Install engine oil sampling valve drain cap (Figure 4, Item 1) on engine oil sampling valve (Figure 4, Item 2).
5 3 2 1 4 6 7
10
8
M1239SWR
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2.
Engine Oil Sampling Valve and Fittings Installation.
Fill engine to capacity with engine oil. (WP 0077) Start engine and check for leaks. (TM 5-3895-379-10)
0098-4
TM 5-3895-379-23-1
0099
FIELD MAINTENANCE GAUGE ROD (DIPSTICK) TUBE ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 0-300 in-lb (Volume 2, WP 0289, Table 1, Item 41) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 14 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Left and right-side door assembly opened. (TM 5-3895-379-10)
0099-1
TM 5-3895-379-23-1
0099
REMOVAL
WARNING
Use caution and allow engine to cool before removal of component. Failure to follow this warning may cause injury. 1. 2. 3. 4. Remove gauge rod (dipstick) (Figure 1, Item 1) from tube assembly (Figure 1, Item 5). Remove screw (Figure 1, Item 4) and washer (Figure 1, Item 3) from bracket (Figure 1, Item 6) and clip (Figure 1, Item 1). Loosen fitting (Figure 1, Item 7) and remove tube assembly (Figure 1, Item 5) with clip (Figure 1, Item 1) from oil pan (Figure 1, Item 8). Remove clip (Figure 1, Item 1) from tube assembly (Figure 1, Item 5).
1 2
5 6
7 8
M0114SWR
Figure 1. Gauge Rod (Dipstick) Tube Assembly Removal. END OF TASK
0099-2
TM 5-3895-379-23-1
0099
INSTALLATION 1. 2. 3. 4. 5. Position clip (Figure 2, Item 1) on tube assembly (Figure 2, Item 5). Install tube assembly (Figure 2, Item 5) in oil pan (Figure 2, Item 8). Do not tighten fitting. Install tube assembly (Figure 2, Item 5) and clip (Figure 2, Item 1) on bracket (Figure 2, Item 6) with washer (Figure 2, Item 3) and screw (Figure 2, Item 4). Tighten screw to 180 lb-in. (20 Nm). Tighten fitting (Figure 2, Item 7) securely. Install gauge rod (dipstick) (Figure 2, Item 2) in tube assembly (Figure 2, Item 5).
1 2
5 6
7 8
M1290SWR
Figure 2. Gauge Rod (Dipstick) Tube Assembly Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Close left and right-side door assemblies. (TM 5-3895-379-10) Start engine and check for leaks. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0099-3/4 blank
TM 5-3895-379-23-1
0100
FIELD MAINTENANCE ENGINE OIL FILLER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Gasket (Volume 2, WP 0290, Table 1, Item 65) Qty: 2 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 13 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Right-side door assembly opened. (TM 5-3895-379-10)
REMOVAL 1. 2. Remove filler cap (Figure 1, Item 1) and seal (Figure 1, Item 6) from filler assembly (Figure 1, Item 5). Inspect seal and replace if damaged. Remove screw (Figure 1, Item 3) and clip (Figure 1, Item 2) from bracket (Figure 1, Item 4).
INSTALL 1
REMOVE
6 5 4
2 3
M0115SWR
Figure 1.
Engine Oil Filler Removal.
0100-1
TM 5-3895-379-23-1
0100
REMOVAL - Continued 3. Remove bolt (Figure 2, Item 5), screw (Figure 2, Item 4), filler assembly (Figure 2, Item 3), gasket (Figure 2, Item 2), bracket (Figure 2, Item 6), and gasket (Figure 2, Item 2) from engine (Figure 2, Item 1). Discard gaskets. Remove screen (Figure 2, Item 7) from engine (Figure 2, Item 1). Inspect and clean screen as required.
4.
3 4
2 5
6
M0116SWR
Figure 2. Engine Oil Filler Removal. END OF TASK INSTALLATION 1. 2. Install screen (Figure 3, Item 7) into engine (Figure 3, Item 1). Install new gasket (Figure 3, Item 2), bracket (Figure 3, Item 6), gasket (Figure 3, Item 2), and filler assembly (Figure 3, Item 3) on engine (Figure 3, Item 1) with screw (Figure 3, Item 4) and bolt (Figure 3, Item 5).
0100-2
TM 5-3895-379-23-1
0100
3 4
2 5
6
M1241SWR
Figure 3. 3. 4.
Engine Oil Filler Installation.
Install clip (Figure 4, Item 2) on bracket (Figure 4, Item 4) with screw (Figure 4, Item 3). Install seal (Figure 4, Item 6) and filler cap (Figure 4, Item 1) on filler assembly (Figure 4, Item 5).
INSTALL 1
REMOVE
6 5 4
2 3
M0117SWR
Engine Oil Filler Installation.
0100-3
TM 5-3895-379-23-1
0100
FOLLOW-ON MAINTENANCE 1. 2. 3. Close right-side door assembly. (TM 5-3895-379-10) Start engine and check for leaks. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0100-4
TM 5-3895-379-23-1
0101
FIELD MAINTENANCE VALVE COVER AND BREATHER TUBE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Lubricating Oil MIL-L-2104 OE/, 30 Grade (Volume 2, WP 0288, Table 1, Item 54, 55) Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Locknut (Volume 2, WP 0290, Table 1, Item 74) Qty: 1 Materials/Parts (cont.) Gasket (Volume 2, WP 0290, Table 1, Item 47) Qty: 1 Gasket (Volume 2, WP 0290, Table 1, Item 25) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 1, 8, and 12 Equipment Condition Operator platform assembly raised. (Volume 2, WP 0235)
0101-1
TM 5-3895-379-23-1
0101
REMOVAL
WARNING
NOTE
Valve cover and breather tube are replaced the same way for CB534B and CB534C Rollers except where noted. CB534B Roller is shown. If removing breather tube only, go to Step (3). 1. For CB534B Roller, remove locknut (Figure 1, Item 15), washer (Figure 1, Item 2), washer (Figure 1, Item 3), bolt (Figure 1, Item 1), washer (Figure 1, Item 2), and washer (Figure 1, Item 3) from radiator bracket (Figure 1, Item 4) and engine lifting bracket (Figure 1, Item 5). Discard locknut. Remove three screws (Figure 1, Item 13), washers (Figure 1, Item 14), clip (Figure 1, Item 12), and engine lifting bracket (Figure 1, Item 5) from cylinder head (Figure 1, Item 6). For CB534C Roller, remove two bolts (Figure 1, Item 11) and engine lifting bracket (Figure 1, Item 7). Loosen hose clamp (Figure 1, Item 9) and remove breather tube (Figure 1, Item 10) from valve cover connector (Figure 1, Item 8).
1 2 3 4 5 3 2 15 8 13 14 9 10 12
M0118SWR
2. 3. 4.
6 7 6
8 10 11
Figure 1. Valve Cover and Breather Tube Removal.
0101-2
TM 5-3895-379-23-1
0101
REMOVAL - Continued 5. 6. Loosen screw (Figure 2, Item 2) and remove bracket (Figure 2, Item 1) from engine (Figure 2, Item 3). Remove breather tube (Figure 2, Item 4) from bracket (Figure 2, Item 1).
1
2 3 4
M0119SWR
Figure 2. Valve Cover and Breather Tube Removal.
0101-3
TM 5-3895-379-23-1
0101
REMOVAL - Continued
NOTE
When performing Step (7), ensure that the rocker bracket nuts are not loosened. Check rocker bracket nuts for tightness each time valve cover is removed. 7. Remove three bolts (Figure 3, Item 3), washers (Figure 3, Item 4), and seals (Figure 3, Item 2) from valve cover (Figure 3, Item 1). Inspect and replace seals if damaged.
CAUTION
Use care that contaminants do not enter valves when cover is removed. Failure to follow this caution may cause damage to equipment. 8. Remove valve cover (Figure 3, Item 1) and gasket (Figure 3, Item 6) from cylinder head (Figure 3, Item 5). Discard gasket.
3 4
6 5 CB534B ROLLER
M0120SWR
Figure 3. Valve Cover and Breather Tube Removal. END OF TASK
0101-4
TM 5-3895-379-23-1
0101
INSTALLATION
NOTE
If installing the breather tube only, go to Step (4). Grooved side of gasket must face cylinder head. 1. 2. For CB534B Roller, position three tabs (Figure 4, Item 5) of new gasket (Figure 4, Item 7) into three notches in valve cover (Figure 4, Item 1). For CB534C Roller, position new gasket (Figure 4, Item 7) in valve cover (Figure 4, Item 1).
CAUTION
Do not overtighten valve cover nuts. Failure to follow this caution may cause rocker bracket nuts being overtightened.
NOTE
Lubricate seals with clean engine oil prior to installation. 3. Install valve cover (Figure 4, Item 1) and gasket (Figure 4, Item 7) on cylinder head (Figure 4, Item 6) with three seals (Figure 4, Item 2) if damaged, washers (Figure 4, Item 4), and nuts (Figure 4, Item 3). Tighten nuts to 22 lb-ft (30 Nm).
3 4
7 6 CB534B ROLLER 5
M0121SWR
Figure 4. Valve Cover and Breather Tube Installation.
0101-5
TM 5-3895-379-23-1
0101
INSTALLATION - Continued 4. 5. 6. Position breather tube (Figure 5, Item 4) through bracket (Figure 5, Item 1). Feed breather tube (Figure 5, Item 4) from bottom to valve cover connector (Figure 6, Item 8). Install bracket (Figure 5, Item 1) to engine (Figure 5, Item 3) and tighten screw (Figure 5, Item 2) to 22 lb-ft (30 Nm).
1
2 3 4
M0122SWR
Figure 5. Valve Cover and Breather Tube Installation. 7. 8. Install breather tube (Figure 6, Item 10) to valve cover connector (Figure 6, Item 8) with hose clamp (Figure 6, Item 9). Tighten hose clamp. CB534B Roller, install engine lifting bracket (Figure 6, Item 5) and clip (Figure 6, Item 12) to cylinder head (Figure 6, Item 6) with three washers (Figure 6, Item 14) and screws (Figure 6, Item 13). Tighten screws to 33-47 lb-ft (45-64 Nm). CB534B Roller, install engine lifting bracket (Figure 6, Item 5) on radiator bracket (Figure 6, Item 4) with washer (Figure 6, Item 3), washer (Figure 6, Item 2), bolt (Figure 6, Item 1), washer (Figure 6, Item 3), washer (Figure 6, Item 2), and new locknut (Figure 6, Item 15). Tighten locknut to 33-47 lb-ft (45-64 Nm). CB534C Roller, install engine lifting bracket (Figure 6, Item 7) and two bolts (Figure 6, Item 11). Tighten bolts to 33-47 lb-ft (45-64 Nm).
9.
10.
0101-6
TM 5-3895-379-23-1
0101
1 2 3 4 5 3 2 15 8 13 14 9 10 12
M0123SWR
6 7 6
8 10 11
Figure 6. Valve Cover and Breather Tube Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Lower operator platform assembly. (Volume 2, WP 0235) Operate roller and check for leaks. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0101-7/8 blank
TM 5-3895-379-23-1
0102
FIELD MAINTENANCE OIL FILTER HEAD ASSEMBLY REPLACEMENT (CB534B)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Gasket (Volume 2, WP 0290, Table 1, Item 61) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 15 Equipment Condition Engine oil drained and oil filter removed. (WP 0077) Engine oil sampling valve and tee removed. (WP 0098) Hourmeter pressure switch removed. (WP 0171) Engine oil cooler removed. (WP 0095)
0102-1
TM 5-3895-379-23-1
0102
REMOVAL 1. Remove two bolts (Figure 1, Item 7), nut (Figure 1, Item 5), washer (Figure 1, Item 4), spacer (Figure 1, Item 3), oil filter head assembly (Figure 1, Item 6), and gasket (Figure 1, Item 1) from engine (Figure 1, Item 2). Discard gasket. Remove bolt (Figure 1, Item 8) and connector (Figure 1, Item 9) from oil filter head assembly (Figure 1, Item 6).
1 2 3 4 5
2.
6 7
8
M0124SWR
Figure 1. Oil Filter Head Assembly Removal. END OF TASK
0102-2
TM 5-3895-379-23-1
0102
INSTALLATION 1. 2. Install bolt (Figure 2, Item 8), connector (Figure 2, Item 9) on oil filter head assembly (Figure 2, Item 6). Tighten securely. Install new gasket (Figure 2, Item 1) and oil filter head assembly (Figure 2, Item 6) on engine (Figure 2, Item 2) with spacer (Figure 2, Item 3), washer (Figure 2, Item 4), and nut (Figure 2, Item 5). Tighten bolts to 33-47 lb-ft (45-64 Nm).
1 2 3 4 5
6 7
8
M1243SWR
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Install engine oil cooler. (WP 0095)
Oil Filter Head Assembly Installation.
Install hourmeter pressure switch. (WP 0171) Install tee and engine oil sampling valve. (WP 0098) Install oil filter and refill engine crankcase. (WP 0077) Start engine and check for leaks. (TM 5-3895-379-10)
0102-3/4 blank
TM 5-3895-379-23-1
0103
FIELD MAINTENANCE OIL FILTER HEAD ASSEMBLY REPLACEMENT (CB534C)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Goggles (Volume 2, WP 0289, Table 1, Item 13) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Cleaning Compound, Solvent (Volume 2, WP 0288, Table 1, Item 13, 14, 15) Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Gasket (Volume 2, WP 0290, Table 1, Item 99) Qty: 2 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-10 TM 5-3895-379-23P, Figure 15 Equipment Condition Engine oil sampling valve and tee removed. (WP 0098) Hourmeter pressure switch removed. (WP 0171) Engine oil cooler removed. (WP 0095)
0103-1
TM 5-3895-379-23-1
0103
REMOVAL
WARNING
Oil is very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury. 1. 2. Remove oil filter (WP 0077). Remove two bolts (Figure 1, Item 3), two bolts (Figure 1, Item 4), oil filter head assembly (Figure 1, Item 5), gasket (Figure 1, Item 1), access cover (Figure 1, Item 2), and gasket (Figure 1, Item 1). Discard gaskets.
1 2 1
3 5
4
M0125SWR
Figure 1. Oil Filter Head Assembly Removal. END OF TASK CLEANING
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. 1. 2. Remove any original gasket material from oil filter head assembly. Clean all surfaces with cleaning compound, solvent.
0103-2
TM 5-3895-379-23-1
0103
CLEANING - Continued 3. Allow surfaces to air dry before installation.
END OF TASK INSTALLATION Install new gasket (Figure 2, Item 1), access cover (Figure 2, Item 2), new gasket (Figure 2, Item 1), and oil filter head assembly (Figure 2, Item 5) with two bolts (Figure 2, Item 4) and two bolts (Figure 2, Item 3). Tighten bolts to 33-47 lb-ft (45-64 Nm).
1 2 1
3 5
4
M1119SWR
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Install engine oil cooler. (WP 0095)
Oil Filter Head Assembly Installation.
Install hourmeter pressure switch. (WP 0171) Install tee and oil sampling valve. (WP 0098) Install oil filter and refill engine crankcase. (WP 0077) Start engine and check for leaks. (TM 5-3895-379-10)
0103-3/4 blank
TM 5-3895-379-23-1
0104
FIELD MAINTENANCE OIL STRAINER AND SUCTION TUBE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Goggles (Volume 2, WP 0289, Table 1, Item 13) Wrench, Torque, 0-300 in-lb (Volume 2, WP 0289, Table 1, Item 41) Materials/Parts Cleaning Compound, Solvent (Volume 2, WP 0288, Table 1, Item 13, 14, 15) Gasket (Volume 2, WP 0290, Table 1, Item 50) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-10 TM 5-3895-379-23P, Figure 14 Equipment Condition Oil pan removed. (WP 0093)
REMOVAL 1. 2. Remove two screws (Figure 1, Item 7) from strainer and suction tube assembly (Figure 1, Item 6) and oil pump (Figure 1, Item 4). Remove screw (Figure 1, Item 3), washer (Figure 1, Item 4), strainer and suction tube assembly (Figure 1, Item 6), gasket (Figure 1, Item 8), and bracket (Figure 1, Item 2) from bridge (Figure 1, Item 5). Discard gasket.
3
M0126SWR
Figure 1.
Oil Strainer and Suction Tube Removal.
0104-1
TM 5-3895-379-23-1
0104
REMOVAL - Continued 3. 4. Remove nut (Figure 2, Item 1), screw (Figure 2, Item 6), and bracket (Figure 2, Item 4) from retaining clip (Figure 2, Item 2) and mounting plate (Figure 2, Item 5). Remove nut (Figure 2, Item 1), screw (Figure 2, Item 7), retaining clip (Figure 2, Item 2), and mounting plate (Figure 2, Item 5) from strainer and suction tube assembly (Figure 2, Item 3).
2 7 6 5 4
M0127SWR
Figure 2. Oil Strainer and Suction Tube Removal. END OF TASK CLEANING
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. 1. 2. Clean strainer and suction tube assembly with cleaning compound, solvent. Dry strainer and suction tube assembly and ensure that all cleaning compound is removed prior to installation.
END OF TASK
0104-2
TM 5-3895-379-23-1
0104
INSTALLATION 1. 2. Install retaining clip (Figure 3, Item 2) and mounting plate (Figure 3, Item 5) on strainer and suction tube assembly (Figure 3, Item 3) with screw (Figure 3, Item 7) and nut (Figure 3, Item 1). Do not tighten nut. Install bracket (Figure 3, Item 4) on retaining clip (Figure 3, Item 2) and mounting plate (Figure 3, Item 5) with screw (Figure 3, Item 6) and nut (Figure 3, Item 1). Do not tighten nut.
2 7 6 5 4
M1248SWR
Figure 3. Oil Strainer and Suction Tube Installation. 3. 4. Install new gasket (Figure 4, Item 8) and strainer and suction tube assembly (Figure 4, Item 6) on oil pump (Figure 4, Item 4) with two screws (Figure 4, Item 7). Tighten screws to 192 lb-in. (22 Nm). Install bracket (Figure 4, Item 2) and strainer and suction tube assembly (Figure 4, Item 6) on bridge (Figure 4, Item 5) with washer (Figure 4, Item 4) and screw (Figure 4, Item 3). Tighten screw to 192 lb-in. (22 Nm). Tighten two nuts (Figure 3, Item 1).
5.
3
M0128SWR
Push Rod Cover Installation.
0104-3
TM 5-3895-379-23-1
0104
FOLLOW-ON MAINTENANCE 1. 2. Install oil pan. (WP 0093) Start engine and check for leaks. (TM 5-3895-379-10)
0104-4
TM 5-3895-379-23-1
0105
FIELD MAINTENANCE INTAKE MANIFOLD REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Gasket (Volume 2, WP 0290, Table 1, Item 55) Qty: 1 Gasket (Volume 2, WP 0290, Table 1, Item 16) Qty: 2 Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-10 TM 5-3895-379-23P, Figure 16 Equipment Condition Operator platform assembly raised. (Volume 2, WP 0235) Exhaust manifold removed (CB534B). (WP 0106) Exhaust manifold removed (CB534C). (WP 0107)
REMOVAL
NOTE
Intake manifold is replaced the same way for CB534 and CB534C Rollers, except where noted. CB534B Roller is shown. Tag and mark all wires prior to removal. 1. 2. Disconnect wire (Figure 1, Item 1) from cold start heater connector (Figure 1, Item 2). Loosen nut (Figure 1, Item 4) and disconnect fuel line (Figure 1, Item 5) from cold start heater (Figure 1, Item 3).
3
M0129SWR
Figure 1.
Intake Manifold Removal.
0105-1
TM 5-3895-379-23-1
0105
REMOVAL - Continued 3. 4. 5. 6. Loosen two hose clamps and slide hose at intake manifold flange (Figure 2, Item 7) toward the turbocharger. For CB534B Roller, remove screw (Figure 2, Item 4) and clip (Figure 2, Item 5) from intake manifold (Figure 2, Item 1). Remove four bolts (Figure 2, Item 3). Remove clip (Figure 2, Item 2), clip (CB534B Roller), intake manifold flange (Figure 2, Item 7), and gasket (Figure 2, Item 6) from intake manifold (Figure 2, Item 1). Discard gasket.
1 2 3 7 6 4 5
M0130SWR
Figure 2. Intake Manifold Removal.
0105-2
TM 5-3895-379-23-1
0105
REMOVAL - Continued 7. 8. Loosen nut (Figure 3, Item 9) and disconnect tube (Figure 3, Item 4) from intake manifold nipple (Figure 3, Item 10). Remove four screws (Figure 3, Item 6), screw (Figure 3, Item 8), and screw (Figure 3, Item 1), two gaskets (Figure 3, Item 5), gasket (Figure 3, Item 3), and intake manifold (Figure 3, Item 7) from cylinder head (Figure 3, Item 2). Discard gaskets.
2 1 3
4 10
9 8 7 6 5
M0131SWR
NOTCH
Intake Manifold Removal.
0105-3
TM 5-3895-379-23-1
0105
INSTALLATION
NOTE
Ensure gasket surfaces are clean and dry before installation. Ensure manifold gaskets for front and rear are positioned with notch at top left when installed on cylinder head. Center gasket can be installed either way. Do not use any sealant when installing gaskets. 1. Install two new gaskets (Figure 4, Item 5), new gasket (Figure 4, Item 3), and intake manifold (Figure 4, Item 7) on cylinder head (Figure 4, Item 2) using four screws (Figure 4, Item 6), screw (Figure 4, Item 8), and screw (Figure 4, Item 1). Tighten screws to 24 lb-ft (33 Nm). Connect tube (Figure 4, Item 4) to intake manifold nipple (Figure 4, Item 10) and tighten nut (Figure 4, Item 9) to 35-71 lb-ft (47-96 Nm).
2 1 3
2.
4 10
9 8 7 6 5
M1294SWR
NOTCH
Figure 4. Intake Manifold Installation.
0105-4
TM 5-3895-379-23-1
0105
INSTALLATION - Continued 3. 4. Install new gasket (Figure 5, Item 6) and intake manifold flange (Figure 4, Item 7). Install clip (Figure 5, Item 2) and for CB534B Roller, clip (Figure 5, Item 6) on intake manifold (Figure 5, Item 1) using four bolts.
1 2 3 7 6 4 5
M1089SWR
Figure 5. 5. 6. 7. 8.
Intake Manifold Installation.
Slide hose at intake manifold flange (Figure 6, Item 3) into position and tighten two hose clamps. For CB534B Roller, install clip (Figure 5, Item 5), and screw (Figure 5, Item 4) to intake manifold (Figure 5, Item 1). Connect fuel line (Figure 6, Item 5) to cold start heater (Figure 6, Item 3) and tighten nut (Figure 6, Item 4). Connect wire (Figure 6, Item 1) to cold start heater connector (Figure 6, Item 2).
3
M1088SWR
Intake Manifold Installation.
0105-5
TM 5-3895-379-23-1
0105
FOLLOW-ON MAINTENANCE 1. 2. 3. Install exhaust manifold. (WP 0106) or (WP 0107) Lower operator platform assembly. (Volume 2, WP 0235) Start engine and check for leaks. (TM 5-3895-379-10)
0105-6
TM 5-3895-379-23-1
0106
FIELD MAINTENANCE EXHAUST MANIFOLD REPLACEMENT (CB534B)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Antiseize Compound (Volume 2, WP 0288, Table 1, Item 8) Gasket (Volume 2, WP 0290, Table 1, Item 58) Qty: 2 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 16 Equipment Condition Turbocharger removed. (WP 0121)
REMOVAL Remove four nuts (Figure 1, Item 3), exhaust manifold (Figure, Item 2), and two gaskets (Figure 1, Item 1) from engine (Figure 1, Item 4). Discard gaskets.
2 4 3
M0132SWR
Exhaust Manifold Removal.
0106-1
TM 5-3895-379-23-1
0106
INSTALLATION Install two new gaskets (Figure 2, Item 1) and exhaust manifold (Figure 2, Item 2) on engine (Figure 2, Item 4) with four nuts (Figure 2, Item 3). Tighten nuts to 32 lb-ft (44 Nm).
2 4 3
M1220SWR
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE Install turbocharger. (WP 0121) END OF TASK END OF WORK PACKAGE
Exhaust Manifold Installation.
0106-2
TM 5-3895-379-23-1
0107
FIELD MAINTENANCE EXHAUST MANIFOLD REPLACEMENT (CB534C)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Antiseize Compound (Volume 2, WP 0288, Table 1, Item 8) Gasket (Volume 2, WP 0290, Table 1, Item 20) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-10 TM 5-3895-379-23P, Figure 16 Equipment Condition Turbocharger removed. (WP 0121) Intake manifold removed. (WP 0105)
REMOVAL
NOTE
Note number and location of bolts (Figure 1, Item 1) or nuts (Figure 1, Item 2) to insure proper installation. 1. 2. Remove bolts (Figure 1, Item 1) and nuts (Figure 1, Item 2) in reverse order (see Tightening Sequence). Remove exhaust manifold (Figure 1, Item 3) and gasket (Figure 1, Item 4) from engine. Discard gasket.
1 2 8 7 9 6 5 4 1 2 3 10 11 12
TIGHTENING SEQUENCE
M0133SWR
Exhaust Manifold Removal.
0107-1
TM 5-3895-379-23-1
0107
INSTALLATION 1. 2. Apply antiseize compound to stud threads. Install new gasket (Figure 2, Item 4) and exhaust manifold (Figure 2, Item 3) on engine with bolts (Figure 2, Item 1) and nuts (Figure 2, Item 2). Tighten nuts and bolts to 33 lb-ft (45 Nm) in sequence shown.
1 2 8 7 9 6 5 4 1 2 3 10 11 12
TIGHTENING SEQUENCE
M1118SWR
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Install intake manifold. (WP 0105) Install turbocharger. (WP 0121)
Exhaust Manifold Installation.
Start engine and check for proper operation. (TM 5-3895-379-10)
0107-2
TM 5-3895-379-23-1
0108
FIELD MAINTENANCE FUEL INJECTOR AND NOZZLE TEST
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 0-300 in-lb (Volume 2, WP 0289, Table 1, Item 41) Materials/Parts Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-10 Equipment Condition Operator platform assembly raised. (Volume 2, WP 0235)
FUEL INJECTOR AND NOZZLE TEST
NOTE
Injectors are tested the same way for CB534B and CB534C Rollers. Perform the following procedures in order to determine if a fuel injector nozzle is not working correctly. 1. Run the engine at low idle (TM 5-3895-379-10).
0108-1
TM 5-3895-379-23-1
0108
FUEL INJECTOR AND NOZZLE TEST - Continued
NOTE
If leakage occurs at the nut for the fuel supply line, make sure that the fuel supply line and the nut for the fuel supply line are correctly aligned with the inlet connection of the fuel injector nozzle. 2. Loosen the nut (Figure 1, Item 3) for the fuel supply line (Figure 1, Item 1) at each fuel injector nozzle (Figure 1, Item 2).
NOTE
Listen for the low idle to decrease or become rough at each engine cylinder. 3. The fuel injector nozzle (Figure 1, Item 2) is faulty and should be replaced when the fuel supply line (Figure 1, Item 1) is loosened and the following events occur: a. b. 4. The engine rpm does not decrease. The engine does not idle roughly.
If faulty, replace fuel injector nozzle (WP 0109) or (WP 0110).
CAUTION
Do not over-tighten the nut for the fuel supply line. If nut is tightened more, fuel line may become restricted or threads of fuel injector nozzle and nut may be damaged. 5. Tighten each nut to 176.4 lb-in. (20 Nm).
1 3 2
M0136SWR
Figure 1. Fuel Injector and Nozzle Test. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Lower operator platform. (Volume 2, WP 0235) Start engine and check for leaks. (TM 5-3895-379-10)
0108-2
TM 5-3895-379-23-1
0109
FIELD MAINTENANCE FUEL INJECTOR AND NOZZLE REPLACEMENT (CB534B)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 0-300 in-lb (Volume 2, WP 0289, Table 1, Item 41) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 2, WP 0288, Table 1, Item 12) Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Gasket (Volume 2, WP 0290, Table 1, Item 46) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-10 TM 5-3895-379-23P, Figure 17 Equipment Condition Operator platform assembly raised. (Volume 2, WP 0235) Fuel injector lines removed. (WP 0114)
REMOVAL
CAUTION
Cap and plug all openings to prevent any contaminants from entering the system.
NOTE
All fuel injector nozzles are replaced the same way. One fuel injector nozzle is shown. 1. 2. Remove two capscrews (Figure 2, Item 1) and clamp (Figure 2, Item 2) from cylinder head (Figure 1, Item 4). Remove fuel injector (Figure 2, Item 3) and washer (Figure 2, Item 7) from cylinder head (Figure 1, Item 4).
1 2 3
M0135SWR
Figure 1.
Fuel Injector and Nozzle Removal.
0109-1
TM 5-3895-379-23-1
0109
REMOVAL - Continued 3. Remove nozzle (Figure 2, Item 6), gasket (Figure 2, Item 4), and spacer (Figure 2, Item 5) from injector (Figure 2, Item 3). Discard gasket.
1 2
4 5 6
7
M0134SWR
Figure 2. Fuel Injector and Nozzle Removal. END OF TASK
0109-2
TM 5-3895-379-23-1
0109
INSTALLATION 1. 2. Install spacer (Figure 3, Item 5), new gasket (Figure 3, Item 4), and nozzle (Figure 3, Item 6) on fuel injector (Figure 3, Item 3). Install washer (Figure 3, Item 7) and fuel injector (Figure 3, Item 3) to cylinder head (Figure 4, Item 4).
1 2
4 5 6
7
M1276SWR
Figure 3. 3.
Fuel Injector and Nozzle Installation.
Install clamp (Figure 3, Item 2) and two capscrews (Figure 3, Item 1). Tighten capscrews gradually and evenly to 108 lb-in. (12 Nm).
1 2 3
M1277SWR
0109-3
TM 5-3895-379-23-1
0109
FOLLOW-ON MAINTENANCE 1. 2. 3. Install fuel injector lines. (WP 0114) Lower operator platform. (Volume 2, WP 0235) Start engine and check for leaks. (TM 5-3895-379-10)
0109-4
TM 5-3895-379-23-1
0110
FIELD MAINTENANCE FUEL INJECTOR AND NOZZLE REPLACEMENT (CB534C)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 0-300 in-lb (Volume 2, WP 0289, Table 1, Item 41) Materials/Parts Antiseize Compound (Volume 2, WP 0288, Table 1, Item 8) Cap Set, Protective, Dust and Moisture Seal (Volume 2, WP 0288, Table 1, Item 12) Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Washer (Volume 2, WP 0290, Table 1, Item 14) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-10 TM 5-3895-379-23P, Figure 17 Equipment Condition Operator platform assembly raised. (Volume 2, WP 0235) Fuel injection lines removed. (WP 0115)
0110-1
TM 5-3895-379-23-1
0110
REMOVAL
CAUTION
Cap and plug all openings to prevent any contaminants from entering the system.
NOTE
All fuel injector nozzles are replaced the same way. One fuel injector nozzle is shown. Remove fuel injector (Figure 1, Item 1) and washer (Figure 1, Item 2).
M0137SWR
Figure 1. Fuel Injector and Nozzle Removal. END OF TASK
0110-2
TM 5-3895-379-23-1
0110
INSTALLATION
CAUTION
Do not rotate injection nozzle after installation. The seal made by the anti-seize compound could break. A broken seal may allow leakage past the seat of the fuel injection nozzle, resulting in poor performance. 1. 2. 3. Clean threads on fuel injector (Figure 2, Item 1) and mating surface of cylinder head. Place a 0.08 in. (2.0 mm) bead of antiseize compound to the first two threads of injector (Figure 2, Item 1). Install washer (Figure 2, Item 2) on injector (Figure 2, Item 1).
M1117SWR
Figure 2.
0110-3
TM 5-3895-379-23-1
0110
INSTALLATION - Continued 4. 5. Position injector (Figure 3, Item 2) by making sure detent ball (Figure 3, Item 1) is aligned with detent (Figure 3, Item 3) in cylinder head (Figure 3, Item 4). Gradually and evenly tighten fuel injector (Figure 3, Item 2). Tighten to 264 lb-in. (30 Nm) and remove excess antiseize compound.
4
Figure 3. Fuel Injector and Nozzle Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Install fuel injector lines. (WP 0115) Lower operator platform. (Volume 2, WP 0235) Start engine and check for leaks. (TM 5-3895-379-10)
M0138SWR
0110-4
TM 5-3895-379-23-1
0111
FIELD MAINTENANCE FUEL INJECTION PUMP GEAR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Puller Kit, Universal (Volume 2, WP 0289, Table 1, Item 27) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 20 References (cont.) WP 0091 WP 0092 Equipment Condition Operator platform assembly raised. (Volume 2, WP 0235) Fan removed. (WP 0146) Water pump removed. (WP 0144) Crankshaft pulley removed. (WP 0083)
0111-1
TM 5-3895-379-23-1
0111
METHOD 1 (TIMING GEAR CASE COVER OFF) REMOVAL
NOTE
Idler gear marks may not be in mesh with other three gears due to different speed of rotation of idler gear. Turn crankshaft until marks on crankshaft gear, camshaft gear, and fuel pump gear are in mesh with idler gear. Be sure not to lose key installed in fuel injection pump shaft. 1. 2. 3. 4. Remove timing gear case cover (WP 0092). Remove nut (Figure 1, Item 1) and spring washer (Figure 1, Item 2) from fuel injection pump gear (Figure 1, Item 3). Remove idler gear (WP 0091). With gear puller, remove fuel injection pump gear (Figure 1, Item 3) from fuel injection pump (Figure 1, Item 4). Check fuel injection pump gear (Figure 1, Item 3) for wear or damage. Replace if necessary.
1 2 3 4
M0139SWR
Figure 1. Fuel Injection Pump Gear Removal. END OF TASK
0111-2
TM 5-3895-379-23-1
0111
METHOD 1 (TIMING GEAR CASE COVER OFF) INSTALLATION
NOTE
If installing a new gear, check backlash after installation. 1. 2. 3. Install fuel injection pump gear (Figure 2, Item 3) to fuel injection pump (Figure 2, Item 4). Install idler gear (WP 0091). Install nut (Figure 2, Item 1) and spring washer (Figure 2, Item 2) to fuel injection pump gear (Figure 2, Item 3). Tighten nut to 58 lb-ft (79 Nm).
1 2 3 4
M1255SWR
Figure 2.
Fuel Injection Pump Gear Installation.
NOTE
Be sure not to lose key installed in fuel injection pump shaft. Turn fuel injection pump gear to align timing marks with idler gear before installation. The fuel injection pump gear is marked with a "4." 4. Install timing gear cover (WP 0092).
END OF TASK
0111-3
TM 5-3895-379-23-1
0111
METHOD 2 (TIMING GEAR CASE COVER ON) REMOVAL 1. 2. Remove four bolts (Figure 3, Item 1) and cover (Figure 3, Item 2). Remove nut (Figure 3, Item 3) and washer (Figure 3, Item 4).
1 2 3, 4
M0140SWR
Figure 3. Fuel Injection Pump Gear Removal. 3. 4. Rotate crankshaft until keyway is at 1:00 o'clock. Install gear puller and disengage fuel injection pump gear (Figure 4, Item 1) from fuel injection pump (Figure 4, Item 2).
1, 2
M1257SWR
Figure 4. Fuel Injection Pump Gear Removal. END OF TASK METHOD 2 (TIMING GEAR CASE COVER ON) INSTALLATION 1. 2. Install washer (Figure 5, Item 4) and nut (Figure 5, Item 3). Tighten nut to 58 lb-ft (78 Nm). Install four bolts (Figure 5, Item 1) and cover (Figure 5, Item 1).
0111-4
TM 5-3895-379-23-1
0111
METHOD 2 (TIMING GEAR CASE COVER ON) INSTALLATION - Continued

1 2 3, 4
M1256SWR
Figure 5. 3.
Rotate crankshaft until keyway is at 1:00 o'clock. Install fuel injection pump gear (Figure 6, Item 1) to fuel injection pump (Figure 6, Item 2).
1, 2
M0141SWR
Figure 6. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install crankshaft pulley. (WP 0083) Install water pump. (WP 0144) Install fan. (WP 0146)
Lower operator platform. (Volume 2, WP 0235)
0111-5/6 blank
TM 5-3895-379-23-1
0112
FIELD MAINTENANCE FUEL INJECTION PUMP REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 0-300 in-lb (Volume 2, WP 0289, Table 1, Item 41) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 2, WP 0288, Table 1, Item 12) Gasket (Volume 2, WP 0290, Table 1, Item 56) Qty: 1 O-ring (Volume 2, WP 0290, Table 1, Item 18) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-10 TM 5-3895-379-23P, Figures 19 and 20 Equipment Condition Throttle cable disconnected (CB534B). (WP 0131) Throttle control disconnected (CB534C). (WP 0133) Fuel injection pump gear removed. (WP 0111)
0112-1
TM 5-3895-379-23-1
0112
REMOVAL
NOTE
Cap and plug all openings to prevent any contaminants from entering the system. 1. 2. 3. 4. 5. Place position marks (Figure 1, Item 1) on fuel injection pump. Disconnect hose (Figure 1, Item 2) from fuel injection pump (Figure 1, Item 5). Remove three nuts (Figure 1, Item 7) from fuel injection pump (Figure 1, Item 5). Remove fuel injection pump (Figure 1, Item 5) and gasket (Figure 1, Item 3) from timing case (Figure 1, Item 4). Discard gasket. Remove O-ring (Figure 1, Item 6) from fuel injection pump (Figure 1, Item 5). Discard O-ring.
1 2 3 4 5
M0142SWR
Figure 1. Fuel Injection Pump Removal. END OF TASK INSTALLATION 1. 2. 3. 4. 5. Lightly apply a coat of clean engine oil to new O-ring (Figure 2, Item 6) and install O-ring on fuel injection pump (Figure 2, Item 5). Install new gasket (Figure 2, Item 3) on timing case (Figure 2, Item 4). Align marks (Figure 2, Item 1) to position fuel injection pump (Figure 2, Item 5). Install three nuts (Figure 2, Item 7) and fuel injection pump (Figure 2, Item 5) on timing case (Figure 2, Item 4). Tighten nuts to 192 lb-in. (22 Nm). Connect hose (Figure 2, Item 2) to fuel injection pump (Figure 2, Item 5).
0112-2
TM 5-3895-379-23-1
0112
1 2 3 4 5
M0143SWR
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install fuel injection pump. (WP 0111)
Fuel Injection Pump Installation.
Connect throttle control cable. (WP 0131) Connect throttle control. (WP 0133) Operate roller and check for proper operation. (TM 5-3895-379-10)
0112-3/4 blank
TM 5-3895-379-23-1
0113
FIELD MAINTENANCE FUEL INJECTION PUMP TEST AND ADJUSTMENT (CB534B)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References WP 0132
ON-ENGINE SPEED DROOP GOVERNOR ADJUSTMENT 1. Start engine and apply approximately 50 percent load until engine reaches normal operating temperature.
NOTE
If engine surges during warm-up period, turn speed droop adjusting cap clockwise until surging stops. 2. 3. When engine has reached operating temperature, position throttle to get full load speed and apply 100 percent load. Adjust throttle if necessary to obtain satisfactory 100 percent load performance. Remove load and check for no-load speed. If incorrect, adjust speed droop adjusting cap in small increments (turn clockwise for increased droop or counterclockwise for less droop.) If surging exists when load is removed, turn speed droop adjusting cap clockwise to eliminate.
NOTE
When speed droop adjustments are made, throttle position adjustments (WP 0132) will also be necessary. 4. Recheck 100 percent load and no-load performance and readjust as necessary.
0113-1/2 blank
TM 5-3895-379-23-1
0114
FIELD MAINTENANCE FUEL INJECTOR LINES AND FITTINGS REPLACEMENT (CB534B)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (Volume 2, WP 0289, Table 1, Item 23) Wrench, Torque, 0-300 in-lb (Volume 2, WP 0289, Table 1, Item 41) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 2, WP 0288, Table 1, Item 12) Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) O-ring (Volume 2, WP 0290, Table 1, Item 81) Qty: 5 Packing, Preformed (Volume 2, WP 0290, Table 1, Item 77) Qty: 3 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 17, 18, and 27 WP 0116 WP 0124 WP 0127 Equipment Condition Engine off. (TM 5-3895-379-10) Operator platform assembly raised. (Volume 2, WP 0235) Battery disconnect switch in OFF position. (TM 5-3895-379-10) Right and left-side door assemblies opened. (TM 5-3895-379-10) Fuel tank drained. (WP 0124)
0114-1
TM 5-3895-379-23-1
0114
FUEL LINES AND FITTINGS REMOVAL
WARNING
DO NOT perform fuel system checks, inspections or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing injury or death, or damage to machine. Fuel is very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury.
CAUTION
Wipe area clean around all fuel connections to be opened during removal. Cap lines and plug openings after removing lines. Contamination of fuel system could result in premature failure.
NOTE
When removing fuel shut-off valve, fuel drain valve, or fuel return lines, drain fuel side of tank completely (WP 0124). Capacity of fuel tank is 55 gal (208 Liters). Use drain pan to catch any fuel that may drain from system. Dispose of fuel IAW local policy and ordinances. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Turn two fuel shut-off valves (Figure 1, Item 1) to OFF position (WP 0116). Remove three bolts (Figure 1, Item 5), three plates (Figure 1, Item 6), and six block clamps (Figure 1, Item 4). Remove bolt (Figure 1, Item 15), two washers (Figure 1, Item 13), and nut (Figure 1, Item 12) from loop clamp (Figure 1, Item 14). Disconnect hose (Figure 1, Item 3) and hose (Figure 1, Item 17) from two elbows (Figure 1, Item 21) and remove O-rings (Figure 1, Item 7). Discard O-rings. Remove two elbows (Figure 1, Item 21) and two valves (Figure 1, Item 1) from fuel tank (Figure 1, Item 2). Disconnect hose (Figure 1, Item 17) from connector (Figure 1, Item 18) and remove O-ring (Figure 1, Item 7). Discard O-ring. Remove connector (Figure 1, Item 18) and tube (Figure 1, Item 19) from secondary water separator (Figure 1, Item 20). Remove loop clamp (Figure 1, Item 14) from hose (Figure 1, Item 17). Disconnect hose (Figure 1, Item 3) from adapter (Figure 1, Item 8). Remove O-ring (Figure 1, Item 7) and preformed packing (Figure 1, Item 9). Discard O-ring and preformed packing. Disconnect hose (Figure 1, Item 11) from adapter (Figure 1, Item 8) at primary water separator (Figure 1, Item 10). Remove O-ring (Figure 1, Item 7) and preformed packing (Figure 1, Item 9). Discard O-ring and preformed packing. Disconnect hose (Figure 1, Item 11) from adapter (Figure 1, Item 8) at fuel pump (Figure 1, Item 16). Remove O-ring (Figure 1, Item 7) and preformed packing (Figure 1, Item 9). Discard O-ring and preformed packing.
0114-2
TM 5-3895-379-23-1
0114
FUEL LINES AND FITTINGS REMOVAL - Continued 15. Remove and inspect hoses (Figure 1, Items 3, 11, and 17).
3 21 7 21 7 4
4 5 6 5 6 20 15 19 18 7 17 14 5 13 4 12 7 6 8 9 13 9 8 7
11 16
8 9 10
M0144SWR
Fuel Lines and Fittings Removal.
0114-3
TM 5-3895-379-23-1
0114
FUEL LINES AND FITTINGS INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Install new O-ring (Figure 2, Item 7) and new preformed packing (Figure 2, Item 9) on adapter (Figure 2, Item 8). Connect adapter (Figure 2, Item 8) to hose (Figure 2, Item 11) and fuel pump (Figure 2, Item 16). Install new O-ring (Figure 2, Item 7) and new preformed packing (Figure 2, Item 9). Connect adapter (Figure 2, Item 8) to hose (Figure 2, Item 11) and primary water separator (Figure 2, Item 10). Install new O-ring (Figure 2, Item 7) and new preformed packing (Figure 2, Item 9). Connect hose (Figure 2, Item 3) to adapter (Figure 2, Item 8) and install hose (Figure 2, Item 3). Install loop clamp (Figure 2, Item 14) to hose (Figure 2, Item 17). Install connector (Figure 2, Item 18) and tube (Figure 2, Item 19) to secondary water separator (Figure 2, Item 20). Connect hose (Figure 2, Item 17) from connector (Figure 2, Item 18) and install new O-ring (Figure 2, Item 7). Install two elbows (Figure 2, Item 21) and two valves (Figure 2, Item 1) to fuel tank (Figure 2, Item 2). Connect hose (Figure 2, Item 9) and hose (Figure 2, Item 17) to two elbows (Figure 2, Item 21) and install new O-rings (Figure 2, Item 7). Install bolt (Figure 2, Item 15), two washers (Figure 2, Item 13), and nut (Figure 2, Item 12) to loop clamp (Figure 2, Item 14). Install three bolts (Figure 2, Item 5), three plates (Figure 2, Item 6), and six block clamps (Figure 2, Item 4). Turn two fuel shut-off valves (Figure 2, Item 1) to ON position (WP 0116).
0114-4
TM 5-3895-379-23-1
0114
FUEL LINES AND FITTINGS INSTALLATION - Continued
3 21 7 21 7 4
4 5 6 5 6 20 15 19 18 7 17 14 5 13 4 12 7 6 8 9 13 9 8 7
11
8 9
16 10
M1179SWR
Fuel Lines and Fittings Installation.
0114-5
TM 5-3895-379-23-1
0114
FUEL INJECTOR LINES AND FITTINGS REMOVAL
NOTE
Cap all openings or plug all openings immediately. 1. 2. Remove fuel filter assembly (WP 0127). Disconnect four fuel injection lines (Figure 3, Item 2) from fuel injections nozzles (Figure 3, Item 1).
NOTE
Secure fittings (Figure 3, Item 7) with a wrench when removing fuel injection lines (Figure 3, Item 2) at the fuel injection pump (Figure 3, Item 8). 3. 4. 5. 6. Disconnect four fuel injection lines (Figure 3, Item 2) from fuel injection pump (Figure 3, Item 8). Remove four fuel injection lines (Figure 3, Item 2) from roller. Remove bolt (Figure 3, Item 5), three bolts (Figure 3, Item 4), and eight washers (Figure 3, Item 3) from fuel return line (Figure 3, Item 6). Discard washers. Remove fuel return line (Figure 3, Item 6).
3 4
7 8
M0145SWR
Figure 3. Fuel Injector Lines and Fittings Removal. END OF TASK FUEL INJECTOR LINES AND FITTINGS INSTALLATION 1. 2. 3. Install fuel return lines (Figure 4, Item 6). Install eight washers (Figure 4, Item 3), three bolts (Figure 4, Item 4), and bolt (Figure 4, Item 5). Install four fuel injection lines (Figure 4, Item 2) to roller.
0114-6
TM 5-3895-379-23-1
0114
FUEL INJECTOR LINES AND FITTINGS INSTALLATION - Continued
NOTE
Secure fittings (Figure 4, Item 7) with a wrench when connecting fuel injection line (Figure 4, Item 2) to fuel injection pump. 4. 5. Install four fuel injection lines (Figure 4, Item 2) to fuel injection pump (Figure 4, Item 8). Install four fuel injection lines (Figure 4, Item 2) to fuel injection nozzles. Tighten fuel injection line fittings to 156 lb-in. (18 Nm).
3 4
7 8
M1180SWR
Figure 4. Fuel Injector Lines and Fittings Installation. 6. Install fuel filter assembly (WP 0127).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Place battery disconnect switch in ON position. (TM 5-3895-379-10) Lower operator platform. (Volume 2, WP 0235) Close left and right-side door assemblies. (TM 5-3895-379-10) Fill fuel tank. (WP 0124) Prime fuel system. (WP 0128) Start engine and check for proper operation and fuel leaks. (TM 5-3895-379-10)
0114-7/8 blank
TM 5-3895-379-23-1
0115
FIELD MAINTENANCE FUEL INJECTOR LINES AND FITTINGS REPLACEMENT (CB534C)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (Volume 2, WP 0289, Table 1, Item 23) Wrench, Torque, 0-300 in-lb (Volume 2, WP 0289, Table 1, Item 41) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 2, WP 0288, Table 1, Item 12) Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) O-ring (Volume 2, WP 0290, Table 1, Item 81) Qty: 10 Seal (Volume 2, WP 0290, Table 1, Item 118) Qty: 3 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 17, 18, and 27 References (cont.) WP 0127 WP 0128 Equipment Condition Engine off. (TM 5-3895-379-10) Operator platform assembly raised. (Volume 2, WP 0235) Battery disconnect switch in OFF position. (TM 5-3895-379-10) Right and left-side door assemblies opened. (TM 5-3895-379-10) Fuel tank drained. (WP 0124)
0115-1
TM 5-3895-379-23-1
0115
FUEL LINES AND FITTINGS REMOVAL
WARNING
CAUTION
Wipe area clean around all fuel connections to be opened during removal. Cap lines and plug openings after removing lines. Contamination of fuel system could result in premature failure of engine.
NOTE
Use drain pan to catch any fuel that may drain from fuel system. Dispose of fuel IAW local policy and ordinances. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Turn two fuel shut-off valves (Figure 1, Item 8) to OFF position (WP 0124). Remove three bolts (Figure 1, Item 5), three plates (Figure 1, Item 4), and six block clamps (Figure 1, Item 3) from frame. Remove two bolts (Figure 1, Item 19), six washers (Figure 1, Item 20), and two nuts (Figure 1, Item 24) from two loop clamps (Figure 1, Item 25). Disconnect hose (Figure 1, Item 2) and hose (Figure 1, Item 28) from two adapters (Figure 1, Item 29). Remove two O-rings (Figure 1, Item 6) from adapters (Figure 1, Item 29). Discard O-rings. Remove two adapters (Figure 1, Item 30) from fuel side of tank (Figure 1, Item 1). Remove hose (Figure 1, Item 21), connector (Figure 1, Item 22), and O-ring (Figure 1, Item 6) from connector (Figure 1, Item 23). Discard O-ring. Disconnect hose (Figure 1, Item 21) from adapter (Figure 1, Item 7). Remove connector (Figure 1, Item 26), two O-rings (Figure 1, Item 6), valve (Figure 1, Item 8), adapter (Figure 1, Item 7), and two loop clamps (Figure 1, item 25) from hose (Figure 1, Item 28). Discard O-rings. Disconnect adapter (Figure 1, Item 13) from fuel/water separator (Figure 1, Item 21). Remove O-ring (Figure 1, Item 14), adapter (Figure 1, Item 13), seal (Figure 1, Item 12), elbow (Figure 1, Item 11), O-ring (Figure 1, Item 10), connector (Figure 1, Item 9), valve (Figure 1, Item 7), adapter (Figure 1, Item 7), and O-ring (Figure 1, Item 6) from hose (Figure 1, Item 2). Discard O-rings and seal. Remove hose (Figure 1, Item 18), connector (Figure 1, Item 17), O-ring (Figure 1, Item 6), and seal (Figure 1, Item 16) from fuel/water separator (Figure 1, Item 15). Discard O-ring and seal. Remove hose (Figure 1, Item 18), connector (Figure 1, Item 17), O-ring (Figure 1, Item 6), and seal (Figure 1, Item 16) from fuel pump (Figure 1, Item 27). Discard O-ring and seal. Remove and inspect hoses (Figure 1, Items 2, 18, 21, and 28).
12. 13. 14.
0115-2
TM 5-3895-379-23-1
0115
FUEL LINES AND FITTINGS REMOVAL - Continued
15
14 1 11 10 9 8 2 3 4 5 3 3 3 30 29 6 19 20 25 26 17 6 26 25 20 24 8 7 6 18 4 5 6 17 5 16 7 6 13 12
21 30 29 6 28
27 6 15 23
M0146SWR
22
Fuel Lines and Fittings Removal.
0115-3
TM 5-3895-379-23-1
0115
FUEL LINES AND FITTINGS INSTALLATION 1. 2. 3. Install hose (Figure 2, Item 18), connector (Figure 2, Item 17), new O-ring (Figure 2, Item 6), and new seal (Figure 2, Item 16) on fuel pump (Figure 2, Item 27). Install hose (Figure 2, Item 18), connector (Figure 2, Item 17), new O-ring (Figure 2, Item 6), and new seal (Figure 2, Item 16) to fuel/water separator (Figure 2, Item 15). Install new O-ring (Figure 2, Item 14), adapter (Figure 2, Item 13), new seal (Figure 2, Item 12), elbow (Figure 2, Item 11), new O-ring (Figure 2, Item 10), connector (Figure 2, Item 9), valve (Figure 2, Item 8), adapter (Figure 2, Item 7), and new O-ring (Figure 2, Item 6) to hose (Figure 2, Item 2). Connect adapter (Figure 2, Item 13) to fuel/water separator (Figure 2, Item 15). Install connector (Figure 2, Item 26), two new O-rings (Figure 2, Item 6), valve (Figure 2, Item 8), adapter (Figure 2, Item 7), and two loop clamps (Figure 2, Item 25) on hose (Figure 2, Item 28). Install hose (Figure 2, Item 21), connector (Figure 2, Item 22), and new O-ring (Figure 2, Item 6) on fuel/water separator (Figure 2, Item 15). Connect hose (Figure 2, Item 21) to adapter (Figure 2, Item 7). Install two adapters (Figure 2, Item 30) on fuel tank (Figure 2, Item 1). Install two new O-rings (Figure 2, Item 6) to adapters (Figure 2, Item 29). Connect hose (Figure 2, Item 2) and hose (Figure 2, Item 28) to two adapters (Figure 2, Item 29). Install two bolts (Figure 2, Item 19), six washers (Figure 2, Item 20), and two nuts (Figure 2, Item 24) to two loop clamps (Figure 2, Item 25). Install three bolts (Figure 2, Item 5), three plates (Figure 2, Item 4), and six block clamps (Figure 2, Item 3). Turn two fuel shut-off valves (Figure 2, Item 8) to ON position (WP 0124).
4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
0115-4
TM 5-3895-379-23-1
0115
FUEL LINES AND FITTINGS INSTALLATION - Continued
15
14 1 11 10 9 8 2 3 4 5 3 3 3 30 29 6 19 20 25 26 17 6 26 25 20 24 8 7 6 18 4 5 6 17 5 16 7 6 13 12
21 30 29 6 28
27 6 15 23
M1302SWR
22
Fuel Lines and Fittings Installation.
0115-5
TM 5-3895-379-23-1
0115
FUEL INJECTOR LINES AND FITTINGS REMOVAL
WARNING
CAUTION
Cap or plug all openings immediately to prevent contamination. Contamination may cause damage to the equipment. 1. 2. Remove fuel filter assembly (WP 0127). Disconnect four fuel injection lines (Figure 3, Item 3) from fuel injection nozzles (Figure 3, Item 2).
NOTE
Secure fittings with a wrench when removing fuel injection lines at the fuel injection pump. 3. 4. 5. 6. Disconnect four fuel injection lines (Figure 3, Item 3) from fuel injection pump (Figure 3, Item 7). Remove four fuel injection lines (Figure 3, Item 3) from roller. Remove bolt (Figure 3, Item 5), three bolts (Figure 3, Item 6), and eight washers (Figure 3, Item 4) from fuel return line (Figure 3, Item 1). Remove fuel return line (Figure 3, Item 1).
0115-6
TM 5-3895-379-23-1
0115
FUEL INJECTOR LINES AND FITTINGS REMOVAL - Continued
3 2 1
4 5 8 6
M0147SWR
Fuel Injector Lines and Fittings Removal.
0115-7
TM 5-3895-379-23-1
0115
FUEL INJECTOR LINES AND FITTINGS INSTALLATION 1. 2. 3. Install fuel return line (Figure 4, Item 1) to fuel injectors (Figure 4, Item 2). Install eight washers (Figure 4, Item 4), three bolts (Figure 4, Item 6), and bolt (Figure 4, Item 5) to fuel injectors (Figure 4, Item 2). Install four fuel injection lines (Figure 2, Item 3) to roller.
NOTE
Secure fittings (Figure 4, Item 8) with a wrench when connecting fuel injection line (Figure 4, Item 3) to fuel injection pump. 4. 5. Install four fuel injection lines (Figure 4, Item 3) on fuel injection pump (Figure 4, Item 7). Install four fuel injection lines (Figure 4, Item 3) on fuel injection nozzles. Tighten fuel injection line fittings to 156 lb-in. (18 Nm).
3 2 1
4 5 8 6
M1268SWR
Figure 4. Fuel Injector Lines and Fittings Installation. END OF TASK
0115-8
TM 5-3895-379-23-1
0115
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. Install fuel filter assembly. (WP 0127) Place battery disconnect switch in ON position. (TM 5-3895-379-10) Lower operator platform. (Volume 2, WP 0235) Close left and right-side door assemblies. (TM 5-3895-379-10) Fill fuel tank. (WP 0124) Prime fuel system. (WP 0128) Start engine and check for proper operation and fuel leaks. (TM 5-3895-379-10)
0115-9/10 blank
TM 5-3895-379-23-1
0116
FIELD MAINTENANCE FUEL LIFT PUMP REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Goggles (Volume 2, WP 0289, Table 1, Item 13) Pan, Drain, 5 Gal Cap. (Volume 2, WP 0289, Table 1, Item 23) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 2, WP 0288, Table 1, Item 12) Cleaning Compound, Solvent (Volume 2, WP 0288, Table 1, Item 13, 14, 15) Sealing Compound, Loctite 271 (Volume 2, WP 0288, Table 1, Item 62) O-ring (Volume 2, WP 0290, Table 1, Item 81) Qty: 1 Materials/Parts (cont.) Gasket (Volume 2, WP 0290, Table 1, Item 56) Qty: 1 Gasket (Volume 2, WP 0290, Table 1, Item 76) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 19 and 27 Equipment Condition Engine off. (TM 5-3895-379-10) Operator platform assembly raised. (Volume 2, WP 0235)
0116-1
TM 5-3895-379-23-1
0116
REMOVAL
WARNING
NOTE
Use a drain pan to catch any fuel that may drain from the system. Dispose of fuel IAW local policy and ordinances. Ensure all spills are cleaned up. 1. Close fuel supply valves (Figure 1, Item 1).
1 1
CB534B ROLLER
CB534C ROLLER
M0148SWR
Figure 1. Fuel Lift Pump Removal.
0116-2
TM 5-3895-379-23-1
0116
REMOVAL - Continued 2. Loosen two clamps (Figure 2, Item 4). Remove hose (Figure 2, Item 2) from air filter assembly (Figure 2, Item 3) and turbocharger (Figure 2, Item 1).
2 VIEW FROM REAR OF AIR CLEANER ASSEMBLY 4
M0149SWR
Figure 2.
Fuel Lift Pump Removal.
0116-3
TM 5-3895-379-23-1
0116
REMOVAL - Continued
NOTE
Inspect all hoses, lines, and fittings for cracks, bends, nicks, dents, stripped threads, and cuts. Replace all damaged parts. 3. 4. 5. 6. 7. 8. 9. Position drain pan under fuel lift pump (Figure 3, Item 5). Remove fuel line (Figure 3, Item 1) and bushing (Figure 3, Item 12) from fuel lift pump (Figure 3, Item 5). Cap fuel line (Figure 3, Item 1). Remove fuel hose (Figure 3, Item 6) and O-ring (Figure 3, Item 7) from adapter (Figure 3, Item 8). Discard O-ring. Plug fuel hose (Figure 3, Item 6). Remove adapter (Figure 3, Item 8) and gasket (Figure 3, Item 9) from fuel lift pump (Figure 3, Item 5). Discard gasket. Remove adapter (Figure 3, Item 2) and fuel tube (Figure 3, Item 3) from fuel lift pump (Figure 3, Item 5).
NOTE
If fuel lift pump is difficult to remove, rotate crankshaft until camshaft lobe is in a position which will free fuel lift pump lever. 10. Remove four screws (Figure 3, Item 10), two plates (Figure 3, Item 11), fuel lift pump (Figure 3, Item 5), and gasket (Figure 3, Item 4) from engine (Figure 3, Item 13). Discard gasket.
0116-4
TM 5-3895-379-23-1
0116
REMOVAL - Continued
CAMSHAFT LOBE 5 4 1 2 6 9 8 13 7 10 3 LEVER
12
11
M0150SWR
Fuel Lift Pump Removal.
0116-5
TM 5-3895-379-23-1
0116
CLEANING
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. Clean fuel tube (Figure 4, Item 3) with cleaning compound, solvent. END OF TASK INSTALLATION
CAUTION
The fuel injection pump needs fuel for lubrication. The precision parts of the fuel injection pump are easily damaged. For this reason, the engine must NOT be started until the fuel injection pump is full of fuel that is free of air. The system must be primed any time any part of the system is drained of fuel. For example, when the fuel system is changed or a fuel line is removed or when the inspection cover on the fuel injection pump is removed for service or repair, the fuel system must be primed (air removed).
NOTE
Ensure camshaft lobe is turned away from lever before installing fuel lift pump. Ensure mating surfaces of engine block and fuel lift pump are clean and free of old gasket and oil material prior to installation. 1. 2. 3. 4. 5. Install gasket (Figure 4, Item 4) and fuel lift pump (Figure 4, Item 5) on engine (Figure 4, Item 13) with two plates (Figure 4, Item 11) and four screws (Figure 4, Item 10). Tighten screws to 15-25 lb-ft (20-34 Nm). Install adapter (Figure 4, Item 8) and new gasket (Figure 4, Item 9) in fuel lift pump (Figure 4, Item 5). Install adapter (Figure 4, Item 2) and fuel tube (Figure 4, Item 3) in fuel lift pump (Figure 4, Item 5). Install fuel hose (Figure 4, Item 6) and new O-ring (Figure 4, Item 7) on adapter. Install fuel line (Figure 4, Item 1) and new gasket (Figure 4, Item 12) in fuel lift pump (Figure 4, Item 5).
0116-6
TM 5-3895-379-23-1
0116
CAMSHAFT LOBE 5 4 1 2 6 9 8 13 7 10 3 LEVER
12
11
M0151SWR
Figure 4. 6.
Fuel Lift Pump Installation.
Install hose (Figure 5, Item 2) and two clamps (Figure 5, Item 4) to air filter (Figure 5, Item 3) and turbocharger (Figure 5, Item 1). Tighten clamps securely.
2 VIEW FROM REAR OF AIR CLEANER ASSEMBLY 4
M1057SWR
Figure 5.
Fuel Lift Pump Installation.
0116-7
TM 5-3895-379-23-1
0116
INSTALLATION - Continued 7. Open fuel supply valves (Figure 6, Item 1).
1 1
CB534B ROLLER
CB534C ROLLER
M0152SWR
Figure 6. Fuel Lift Pump Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Lower operator platform assembly. (Volume 2, WP 0235) Prime fuel system. (WP 0128) Start engine and check for leaks. (TM 5-3895-379-10)
0116-8
TM 5-3895-379-23-1
0117
FIELD MAINTENANCE AIR CLEANER CAP REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Personnel Required Construction Equipment Repairer 91L References FM 21-40 TM 5-3895-379-23P, Figure 23 Equipment Condition Engine off. (TM 5-3895-379-10) Left-side door assembly opened. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0117-1
TM 5-3895-379-23-1
0117
REMOVAL
WARNING
If NBC exposure is suspected, 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.
CAUTION
Area around filter must be very clean. Any contaminants entering filter housing will damage equipment. 1. 2. Loosen clamp (Figure 1, Item 2) and remove cap (Figure 1, Item 1) from air cleaner assembly (Figure 1, Item 3). Cover air cleaner assembly (Figure 1, Item 3) opening with rag.
1
M0153SWR
Figure 1. Air Cleaner Removal. END OF TASK
0117-2
TM 5-3895-379-23-1
0117
INSTALLATION 1. 2. 3. Remove rag from air cleaner assembly (Figure 2, Item 3) opening. Position clamp (Figure 2, Item 2) on cap (Figure 2, Item 1). Install cap (Figure 2, Item 1) on air cleaner assembly (Figure 2, Item 3) and tighten clamp (Figure 2, Item 2).
1
M1166SWR
Air Cleaner Installation.
Close left-side door assembly. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0117-3/4 blank
TM 5-3895-379-23-1
0118
FIELD MAINTENANCE AIR CLEANER ELEMENTS AND AIR CLEANER ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Filter Element, Primary (Volume 2, WP 0290, Table 1, Item 6) Qty: 1 Filter Element, Secondary (Volume 2, WP 0290, Table 1, Item 7) Qty: 1 Personnel Required Construction Equipment Repairer 91L References FM 21-40 TM 5-3895-379-23P, Figures 23 and 24 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Left-side door assembly opened. (TM 5-3895-379-10)
0118-1
TM 5-3895-379-23-1
0118
REMOVAL
WARNING
If NBC exposure is suspected, 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. 1. 2. 3. 4. Release two latches (Figure 1, Item 3) and remove cover (Figure 1, Item 7) from air cleaner body assembly (Figure 1, Item 4). Remove primary air cleaner element (Figure 1, Item 6) from air cleaner body assembly (Figure 1, Item 4). Remove secondary air cleaner element (Figure 1, Item 5) from air cleaner body assembly (Figure 1, Item 4). Loosen clamp (Figure 1, Item 1) and remove cap (Figure 1, Item 2) from air cleaner body assembly (Figure 1, Item 4).
2 1 3 4 5 6 7
M0475SWR
Figure 1. 5. 6.
Air Cleaner Elements and Air Cleaner Assembly Removal.
Remove tube (Figure 2, Item 4) from tube connector (Figure 2, Item 5). Loosen clamp (Figure 2, Item 2) and remove hose (Figure 2, Item 1) from air cleaner body assembly (Figure 2, Item 3).
0118-2
TM 5-3895-379-23-1
0118
REMOVAL - Continued
VIEW FROM REAR OF AIR CLEANER
2 4
M0476SWR
Figure 2. 7. 8. 9. 10.
Remove two screws (Figure 3, Item 3) and nuts (Figure 3, Item 5) from two air cleaner clamps (Figure 3, Item 4). Remove two screws (Figure 3, Item 8), washers (Figure 3, Item 7), nuts (Figure 3, Item 2), and front air cleaner band (Figure 3, Item 4) from support assembly (Figure 3, Item 1). Remove air cleaner body assembly (Figure 3, Item 6) from rear air cleaner clamp (Figure 3, Item 4). Remove two screws (Figure 3, Item 8), washers (Figure 3, Item 7), nuts (Figure 3, Item 2), and rear air cleaner clamp (Figure 3, Item 4) from support assembly (Figure 3, Item 1).
1 2 3 4
5 8 7 6
M0477SWR
Figure 3.
0118-3
TM 5-3895-379-23-1
0118
REMOVAL - Continued 11. Loosen clamp (Figure 4, Item 3) and remove hose (Figure 4, Item 4) from turbocharger assembly (Figure 4, Item 1).
CAUTION
Ensure that dirt or other contaminants do not enter turbocharger or exposed hoses and lines. Cover openings with a clean rag to prevent contamination. 12. Cover turbocharger inlet opening (Figure 4, Item 2) with clean rag.
M0478SWR
Figure 4.
0118-4
TM 5-3895-379-23-1
0118
REMOVAL - Continued 13. 14. 15. 16. Remove nut (Figure 5, Item 5) from pipe coupling (Figure 5, Item 4). Remove pipe coupling (Figure 5, Item 4) from nipple (Figure 5, Item 3). Remove nipple (Figure 5, Item 3) from elbow (Figure 5, Item 2). Remove elbow (Figure 5, Item 2) from air cleaner body assembly (Figure 5, Item 1).
5
M0479SWR
0118-5
TM 5-3895-379-23-1
0118
INSTALLATION 1. 2. 3. 4. Install elbow (Figure 6, Item 2) on air cleaner body assembly (Figure 6, Item 1). Install nipple (Figure 6, Item 3) on elbow (Figure 6, Item 2). Install pipe coupling (Figure 6, Item 4) on nipple (Figure 6, Item 3). Install nut (Figure 6, Item 5) on pipe coupling (Figure 6, Item 4).
5
Figure 6. 5. 6.
M1115SWR
Air Cleaner and Air Cleaner Assembly Installation.
Remove rag from turbocharger inlet opening (Figure 7, Item 2). Install hose (Figure 7, Item 4) on turbocharger assembly (Figure 7, Item 1) and tighten clamp (Figure 7, Item 3).
0118-6
TM 5-3895-379-23-1
0118
M0480SWR
Figure 7. 7.
Air Cleaner Elements and Air Cleaner Assembly Installation.
Install rear air cleaner clamp (Figure 8, Item 4) on support assembly (Figure 8, Item 1) with two screws (Figure 8, Item 8), washers (Figure 8, Item 7), and nuts (Figure 8, Item 2). Tighten nuts to 45-65 lb-ft (61-88 Nm). Position air cleaner body assembly (Figure 8, Item 6) on rear air cleaner clamp (Figure 8, Item 4). Install front air cleaner clamp (Figure 8, Item 4) on support assembly (Figure 8, Item 1) with two washers (Figure 8, Item 7), screws (Figure 8, Item 8), and nuts (Figure 8, Item 2). Tighten nuts to 45-65 lb-ft (61-88 Nm). Install two screws (Figure 8, Item 3) and nuts (Figure 8, Item 5) in two air cleaner clamp assemblies (Figure 8, Item 4). Tighten nuts to 21-35 lb-ft (28-47 Nm).
1 2 8 3 4 6 5 7
8. 9.
10.
M0481SWR
Figure 8.
0118-7
TM 5-3895-379-23-1
0118
INSTALLATION - Continued 11. 12. Install hose (Figure 9, Item 1) on air cleaner body assembly (Figure 9, Item 3) and tighten clamp (Figure 9, Item 2). Install tube (Figure 9, Item 4) on tube connector (Figure 8, Item 5).
1
2 4
M0482SWR
Figure 9. 13. 14. 15. 16.
Install cap (Figure 10, Item 2) on air cleaner body assembly (Figure 10, Item 4) and tighten clamp (Figure 10, Item 1). Install secondary air cleaner element (Figure 10, Item 5) in air cleaner body assembly (Figure 10, Item 4). Install primary air cleaner element (Figure 10, Item 6) in air cleaner body assembly (Figure 10, Item 4). Install cover (Figure 10, Item 7) on air cleaner body assembly (Figure 10, Item 4) and close two latches (Figure 10, Item 3).
2 1 3 4 5 6 7
M0483SWR
0118-8
TM 5-3895-379-23-1
0118
FOLLOW-ON MAINTENANCE 1. 2. Close left-side door assembly. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0118-9/10 blank
TM 5-3895-379-23-1
0119
FIELD MAINTENANCE AIR CLEANER SUPPORT ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Strap, Tiedown, Electrical (Volume 2, WP 0288, Table 1, Item 67, 68, 69) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 23, 27, 83, and 84 Equipment Condition Fuel/water separator removed. (WP 0129) Air cleaner assembly removed. (WP 0118) Air cleaner service indicator removed. (WP 0120) Alternator circuit breaker removed. (WP 0151)
REMOVAL
NOTE
Tag and mark hose positions in clamps prior to removal. 1. 2. Remove screw (Figure 1, Item 11), plate (Figure 1, Item 10), clamp (Figure 1, Item 9), and two hoses (Figure 1, Items 7 and 8) from screw (Figure 1, Item 2). Remove plate (Figure 1, Item 1), screw (Figure 1, Item 2), clamp (Figure 1, Item 3), and two hoses (Figure 1, Items 5 and 6) from mounting bracket (Figure 1, Item 4).
1 2 3 4 5
11
10
6
M0484SWR
Figure 1. Air Cleaner Support Assembly Removal.
0119-1
TM 5-3895-379-23-1
0119
REMOVAL - Continued 3. 4. 5. Remove two screws (Figure 2, Item 12), plate (Figure 2, Item 11), clamp (Figure 2, Item 10), and hose (Figure 2, Item 9) from two screws (Figure 2, Item 8). Remove plate (Figure 2, Item 13), two screws (Figure 2, Item 8), clamp (Figure 2, Item 7), and hose (Figure 2, Item 6) from two screws (Figure 2, Item 1). Remove plate (Figure 2, Item 5), two screws (Figure 2, Item 1), clamp (Figure 2, Item 2), and hose (Figure 2, Item 4) from mounting bracket (Figure 2, Item 3).
1 2 3
13
12
11
10
M0485SWR
NOTE
Remove electrical tiedown straps from wiring harness as required. Discard electrical tiedown straps. 6. Remove wiring harness (Figure 3, Item 4) from air cleaner support assembly (Figure 3, Item 3).
NOTE
Do not remove hydraulic lines. 7. Remove two nuts (Figure 3, Item 2), washers (Figure 3, Item 1), screws (Figure 3, Item 5), washers (Figure 3, Item 6), and brake control valve (Figure 3, Item 7) from mounting bracket (Figure 3, Item 3).
0119-2
TM 5-3895-379-23-1
0119
REMOVAL - Continued
1 2 3 7 6
M0486SWR
Figure 3. Air Cleaner Support Assembly Removal. 8. Remove two screws (Figure 4, Item 3) and washers (Figure 4, Item 2) from mounting bracket (Figure 4, Item 1).
1
M0487SWR
0119-3
TM 5-3895-379-23-1
0119
REMOVAL - Continued 9. Remove screw (Figure 5, Item 1), washer (Figure 5, Item 3), and mounting bracket (Figure 5, Item 4) from engine (Figure 5, Item 2).
1 2
M0488SWR
Figure 5. Air Cleaner Support Assembly Removal. END OF TASK INSTALLATION 1. Install mounting bracket (Figure 6, Item 4) on engine (Figure 6, Item 2) with washer (Figure 6, Item 3) and screw (Figure 6, Item 1). Do not tighten screw.
1 2
M1311SWR
Figure 6. Air Cleaner Support Assembly Installation. 2. Install two washers (Figure 7, Item 2) and screws (Figure 7, Item 3) on mounting bracket (Figure 7, Item 1). Tighten screws to 33-47 lb-ft (45-64 Nm).
0119-4
TM 5-3895-379-23-1
0119
1
M1073SWR
Figure 7. Air Cleaner Support Assembly Installation. 3. 4. Tighten screw (Figure 6, Item 6) to 33-47 lb-ft (45-64 Nm). Install brake control valve (Figure 8, Item 7) on air cleaner support assembly (Figure 8, Item 3) with two washers (Figure 8, Item 1), screws (Figure 8, Item 5), washers (Figure 8, Item 1), and nuts (Figure 8, Item 2). Tighten nuts to 33-47 lb-ft (45-64 Nm).
NOTE
Install new electrical tiedown straps on wiring harness as required. 5. Install wiring harness (Figure 8, Item 4) on mounting bracket (Figure 8, Item 5).
1 2 3 7 6
M1072SWR
Figure 8. Air Cleaner Support Assembly Installation.
0119-5
TM 5-3895-379-23-1
0119
INSTALLATION - Continued 6. 7. 8. Position hose (Figure 9, Item 5) in clamp (Figure 9, Item 3) and install clamp on mounting bracket (Figure 9, Item 4) with two screws (Figure 9, Item 2) and plate (Figure 9, Item 6). Position hose (Figure 9, Item 7) in clamp (Figure 9, Item 8) and install clamp on two screws (Figure 9, Item 2) with two screws (Figure 9, Item 9) and plate (Figure 9, Item 1). Position hose (Figure 9, Item 10) in clamp (Figure 9, Item 11) and install clamp and plate (Figure 9, Item 12) on two screws (Figure 9, Item 9) with two screws (Figure 9, Item 13).
2 3 4
13
12
11
10
M1071SWR
Figure 9. Air Cleaner Support Assembly Installation. 9. 10. Position two hoses (Figure 10, Items 5 and 6) in clamp (Figure 10, Item 3) and install clamp on mounting bracket (Figure 10, Item 4) with screw (Figure 10, Item 2) and plate (Figure 10, Item 1). Position two hoses (Figure 10, Items 7 and 8) in clamp (Figure 10, Item 9) and install clamp and plate (Figure 10, Item 10) on screw (Figure 10, Item 2) with screw (Figure 10, Item 11).
0119-6
TM 5-3895-379-23-1
0119
1 2 3 4 5
11
10
6
M0489SWR
Air Cleaner Support Assembly Installation.
Install alternator circuit breaker. (WP 0151) Install air cleaner service indicator. (WP 0120) Install air cleaner assembly. (WP 0118) Install fuel/water separator. (WP 0129)
0119-7/8 blank
TM 5-3895-379-23-1
0120
FIELD MAINTENANCE AIR CLEANER SERVICE INDICATOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 0-300 in-lb (Volume 2, WP 0289, Table 1, Item 41) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 23 Equipment Condition Engine off. (TM 5-3895-379-10) Left-side door assembly opened. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
REMOVAL 1. 2. 3. 4. Remove service indicator (Figure 1, Item 1) from adapter (Figure 1, Item 8) by turning to the left. Remove tube (Figure 1, Item 4) from adapter (Figure 1, Item 3). Remove two nuts (Figure 1, Item 5), screws (Figure 1, Item 7), washers (Figure 1, Item 6), and adapter (Figure 1, Item 8) from mounting bracket (Figure 1, Item 2). Remove adapter (Figure 1, Item 3) from adapter (Figure 1, Item 8).
INSTALL 1
REMOVE
4 2 8 3
6
M0490SWR
Figure 1. Air Cleaner Service Indicator Removal.
0120-1
TM 5-3895-379-23-1
0120
REMOVAL - Continued 5. Remove tube (Figure 2, Item 2) from tube connector (Figure 2, Item 1).
VIEW FROM BACK SIDE OF AIR CLEANER ASSEMBLY
M0491SWR
Figure 2. Air Cleaner Service Indicator Removal. END OF TASK INSTALLATION 1. Install tube (Figure 3, Item 2) on tube connector (Figure 3, Item 1).
VIEW FROM BACK SIDE OF AIR CLEANER ASSEMBLY
M1312SWR
Figure 3.
Air Cleaner Service Indicator Installation.
0120-2
TM 5-3895-379-23-1
0120
INSTALLATION - Continued 2. 3. 4. 5. 6. Install adapter (Figure 4, Item 4) on adapter (Figure 4, Item 9). Install adapter (Figure 4, Item 9) on mounting bracket (Figure 4, Item 3) with two washers (Figure 4, Item 7), screws (Figure 4, Item 8), and nuts (Figure 4, Item 6). Tighten screws to 108-180 lb-in. (12-20 Nm). Install tube (Figure 4, Item 5) on adapter (Figure 4, Item 4). Install service indicator (Figure 4, Item 1) on adapter (Figure 4, Item 9) by turning clockwise. Push button (Figure 4, Item 2) on service indicator (Figure 4, Item 1) to reset.
INSTALL 1
REMOVE 2 5 3 4
M0492SWR
Figure 4. Air Cleaner Service Indicator Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Close left-side door assembly. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0120-3/4 blank
TM 5-3895-379-23-1
0121
FIELD MAINTENANCE TURBOCHARGER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Antiseize Compound (Volume 2, WP 0288, Table 1, Item 8) Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Gasket (Volume 2, WP 0290, Table 1, Item 51) Qty: 1 Gasket (Volume 2, WP 0290, Table 1, Item 63) Qty: 1 Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figure 25 WP 0071 WP 0073 Equipment Condition Engine off. (TM 5-3895-379-10) Operator platform assembly raised. (Volume 2, WP 0235) Muffler and tailpipe removed. (WP 0134) Starter removed. (WP 0152)
0121-1
TM 5-3895-379-23-1
0121
REMOVAL
CAUTION
Ensure that dirt or other contaminants do not enter turbocharger or exposed hoses and lines. Cover openings with a clean rag to prevent contamination.
NOTE
Turbocharger is replaced the same way for CB534B and CB534C Rollers, except where noted. CB534B Roller is shown. 1. 2. Loosen clamp (Figure 1, Item 5) and remove hose (Figure 1, Item 6) from turbocharger (Figure 1, Item 4). Loosen two clamps (Figure 1, Item 3) and remove hose (Figure 1, Item 2) from intake manifold elbow (Figure 1, Item 1).
1 2 3
4 5 6
M0493SWR
Figure 1. Turbocharger Removal.
0121-2
TM 5-3895-379-23-1
0121
REMOVAL - Continued 3. Remove two screws (Figure 2, Item 1), tube assembly (Figure 2, Item 4), and gasket (Figure 2, Item 3) from turbocharger (Figure 2, Item 2). Discard gasket.
4 3 2
M0494SWR
Figure 2. 4.
Turbocharger Removal.
Loosen two clamps (Figure 3, Item 2) and slide hose (Figure 3, Item 4) down tube (Figure 3, Item 3) away from turbocharger (Figure 3, Item 1).
4 3
M0495SWR
Figure 3.
Turbocharger Removal.
0121-3
TM 5-3895-379-23-1
0121
REMOVAL - Continued 5. 6. 7. For CB534C Roller, remove clip (Figure 4, Item 7) and disconnect actuator arm (Figure 4, Item 1) from turbocharger (Figure 3, Item 1). With assistance, remove four nuts (Figure 4, Item 2) from exhaust manifold (Figure 4, Item 3). Remove three screws (Figure 4, Item 6) from turbocharger bracket (Figure 4, Item 5) and remove turbocharger (Figure 3, Item 1) and gasket (Figure 3, Item 4). Discard gasket.
1 2 3 7
4 5
6
M0496SWR
Figure 4. Turbocharger Removal. END OF TASK
0121-4
TM 5-3895-379-23-1
0121
INSTALLATION
NOTE
Apply antiseize compound to threads of studs and screws before installation. 1. 2. 3. With assistance, install new gasket (Figure 5, Item 4) and turbocharger (Figure 6, Item 1) on exhaust manifold (Figure 5, Item 3) with four nuts (Figure 5, Item 2). Tighten nuts to 32 lb-ft (44 Nm). For CB534C Roller only, connect actuator arm (Figure 5, Item 1) to turbocharger and install clip (Figure 5, Item 7). With assistance, install turbocharger bracket (Figure 5, Item 5) with three screws (Figure 5, Item 6). Tighten screws to 22-30 lb-ft (30-41 Nm).
1 2 3 7
4 5
6
M0497SWR
Figure 5.
Turbocharger Installation.
0121-5
TM 5-3895-379-23-1
0121
INSTALLATION - Continued 4. Slide hose (Figure 6, Item 4) up tube (Figure 6, Item 3) and tighten two hose clamps (Figure 6, Item 2) to connect hose to turbocharger (Figure 6, Item 1) and tube.
CAUTION
Turbocharger must be pre-lubricated or damage to turbocharger will occur when engine is started. 5. Add clean engine oil to oil inlet on turbocharger (Figure 6, Item 1) until full. Refer to KEY in (WP 0071), Field Maintenance Preventive Maintenance Checks and Services (PMCS) Introduction, for correct grade of oil. Spin turbine wheel several times in order to lubricate the bearing. Refill oil inlet with oil.
6.
4 3
M0498SWR
Figure 6.
0121-6
TM 5-3895-379-23-1
0121
INSTALLATION - Continued 7. Install new gasket (Figure 7, Item 3) and tube assembly (Figure 7, Item 4) on turbocharger (Figure 7, Item 2) with two screws (Figure 7, Item 1). Tighten screws to 25 lb-ft (34 Nm).
1
4 3 2
M0499SWR
Figure 7. 8. 9.
Install hose (Figure 8, Item 2) on intake manifold (Figure 8, Item 1) and tighten two hose clamps (Figure 8, Item 3). Install hose (Figure 8, Item 6) on turbocharger (Figure 8, Item 4) and tighten hose clamp (Figure 8, Item 5).
1 2 3
4 5 6
M0500SWR
0121-7
TM 5-3895-379-23-1
0121
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Install starter. (WP 0152) Install muffler and tailpipe. (WP 0134) Lower operator platform assembly. (Volume 2, WP 0235) Check engine oil level and add as needed. (WP 0077) Operate roller and check for proper operation and leaks. (TM 5-3895-379-10)
0121-8
TM 5-3895-379-23-1
0122
FIELD MAINTENANCE TURBOCHARGER REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Sealing Compound, Loctite 271 (Volume 2, WP 0288, Table 1, Item 62) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Gasket (Volume 2, WP 0290, Table 1, Item 53) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-10 TM 5-3895-379-23P, Figures 25 and 26 Equipment Condition Turbocharger removed. (WP 0121)
DISASSEMBLY
NOTE
Tag and mark components for orientation before disassembly. 1. For CB534C Roller, disconnect hose (Figure 1, Item 2), remove screw (Figure 1, Item 5), two bolts (Figure 1, Item 4), and actuator assembly (Figure 1, Item 3) from turbocharger group (Figure 1, Item 1).
1 1 2
4 5
CB534B ROLLER
CB534C ROLLER
M0501SWR
Figure 1.
Turbocharger Disassembly.
0122-1
TM 5-3895-379-23-1
0122
DISASSEMBLY - Continued 2. 3. 4. 5. 6. 7. 8. Remove exhaust elbow (Figure 2, Item 11) and outlet sleeve (Figure 2, Item 10) from housing (Figure 2, Item 1). Remove two bolts (Figure 2, Item 13), gasket (Figure 2, Item 12), and hose assembly (Figure 2, Item 9). Discard gasket. Remove six bolts (Figure 2, Item 6) and three clamp sets (Figure 2, Item 5). Separate turbocharger group (Figure 2, Item 4) from cartridge group (Figure 2, Item 2). Remove six bolts (Figure 2, Item 3). Remove three screws (Figure 2, Item 7) and clamps (Figure 2, Item 8). Separate cartridge group (Figure 2, Item 2) from housing (Figure 2, Item 1).
4 3 2 1
12 11 13 9 10
M0502SWR
7 6 5
Figure 2. Turbocharger Disassembly. END OF TASK ASSEMBLY 1. 2. 3. 4. 5. Install cartridge group (Figure 3, Item 2) to housing (Figure 3, Item 1). Install three clamps (Figure 3, Item 8) and screws (Figure 3, Item 7). Apply sealing compound on threads of six bolts (Figure 3, Item 3) and install. Tighten to 164-180 lb-in. (18.5-20.3 Nm). Install turbocharger group (Figure 3, Item 4) to cartridge group (Figure 3, Item 2). Apply sealing compound on threads of six bolts (Figure 3, Item 6) and install with three clamp sets (Figure 3, Item 5). Tighten to 135-165 lb-in. (15.2-18.6 Nm).
0122-2
TM 5-3895-379-23-1
0122
ASSEMBLY - Continued 6. 7. Install gasket (Figure 3, Item 12), hose assembly (Figure 3, Item 9), and two bolts (Figure 3, Item 13). Install outlet sleeve (Figure 3, Item 10) and exhaust elbow (Figure 3, Item 11) to housing (Figure 3, Item 1).
4 3 2 1
12 11 13 9 10
M1116SWR
7 6 5
Figure 3. 8.
Turbocharger Assembly.
For CB534C Roller, install screw (Figure 4, Item 5) to actuator assembly (Figure 4, Item 3). Install actuator assembly (Figure 4, Item 3) to turbocharger group (Figure 4, Item 1). Connect hose (Figure 4, Item 2) and install two bolts (Figure 4, Item 4) to turbocharger group (Figure 4, Item 1).
1 1 2
4 5
CB534B ROLLER
CB534C ROLLER
M0503SWR
Turbocharger Assembly.
0122-3
TM 5-3895-379-23-1
0122
FOLLOW-ON MAINTENANCE 1. 2. Install turbocharger. (WP 0121) Start engine and check for proper operation. (TM 5-3895-379-10)
0122-4
TM 5-3895-379-23-1
0123
FIELD MAINTENANCE TURBOCHARGER OIL LINES, HOSES, AND FITTINGS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 0-300 in-lb (Volume 2, WP 0289, Table 1, Item 41) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Gasket (Volume 2, WP 0290, Table 1, Item 51) Qty: 1 Materials/Parts (cont.) Gasket (Volume 2, WP 0290, Table 1, Item 53) Qty: 1 Gasket (Volume 2, WP 0290, Table 1, Item 52) Qty: 1 Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-10 TM 5-3895-379-23P, Figure 25 Equipment Condition Operator platform assembly raised. (Volume 2, WP 0235) Muffler and tailpipe removed. (WP 0134)
0123-1
TM 5-3895-379-23-1
0123
REMOVAL
WARNING
Use caution and allow engine to cool before removal of component. Failure to follow this warning may cause injury. 1. Remove two screws (Figure 1, Item 1), tube assembly (Figure 1, Item 4), and gasket (Figure 1, Item 3) from turbocharger (Figure 1, Item 2). Discard gasket.
1
4 3 2
M0504SWR
Figure 1. 2. 3. 4. 5.
Turbocharger Oil Lines, Hoses, and Fittings Removal.
Remove screw (Figure 2, Item 2), spacer (Figure 2, Item 9), and clamp (Figure 2, Item 1) from engine block (Figure 2, Item 8) and tube assembly (Figure 2, Item 7). Loosen nut (Figure 2, Item 6) and remove tube assembly (Figure 2, Item 7) from nipple (Figure 2, Item 3). If damaged, remove compression sleeve (Figure 2, Item 5) and nut (Figure 2, Item 6) from tube assembly (Figure 2, Item 7). Remove adapter (Figure 2, Item 3) from manifold (Figure 2, Item 4).
0123-2
TM 5-3895-379-23-1
0123
REMOVAL - Continued
8 7 6 5
M0505SWR
Figure 2. 6. 7. 8.
Remove two hose clamps (Figure 3, Item 5) and hose (Figure 3, Item 6) from tube (Figure 3, Item 7) and elbow (Figure 3, Item 3). Remove two screws (Figure 3, Item 4), tube (Figure 3, Item 7), and gasket (Figure 3, Item 1) from turbocharger (Figure 3, Item 2). Discard gasket. Remove two screws (Figure 3, Item 4), elbow (Figure 3, Item 3), and gasket (Figure 3, Item 1) from engine block. Discard gasket.
1 2
7 4 5 6 5 4 3 1
M0506SWR
0123-3
TM 5-3895-379-23-1
0123
INSTALLATION 1. 2. 3. Install new gasket (Figure 4, Item 1) and elbow (Figure 4, Item 3) on engine block with two screws (Figure 4, Item 4). Tighten screws to 15-25 lb-ft (20-34 Nm). Install new gasket (Figure 4, Item 1) and tube (Figure 4, Item 7) on turbocharger (Figure 4, Item 2) with two screws (Figure 4, Item 4). Tighten screws to 15-25 lb-ft (20-34 Nm). Install hose (Figure 4, Item 6) on tube (Figure 4, Item 7) and elbow (Figure 4, Item 3) and tighten two hose clamps (Figure 4, Item 5).
1 2
7 4 5 6 5 4 3 1
M1081SWR
Figure 4. 4. 5. 6. 7. 8. 9.
Turbocharger Oil Lines, Hoses, and Fittings Installation.
Install adapter (Figure 5, Item 3) on manifold (Figure 5, Item 4). Tighten adapter to 22-28 lb-ft (30-38 Nm). If removed, install compression sleeve (Figure 5, Item 5) and nut (Figure 5, Item 6) on tube assembly (Figure 5, Item 7). Do not tighten nut. Install tube assembly (Figure 5, Item 7) on adapter (Figure 5, Item 3). Install clamp (Figure 5, Item 1) on tube assembly (Figure 5, Item 7). Install spacer (Figure 5, Item 9), clamp (Figure 5, Item 1), and tube assembly (Figure 5, Item 7) on engine block (Figure 5, Item 8) with screw (Figure 5, Item 2). Tighten screw to 25 lb-ft (34 Nm). Tighten nut (Figure 5, Item 6) to 120-144 lb-in. (14-16 Nm).
0123-4
TM 5-3895-379-23-1
0123
8 7 6 5
M1080SWR
Figure 5. 10.
Install new gasket (Figure 6, Item 3) and tube assembly (Figure 6, Figure 4) on turbocharger (Figure 6, Item 2) with two screws (Figure 6, Item 1). Tighten two screws (Figure 6, Item 1) to 25 lb-ft (34 Nm).
4 3 2
M0507SWR
0123-5
TM 5-3895-379-23-1
0123
FOLLOW-ON MAINTENANCE 1. 2. 3. Lower operator platform assembly. (Volume 2, WP 0235) Install muffler and exhaust pipes. (WP 0134) Start engine and check for leaks. (TM 5-3895-379-10)
0123-6
TM 5-3895-379-23-1
0124
FIELD MAINTENANCE FUEL/HYDRAULIC OIL TANK DRAIN/FILL
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Goggles (Volume 2, WP 0289, Table 1, Item 13) Materials/Parts Diesel Fuel Oil DF1 B (Volume 2, WP 0288, Table 1, Item 18, 19, 20) OR Diesel Fuel Oil DF2 B (Volume 2, WP 0288, Table 1, Item 21, 22, 23) OR Turbine Fuel, Aviation (Volume 2, WP 0288, Table 1, Item 73) Lubricating Oil MIL-L-2104 OE/, 10 Grade (Volume 2, WP 0288, Table 1, Item 51, 52, 53) OR Lubricating Oil, Engine, 15W40 Grade (Volume 2, WP 0288, Table 1, Item 29, 30, 31) OR Lubricating Oil Ice Sub Zero (Volume 2, WP 0288, Table 1, Item 48, 49, 50) Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) O-ring (Volume 2, WP 0290, Table 1, Item 88) Qty: 2 Materials/Parts (cont.) Container, 15.5 Gal (59 Liters) Minimum Capacity (CB534B Roller) Container, 24 Gal (91 Liters) Minimum Capacity (CB534C Roller) Container, 55 Gal (208 Liters) Minimum Capacity Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 28, 30, and 31 WP 0071 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Right-side door assembly opened (for hydraulic oil tank service). (TM 5-3895-379-10) Left-side door assembly opened (for fuel tank service). (TM 5-3895-379-10)
0124-1
TM 5-3895-379-23-1
0124
DRAIN FUEL TANK
WARNING
DO NOT smoke or permit any open flame while you are servicing 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, or equipment damage. Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing. Fuel is very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury.
NOTE
Use container to catch fuel that drains from system. Dispose of fuel IAW local policy and ordinances. 1. 2. Remove fuel drain cap (Figure 1, Item 2) and O-ring (Figure 1, Item 3) from adapter (Figure 1, Item 1). Discard O-ring. Allow fuel to drain completely into containers.
3 2
M0508SWR
Fuel Tank Drain.
0124-2
TM 5-3895-379-23-1
0124
DRAIN HYDRAULIC OIL TANK
WARNING
Oil is very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury.
NOTE
Use container to catch oil that drains from system. Dispose of oil IAW local policy and ordinances. 1. 2. Remove hydraulic oil drain cap (Figure 2, Item 3) and O-ring (Figure 2, Item 2) from adapter (Figure 2, Item 1). Discard O-ring. Allow hydraulic oil to drain completely into container.
2 3
M0509SWR
Hydraulic Oil Tank Drain.
CAUTION
Dirt, grit, and metallic particles can cause damage to hydraulic components. Clean cap and hose assembly before cap is installed. 1. 2. Clean caps, adapters, and around adapters with rags. Clean cap threads and hydraulic tank hose assembly threads with clean hydraulic oil and rags.
END OF TASK INSPECTION 1. 2. Inspect for metallic particles in cap. Inspect strainer for damage and remove any debris.
0124-3
TM 5-3895-379-23-1
0124
INSPECTION - Continued 3. Inspect adapter threads and cap threads for damage.
END OF TASK FILL HYDRAULIC OIL TANK 1. 2. Install new O-ring (Figure 3, Item 3) and hydraulic oil drain cap (Figure 3, Item 4) on adapter (Figure 3, Item 2). Remove cap (Figure 3, Item 1) and strainer (Figure 3, Item 6) from hydraulic tank (Figure 3, Item 5).
NOTE
Refer to KEY in (WP 0071) to determine correct grade of oil. Hydraulic tank capacity is 15.5 gal. (59 Liters) for the CB534B Roller. Hydraulic tank capacity is 24 gal. (91 Liters) for the CB534C Roller. 3. 4. Fill hydraulic tank (Figure 3, Item 5) with correct grade of oil. Install cap (Figure 3, Item 1) on hydraulic tank (Figure 3, Item 5).
1 5 6
2 3 4
M0510SWR
Figure 3. Hydraulic Oil Tank Fill. END OF TASK
0124-4
TM 5-3895-379-23-1
0124
FILL FUEL TANK
NOTE
Fuel tank capacity is 55 gal. (208 Liters). 1. 2. 3. 4. Install new O-ring (Figure 4, Item 4) and fuel drain cap (Figure 4, Item 3) on adapter (Figure 4, Item 5). Remove cap (Figure 4, Item 1) from fuel tank (Figure 4, Item 2). Fill fuel tank (Figure 4, Item 2) with 55 gal. (208 Liters) of fuel. Install cap (Figure 4, Item 1) on fuel tank (Figure 4, Item 2).
1 2
5 4 3
M0511SWR
Fuel Tank Fill.
Close right and left-side door assemblies. (TM 5-3895-379-10) Start engine and check for leaks. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0124-5/6 blank
TM 5-3895-379-23-1
0125
FIELD MAINTENANCE FUEL/HYDRAULIC OIL TANK AND DRAIN LINES REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Block, Wooden, 6x6x18 in. (15x15x45 cm) (2) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Goggles (Volume 2, WP 0289, Table 1, Item 13) Lifting Device, Minimum Capacity 360 lb (163 kg) Pan, Drain, 5 Gal Cap. (Volume 2, WP 0289, Table 1, Item 23) Wrench, Torque, 0-300 in-lb (Volume 2, WP 0289, Table 1, Item 41) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Adhesive, Gasket Cement (Volume 2, WP 0288, Table 1, Item 3) Cleaning Compound, Solvent (Volume 2, WP 0288, Table 1, Item 13, 14, 15) Cloth, Cleaning (Volume 2, WP 0288, Table 1, Item 16) Sealing Compound, Loctite 271 (Volume 2, WP 0288, Table 1, Item 62) Strap, Tiedown, Electrical (Volume 2, WP 0288, Table 1, Item 67, 68, 69) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) O-ring (Volume 2, WP 0290, Table 1, Item 88) Qty: 6 O-ring (Volume 2, WP 0290, Table 1, Item 72) Qty: 3 Materials/Parts (cont.) O-ring (Volume 2, WP 0290, Table 1, Item 73) Qty: 7 O-ring (Volume 2, WP 0290, Table 1, Item 89) Qty: 5 O-ring (Volume 2, WP 0290, Table 1, Item 81) Qty: 4 O-ring (Volume 2, WP 0290, Table 1, Item 130) Qty: 6 Packing, Preformed (Volume 2, WP 0290, Table 1, Item 107) Qty: 4 Washer (Volume 2, WP 0290, Table 1, Item 101) Qty: 2 Personnel Required Construction Equipment Repairer 91L (3) References TM 5-3895-379-23P, Figures 27, 28, 29, 30, 52, 91, and 128 WP 0128 Equipment Condition Engine off. (TM 5-3895-379-10) Fuel/hydraulic oil tank drained. (WP 0124) Operator platform assembly raised. (Volume 2, WP 0235) Fuel level sending unit removed. (WP 0183) Air cleaner assembly removed. (WP 0118)
0125-1
TM 5-3895-379-23-1
0125
DRAIN LINES REMOVAL
WARNING
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. Fuel and hydraulic oil are very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury.
NOTE
The CB534B and CB534C Rollers fuel/hydraulic oil tanks and drain lines are replaced the same way, except where noted. Tag and mark all fuel and hydraulic hoses prior to removal. Place drain pan under hose assemblies to catch any fuel and hydraulic oil that may drain from tank. Dispose of fuel and oil IAW local policy and ordinances. 1. 2. Remove fuel drain cap (Figure 1, Item 6), O-ring (Figure 1, Item 2), nut (Figure 1, Item 5), and hose assembly (Figure 1, Item 1) from frame assembly (Figure 1, Item 4). Discard O-ring. If damaged, remove elbow (Figure 1, Item 3) and O-ring (Figure 1, Item 2) from hose assembly (Figure 1, Item 1). Discard O-ring.
1 2 3 4
5 2 6
M0512SWR
Figure 1. Drain Lines Removal.
0125-2
TM 5-3895-379-23-1
0125
DRAIN LINES REMOVAL - Continued
NOTE
Hose assembly and fuel tank connection are located between rear roller drum and operator platform. 3. 4. Loosen nut (Figure 2, Item 3) and remove hose assembly (Figure 2, Item 2) and O-ring (Figure 2, Item 4) from fuel tank connector (Figure 2, Item 5). Discard O-ring. If damaged, remove fuel tank connector (Figure 2, Item 5) and O-ring (Figure 2, Item 6) from fuel tank (Figure 2, Item 1). Discard O-ring.
6 5 4 3 2
M0513SWR
Figure 2.
Drain Lines Removal.
0125-3
TM 5-3895-379-23-1
0125
DRAIN LINES REMOVAL - Continued 5. 6. 7. 8. Remove hydraulic oil drain cap (Figure 3, Item 7), O-ring (Figure 3, Item 5), nut (Figure 3, Item 8), and hose assembly (Figure 3, Item 1) from frame assembly (Figure 3, Item 9). Discard O-ring. If damaged, remove adapter (Figure 3, Item 10) and O-ring (Figure 3, Item 5) from hose assembly (Figure 3, Item 1). Discard O-ring. Loosen nut (Figure 3, Item 6) and remove hose assembly (Figure 3, Item 1) and O-ring (Figure 3, Item 5) from hydraulic oil tank connector (Figure 3, Item 4). Discard O-ring. If damaged, remove hydraulic oil tank connector (Figure 3, Item 4) and O-ring (Figure 3, Item 3) from hydraulic oil tank (Figure 3, Item 2). Discard O-ring.
2 3 1 4 5 6
5 10 9 8 5 7
M0514SWR
Figure 3. Drain Lines Removal. END OF TASK
0125-4
TM 5-3895-379-23-1
0125
TANK REMOVAL 1. Loosen nut (Figure 4, Item 3) and remove hose assembly (Figure 4, Item 2) and O-ring (Figure 4, Item 4) from fuel tank connector (Figure 4, Item 1). Discard O-ring.
1 4
M0515SWR
Figure 4. 2. 3. 4.
Fuel/Hydraulic Oil Tank Removal.
For CB534B Roller, loosen two nuts (Figure 5, Item 6) and remove two hose assemblies (Figure 5, Item 5) and preformed packings (Figure 5, Item 4) from elbows (Figure 5, Item 3). Discard preformed packings. For CB534B Roller, remove two elbows (Figure 5, Item 3) from two valves (Figure 5, Item 2). For CB534B Roller, remove two valves (Figure 5, Item 2) from fuel tank (Figure 5, Item 1).
1 2
3 2
4 3
5 6 5
M0516SWR
Figure 5.
0125-5
TM 5-3895-379-23-1
0125
TANK REMOVAL - Continued 5. 6. For CB534C Roller, loosen two nuts (Figure 6, Item 4) and remove two hose assemblies (Figure 6, Item 5) and preformed packings (Figure 6, Item 3) from two adapters (Figure 6, Item 2). Discard preformed packings. For CB534C Roller, remove two adapters (Figure 6, Item 2) and two adapters (Figure 6, Item 1) from fuel tank (Figure 6, Item 6).
5 4
M0517SWR
Figure 6. Fuel/Hydraulic Oil Tank Removal. 7. Loosen nut (Figure 7, Item 3) and remove hose assembly (Figure 7, Item 1) and O-ring (Figure 7, Item 2) from fuel/hydraulic tank connector (Figure 7, Item 4). Discard O-ring.
2 3 1
M0518SWR
Figure 7. Fuel/Hydraulic Oil Tank Removal.
0125-6
TM 5-3895-379-23-1
0125
TANK REMOVAL - Continued
NOTE
Tag and mark all wires prior to removal. 8. 9. Loosen two screws (Figure 8, Item 3) on hydraulic oil temperature sensor (Figure 8, Item 1) and remove two wires (Figure 8, Item 2). Remove hydraulic oil temperature sensor (Figure 8, Item 1) from fuel/hydraulic oil tank (Figure 8, Item 4).
4 3 2
M0519SWR
Figure 8.
0125-7
TM 5-3895-379-23-1
0125
NOTE
Tag and mark all hoses prior to removal. 10. 11. 12. 13. Loosen three nuts (Figure 9, Item 1) and remove hose assemblies (Figure 9, Item 10) and preformed packings (Figure 9, Item 3) from tees (Figure 9, Item 8). Discard preformed packings. Loosen three nuts (Figure 9, Item 2) and remove hose assemblies (Figure 9, Item 9) and preformed packings (Figure 9, Item 3) from tees (Figure 9, Item 8). Discard preformed packings. Remove three tees (Figure 9, Item 8) and O-rings (Figure 9, Item 4) from boss reducers (Figure 9, Item 5). Discard O-rings. Remove three boss reducers (Figure 9, Item 5) and O-rings (Figure 9, Item 6) from fuel/hydraulic oil tank (Figure 9, Item 7). Discard O-rings.
1 2 3 9 10 3 2 8 4 5 6 7
10
3 2 9
M0520SWR
Figure 9. Fuel/Hydraulic Oil Tank Removal. 14. 15. 16. 17. Loosen two nuts (Figure 10, Item 2) and remove hose assemblies (Figure 10, Item 1) and preformed packings (Figure 10, Item 3) from two elbows (Figure 10, Item 4). Discard preformed packings. Remove elbow (Figure 10, Item 4) and O-ring (Figure 10, Item 5) from suction strainer (Figure 10, Item 7). Discard O-ring. Remove elbow (Figure 10, Item 4) and O-ring (Figure 10, Item 5) from fuel/hydraulic oil tank (Figure 10, Item 6). Discard O-ring. Remove suction strainer (Figure 10, Item 7) from fuel/hydraulic oil tank (Figure 10, Item 6).
0125-8
TM 5-3895-379-23-1
0125

1 2 3 4 5 6
1 2 3 4
7
M0521SWR
Figure 10. 18.
For the CB534B Roller, remove eight screws (Figure 11, Item 3), washers (Figure 11, Item 4), and rear handrail assembly (Figure 11, Item 2) from ROPS (Figure 11, Item 1).
1 2 3 4
1
M0522SWR
Figure 11.
0125-9
TM 5-3895-379-23-1
0125
TANK REMOVAL - Continued 19. For the CB534C Roller, remove four screws (Figure 12, Item 3), washer (Figure 12, Item 4), and rear handrail assembly (Figure 12, Item 2) from ROPS (Figure 12, Item 1).
1 2 3 4
1
M0523SWR
Figure 12. 20.
Loosen two screws (Figure 13, Item 3) on hydraulic oil level indicator (Figure 13, Item 4) and remove hydraulic oil indicator, two washers (Figure 13, Item 5), and four preformed packings (Figure 13, Item 2) from fuel/ hydraulic oil tank (Figure 13, Item 1). Discard washers and preformed packings.
4 5
M0524SWR
Figure 13. 21. 22. 23. 24.
Remove lock (Figure 14, Item 6) from hydraulic oil cap (Figure 14, Item 2). Lift lever (Figure 14, Item 1) and turn hydraulic oil cap (Figure 14, Item 2) to the left until hydraulic oil cap can be removed from fuel/hydraulic oil tank (Figure 14, Item 4). Remove strainer (Figure 14, Item 5) from fuel/hydraulic oil tank (Figure 14, Item 4). Remove vent (Figure 14, Item 3) from fuel/hydraulic oil tank (Figure 14, Item 4).
0125-10
TM 5-3895-379-23-1
0125

1 2 6 4 5 3
M0525SWR
Figure 14. 25. 26. 27.
Remove lock (Figure 15, Item 1) from fuel cap (Figure 15, Item 2). Turn fuel cap (Figure 15, Item 2) to the left until fuel cap can be removed from fuel tank (Figure 15, Item 4). Remove strainer (Figure 15, Item 3) from fuel tank (Figure 15, Item 4).
REMOVE INSTALL 3 4
M0526SWR
Figure 15.
0125-11
TM 5-3895-379-23-1
0125
TANK REMOVAL - Continued 28. Remove two locknuts (Figure 16, Item 4), washers (Figure 16, Item 3), and strap assemblies (Figure 16, Item 1) from frame assembly (Figure 16, Item 2). Discard locknuts.
3 4
Figure 16. 29. Fuel/Hydraulic Oil Tank Removal.
M0527SWR
Remove two nuts (Figure 17, Item 4), washers (Figure 17, Item 7), screws (Figure 17, Item 6), and strap assemblies (Figure 17, Item 5) from frame assembly (Figure 17, Item 3).
WARNING
CAUTION
Place fuel/hydraulic oil tank on blocks and position tank so that connectors and hoses can be removed and installed. Do not allow weight of tank to rest on connectors. Failure to follow this caution may cause damage to tank and connectors.
NOTE
Fuel/hydraulic oil tank weighs 360 lb (163 kg). Fuel/hydraulic oil tank must be pushed or pried toward rear of roller to allow fuel/hydraulic oil tank bosses to clear cut-outs in frame assembly during removal. 30. Attach a lifting device to lift points of fuel/hydraulic oil tank (Figure 17, Item 2). Remove tank from frame assembly (Figure 17, Item 3) with lifting device while assistants pry tank free from frame assembly (Figure 17, Item 3) and guide tank through ROPS (Figure 17, Item 1).
0125-12
TM 5-3895-379-23-1
0125
1 2 3 4 5
M0528SWR
Figure 17. 31.
Remove six rubber sheets (Figure 18, Item 1) from frame assembly (Figure 18, Item 2).
M0529SWR
1
Figure 18. Fuel/Hydraulic Oil Tank Removal.
0125-13
TM 5-3895-379-23-1
0125
TANK REMOVAL - Continued 32. Remove two rubber sheets (Figure 19, Item 1), connectors (Figure 19, Item 3), and O-rings (Figure 19, Item 2) from fuel/hydraulic oil tank (Figure 19, Item 4). Discard O-rings.
1 1
2 3
M0530SWR
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. 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. 1. 2. Clean all metal parts with cleaning compound, solvent. Dry all parts with compressed air.
END OF TASK INSPECTION 1. 2. 3. Inspect tank for rust, cracks, dents, and holes. Inspect strainers for holes, tears, and debris. Inspect all fittings and connectors for stripped threads.
0125-14
TM 5-3895-379-23-1
0125
INSPECTION - Continued 4. Repair or replace all damaged parts.
END OF TASK TANK INSTALLATION 1. Apply sealing compound to threads of two connectors (Figure 20, Item 3) and install connectors and new O-rings (Figure 20, Item 2) on fuel/hydraulic oil tank (Figure 20, Item 4). Install two rubber sheets (Figure 20, Item 1) on fuel/hydraulic oil tank with gasket cement.
1 1
2 3
M0531SWR
Figure 20. 2.
Fuel/Hydraulic Oil Tank Installation.
Install six rubber sheets (Figure 21, Item 1) on fuel/hydraulic oil tank (Figure 20, Item 4) using gasket cement.
M1150SWR
1
Figure 21. Fuel/Hydraulic Oil Tank Installation.
0125-15
TM 5-3895-379-23-1
0125
TANK INSTALLATION - Continued
WARNING
NOTE
Fuel/hydraulic oil tank weighs 360 lb (163 kg). 3. 4. Attach a lifting device to lift points of fuel/hydraulic oil tank (Figure 22, Item 1). One person lifts tank with lifting device while assistants position tank in frame assembly (Figure 22, Item 2). Install two strap assemblies (Figure 22, Item 4) on frame assembly (Figure 22, Item 2) with washers (Figure 22, Item 6), nuts (Figure 22, Item 3), and screws (Figure 22, Item 5).
5 6
M0532SWR
0125-16
TM 5-3895-379-23-1
0125
TANK INSTALLATION - Continued 5. Install two strap assemblies (Figure 23, Item 1) on frame assembly (Figure 23, Item 2) using two washers (Figure 23, Item 3) and locknuts (Figure 23, Item 4).
3 4
M0533SWR
Figure 23. 6. 7. 8.
Install filter (Figure 24, Item 3) into fuel/hydraulic oil tank (Figure 24, Item 4). Turn fuel cap (Figure 24, Item 2) clockwise until cap is secure on fuel tank (Figure 24, Item 4). Install lock (Figure 24, Item 1) on fuel cap (Figure 24, Item 2).
REMOVE INSTALL 3 4
M0534SWR
Figure 24.
0125-17
TM 5-3895-379-23-1
0125
TANK INSTALLATION - Continued 9. 10. 11. 12. Apply sealant to threads of vent (Figure 25, Item 3) and install vent on fuel/hydraulic oil tank (Figure 25, Item 4). Install strainer (Figure 25, Item 5) into fuel/hydraulic oil tank (Figure 25, Item 4). Lift lever (Figure 25, Item 1) and turn hydraulic oil cap (Figure 25, Item 2) clockwise until cap is secure on fuel/ hydraulic oil tank (Figure 25, Item 4). Install lock (Figure 25, Item 6) on hydraulic oil cap (Figure 25, Item 2).
1 2 6 4 5 3
M0535SWR
NOTE
Ensure hydraulic oil level indicator is installed with HIGH readable at the top of the indicator and LOW readable at the bottom of the indicator. 13. Install two washers (Figure 26, Item 5), four new preformed packings (Figure 26, Item 2), and hydraulic oil level indicator (Figure 26, Item 4) on fuel/hydraulic oil tank (Figure 26, Item 1) using two screws (Figure 26, Item 3).
0125-18
TM 5-3895-379-23-1
0125
4 5
M0536SWR
Figure 26. 14.
For CB534B Roller, install rear handrail assembly (Figure 27, Item 3) on ROPS (Figure 27, Item 4) using eight washers (Figure 27, Item 2) and screws (Figure 27, Item 1). Tighten screws 33-47 lb-ft (45-64 Nm).
3 2 1
4
M0537SWR
Figure 27.
0125-19
TM 5-3895-379-23-1
0125
TANK INSTALLATION - Continued 15. For the CB534C Roller, install rear handrail assembly (Figure 28, Item 2) on ROPS (Figure 28, Item 1) using four washers (Figure 28, Item 4) and screw (Figure 28, Item 3). Tighten screws 33-47 lb-ft (45-64 Nm).
1 2
2 3 4
1
M0538SWR
Figure 28. Fuel/Hydraulic Oil Tank Installation. 16. 17. 18. 19. Install suction strainer (Figure 29, Item 7) in fuel/hydraulic oil tank (Figure 29, Item 6). Install new O-ring (Figure 29, Item 5) and elbow (Figure 29, Item 4) on fuel/hydraulic oil tank (Figure 29, Item 6). Install new O-ring (Figure 29, Item 5) and elbow (Figure 29, Item 4) on suction strainer (Figure 29, Item 7). Install two new preformed packings (Figure 29, Item 3) and hose assemblies (Figure 29, Item 1) on two elbows (Figure 29, Item 4) and tighten two nuts (Figure 29, Item 2).
0125-20
TM 5-3895-379-23-1
0125

1 2 3 4 5 6
1 2 3 4
7
M0539SWR
Figure 29.
0125-21
TM 5-3895-379-23-1
0125
CAUTION
Apply sealing compound to threads of all fittings and connections prior to installation. Failure to do so can result in fuel and hydraulic leaks, equipment damage and failure. 20. 21. 22. 23. Install three new O-rings (Figure 30, Item 6) and boss reducers (Figure 30, Item 5) on fuel/hydraulic oil tank (Figure 30, Item 7). Install three new O-rings (Figure 30, Item 4) and tees (Figure 30, Item 8) on three boss reducers (Figure 30, Item 5). Install six new preformed packings (Figure 30, Item 3) and three hose assemblies (Figure 30, Item 9) on tees (Figure 30, Item 8). Tighten nuts (Figure 30, Item 2). Install three new preformed packings (Figure 30, Item 3) and hose assemblies (Figure 30, Item 10) on tees (Figure 30, Item 8). Tighten nuts (Figure 30, Item 1).
1 2 3 9 10 3 2 8 4 5 6 7
10
3 2 9
M0540SWR
Figure 30. Fuel/Hydraulic Oil Tank Installation. 24. 25. Install hydraulic oil temperature sensor (Figure 31, Item 1) in fuel/hydraulic oil tank (Figure 31, Item 4). Tighten sensor to 310-399 lb-in. (35-45 Nm). Install two wires (Figure 31, Item 2) on hydraulic oil temperature sensor (Figure 31, Item 1) and tighten two screws (Figure 31, Item 3) to 7-11 lb-in. (0.8-1.2 Nm).
0125-22
TM 5-3895-379-23-1
0125
4 3 2
M0541SWR
Figure 31. 26.
Install new O-ring (Figure 32, Item 2) and hose assembly (Figure 32, Item 1) on fuel/hydraulic oil tank connector (Figure 32, Item 4) and tighten nut (Figure 32, Item 3).
2 3 1
M0542SWR
Figure 32.
0125-23
TM 5-3895-379-23-1
0125
TANK INSTALLATION - Continued 27. 28. 29. On CB534B Roller, install two valves (Figure 33, Item 2) to fuel tank (Figure 33, Item 1) and tighten. On CB534B Roller, install two elbows (Figure 33, Item 3) to valves (Figure 33, Item 2). For CB534B Roller, install two new preformed packings (Figure 33, Item 4) and hose assemblies (Figure 33, Item 5) to two elbows (Figure 33, Item 3) and tighten two nuts (Figure 33, Item 6).
1 2
3 2
4 3
5 6 5
M0543SWR
Figure 33. Fuel/Hydraulic Oil Tank Installation. 30. 31. 32. For CB534C Roller, install two adapters (Figure 34, Item 2) to fuel tank (Figure 34, Item 6) and tighten. For CB534C Roller, install two adapters (Figure 34, Item 1) to adapters (Figure 34, Item 2). For CB534C Roller, install two new preformed packings (Figure 34, Item 3) and hose assemblies (Figure 34, Item 5) to two adapters (Figure 34, Item 2) and tighten two nuts (Figure 34, Item 4).
5 4
M0544SWR
0125-24
TM 5-3895-379-23-1
0125
TANK INSTALLATION - Continued 33. Install new O-ring (Figure 35, Item 4) and hose assembly (Figure 35, Item 2) to fuel tank connector (Figure 35, Item 1) and tighten nut (Figure 35, Item 3).
1 4
M0545SWR
0125-25
TM 5-3895-379-23-1
0125
DRAIN LINES INSTALLATION 1. 2. 3. 4. 5. Install new O-ring (Figure 36, Item 2) and hydraulic oil tank connector (Figure 36, Item 3) in hydraulic oil tank. Install new O-ring (Figure 36, Item 4) and hose assembly (Figure 36, Item 1) on hydraulic oil tank connector (Figure 36, Item 3) with nut (Figure 36, Item 5). Install new O-ring (Figure 36, Item 4) and adapter (Figure 36, Item 8) on hose assembly (Figure 36, Item 1). Install hose assembly (Figure 36, Item 1) on frame assembly (Figure 36, Item 7) using nut (Figure 36, Item 6). Install new O-ring (Figure 36, Item 4) and hydraulic oil drain cap (Figure 36, Item 5) to hose assembly (Figure 36, Item 1).
2 1 3 4 5
4 8 7 6 4 5
M0546SWR
Figure 36. 6. 7.
Drain Lines Installation.
Install new O-ring (Figure 37, Item 6) and fuel tank connector (Figure 37, Item 5) on fuel tank (Figure 37, Item 1). Install new O-ring (Figure 37, Item 4) and hose assembly (Figure 37, Item 2) on fuel tank connector (Figure 37, Item 5) with nut (Figure 37, Item 3).
0125-26
TM 5-3895-379-23-1
0125
DRAIN LINES INSTALLATION - Continued

1
6 5 4 3 2
M0547SWR
Figure 37. 8. 9. 10.
Install new O-ring (Figure 38, Item 2) and elbow (Figure 38, Item 3) on hose assembly (Figure 38, Item 1). Install hose assembly (Figure 38, Item 1) on frame assembly (Figure 38, Item 4) with nut (Figure 38, Item 5). Install new O-ring (Figure 38, Item 2) and fuel drain cap (Figure 38, Item 6) on hose assembly (Figure 38, Item 1).
1 2 3 4
5 2 6
M0548SWR
0125-27
TM 5-3895-379-23-1
0125
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. Install air cleaner assembly. (WP 0118) Lower operator platform assembly. (Volume 2, WP 0235) Install fuel level sending unit. (WP 0183) Fill fuel/hydraulic oil tank and check for leaks. (WP 0124) Prime fuel system. (WP 0128) Start engine and check for leaks. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0125-28
TM 5-3895-379-23-1
0126
FIELD MAINTENANCE FUEL CAP ASSEMBLY REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Goggles (Volume 2, WP 0289, Table 1, Item 13) Materials/Parts Cleaning Compound, Solvent (Volume 2, WP 0288, Table 1, Item 13, 14, 15) Cloth, Cleaning (Volume 2, WP 0288, Table 1, Item 16) Materials/Parts (cont.) Gasket (Volume 2, WP 0290, Table 1, Item 105) Qty: 1 Gasket (Volume 2, WP 0290, Table 1, Item 79) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 30 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0126-1
TM 5-3895-379-23-1
0126
REMOVAL
WARNING
DO NOT perform fuel system checks, inspections or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing injury or death, or damage to machine. Fuel is very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury. 1. 2. Remove lock (Figure 1, Item 1) from fuel cap assembly (Figure 1, Item 2). Turn fuel cap assembly (Figure 1, Item 2) to the left until fuel cap assembly can be removed from fuel tank (Figure 1, Item 3).
REMOVE 1 2 INSTALL 3
M0549SWR
Figure 1. Fuel Cap Assembly Removal. END OF TASK
0126-2
TM 5-3895-379-23-1
0126
DISASSEMBLY 1. 2. 3. Remove gasket (Figure 2, Item 1) from fuel cap assembly (Figure 2, Item 8). Discard gasket. Remove valve assembly (Figure 2, Item 2), washer (Figure 2, Item 3), baffle (Figure 2, Item 4), and gasket (Figure 2, Item 5) from fuel cap assembly (Figure 2, Item 8). Discard gasket. Remove filter elements (Figure 2, Item 6) and filter (Figure 2, Item 7) from fuel cap assembly (Figure 2, Item 8).
1
2 3
4 5 6 7
M0550SWR
Fuel Cap Disassembly.
0126-3
TM 5-3895-379-23-1
0126
CLEANING
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. 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. 1. 2. Clean all metal parts with cleaning compound, solvent. Use cleaning cloth or compressed air to dry all metal parts.
END OF TASK INSPECTION Check cap for nicks, cracks, dents, and stripped threads. Replace any damaged parts. END OF TASK
0126-4
TM 5-3895-379-23-1
0126
ASSEMBLY 1. 2. 3. Install filter element (Figure 3, Item 6) and filter (Figure 3, Item 7) in fuel cap assembly (Figure 3, Item 8). Install new gasket (Figure 3, Item 5), baffle (Figure 3, Item 4), washer (Figure 3, Item 3), and valve assembly (Figure 3, Item 2) in fuel cap assembly (Figure 3, Item 8). Tighten valve assembly securely. Install new gasket (Figure 3, Item 1) in fuel cap assembly (Figure 3, Item 8).
1
2 3
4 5 6 7
M1067SWR
Fuel Cap Assembly.
0126-5
TM 5-3895-379-23-1
0126
INSTALLATION 1. 2. Install fuel cap assembly (Figure 4, Item 2) on fuel tank (Figure 4, Item 3) by turning fuel cap assembly clockwise. Install lock (Figure 4, Item 1) in eye of fuel cap assembly (Figure 4, Item 2), one eye left of lock stop.
REMOVE 1 2 INSTALL 3
M1066SWR
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE Remove chocks. (TM 5-3895-379-10) END OF TASK END OF WORK PACKAGE
Fuel Cap Assembly Installation.
0126-6
TM 5-3895-379-23-1
0127
FIELD MAINTENANCE FUEL FILTER ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Goggles (Volume 2, WP 0289, Table 1, Item 13) Pan, Drain, 5 Gal Cap. (Volume 2, WP 0289, Table 1, Item 23) Materials/Parts Cloth, Cleaning (Volume 2, WP 0288, Table 1, Item 16) Diesel Fuel Oil DF1 B (Volume 2, WP 0288, Table 1, Item 18, 19, 20) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Bushing (Volume 2, WP 0290, Table 1, Item 80) Qty: 5 Bushing (Volume 2, WP 0290, Table 1, Item 45) Qty: 2 Damper (Volume 2, WP 0290, Table 1, Item 87) Qty: 1 Packing, Preformed (Volume 2, WP 0290, Table 1, Item 3) Qty: 1 Seal (Volume 2, WP 0290, Table 1, Item 4) Qty: 2 Materials/Parts (cont.) Sleeve (Volume 2, WP 0290, Table 1, Item 44) Qty: 2 Washer (Volume 2, WP 0290, Table 1, Item 30) Qty: 2 Washer (Volume 2, WP 0290, Table 1, Item 31) Qty: 2 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 32 and 33 WP 0128 Equipment Condition Engine off. (TM 5-3895-379-10) Operator platform assembly raised. (Volume 2, WP 0235)
0127-1
TM 5-3895-379-23-1
0127
FUEL FILTER ELEMENT REMOVAL
WARNING
NOTE
Use drain pan to catch any fuel that may drain from system. Dispose of fuel IAW local policy and ordinances. Ensure all spills are cleaned up. Use funnel to direct fuel drainage into drain pan with 1 qt (0.91 Liter) minimum capacity. Fuel filter assembly is maintained the same way for CB534B and CB534C Rollers. CB534B Roller is shown. 1. 2. 3. 4. For CB534B Roller, close fuel supply valves (Figure 1, Item 7). For CB534C Roller, close fuel supply valves (Figure 1, Item 1). Turn drain valve (Figure 1, Item 5) on bottom of filter element (Figure 1, Item 4) to left and drain fuel into drain pan. Remove ring (Figure 1, Item 6), filter element (Figure 1, Item 4), and seal (Figure 1, Item 3) from filter assembly (Figure 1, Item 2). Discard seal.
0127-2
TM 5-3895-379-23-1
0127
FUEL FILTER ELEMENT REMOVAL - Continued
7 CB534C ROLLER 2 3 CB534B ROLLER 4 5 6
M0551SWR
Fuel Filter Assembly Removal.
0127-3
TM 5-3895-379-23-1
0127
FUEL FILTER ELEMENT INSTALLATION 1. Remove shipping plug (Figure 2, Item 1) from top of new filter element (Figure 2, Item 2).
M0552SWR
Figure 2. Fuel Filter Assembly Installation.
0127-4
TM 5-3895-379-23-1
0127
FUEL FILTER ELEMENT INSTALLATION - Continued 2. 3. 4. Install new seal (Figure 3, Item 3), filter element (Figure 3, Item 4), and ring (Figure 3, Item 5) on filter assembly (Figure 3, Item 2). Tighten ring until it snaps into place. For CB534B Roller, open fuel supply valves (Figure 3, Item 6). For CB534C Roller, close fuel supply valves (Figure 3, Item 1).
6 CB534C ROLLER
2 3 CB534B ROLLER 4
M1171SWR
Fuel Filter Assembly Installation.
0127-5
TM 5-3895-379-23-1
0127
FUEL FILTER ASSEMBLY REMOVAL 1. 2. 3. 4. 5. For CB534B Roller, close fuel supply valves (Figure 4, Item 1). For CB534C Roller, close fuel supply valves (Figure 4, Item 2). Place drain pan under drain valve (Figure 4, Item 4). Open drain valve (Figure 4, Item 4) on bottom of filter element (Figure 4, Item 3) and drain fuel into drain pan. Loosen nut (Figure 4, Item 11) and slide clamp (Figure 4, Item 10) up to provide clearance for fuel line removal.
NOTE
Tag and mark all hoses prior to removal. Inspect all hoses, lines, and fittings for cracks, bends, nicks, dents, stripped threads, and cuts. Replace all damaged parts. 6. Loosen two nuts (Figure 4, Items 9 and 14) and remove two tubes (Figure 4, Items 12 and 13), two bushings (Figure 4, Items 15 and 16), and two bushings (Figure 4, Item 6) from fuel filter assembly (Figure 4, Item 17) and two adapters (Figure 4, Item 7). Discard bushings. If damaged, remove two adapters (Figure 4, Item 7) and washers (Figure 4, Item 8) from fuel injection pump (Figure 4, Item 5). Discard washers.
7.
0127-6
TM 5-3895-379-23-1
0127
FUEL FILTER ASSEMBLY REMOVAL - Continued
1 2
CB534B ROLLER
CB534C ROLLER
14
15 16
17
13 12 11 3 10 9 6 7 5 8 7
M0553SWR
Figure 4.
0127-7
TM 5-3895-379-23-1
0127
FUEL FILTER ASSEMBLY REMOVAL - Continued 8. Loosen two nuts (Figure 5, Items 3 and 6) and remove two tubes (Figure 5, Items 4 and 5) and bushings (Figure 5, Items 2 and 7) from fuel filter assembly (Figure 5, Item 1). Discard bushings.
M0554SWR
Figure 5. Fuel Filter Assembly Removal. 9. 10. 11. Loosen nut (Figure 6, Item 2) and remove tube (Figure 6, Item 1) and sleeve (Figure 6, Item 3) from connector (Figure 6, Item 9). Discard sleeve. Loosen connector (Figure 6, Item 7) and remove hose (Figure 6, Item 6) from tube (Figure 6, Item 8). Loosen nut (Figure 6, Item 5) and remove tube (Figure 6, Item 8) and damper (Figure 6, Item 4) from connector (Figure 6, Item 9). Discard damper.
1 2 3 4 5 6
M0555SWR
Figure 6. Fuel Filter Assembly Removal. 12. 13. Remove two nuts (Figure 7, Item 7), two screws (Figure 7, Item 2), clip (Figure 7, Item 1), hose (Figure 7, Item 3), and fuel filter assembly (Figure 7, Item 8) from bracket (Figure 7, Item 6). If damaged, remove two screws (Figure 7, Item 4) and bracket (Figure 7, Item 6) from engine block (Figure 7, Item 5).
0127-8
TM 5-3895-379-23-1
0127
FUEL FILTER ASSEMBLY REMOVAL - Continued

1 2 3
8 7 6
5 4
M0556SWR
0127-9
TM 5-3895-379-23-1
0127
FUEL FILTER ELEMENT DISASSEMBLY 1. 2. 3. Place fuel filter assembly (Figure 8, Item 6) on a clean work bench. Remove barrel nut (Figure 8, Item 8), cap (Figure 8, Item 7), and preformed packing (Figure 8, Item 9) from fuel filter assembly (Figure 8, Item 6). Discard preformed packing. Remove plug (Figure 8, Item 10) from fuel filter (Figure 8, Item 6).
NOTE
Note position of connector before removal. 4. 5. Remove bolt (Figure 8, Item 1), washer (Figure 8, Item 11), connector (Figure 8, Item 2), and washer (Figure 8, Item 11) from fuel filter assembly (Figure 8, Item 6). Discard washers. Remove ring (Figure 8, Item 3), filter element (Figure 8, Item 4), and seal (Figure 8, Item 5) from fuel filter assembly (Figure 8, Item 6). Discard seal.
1 2 11 3
10 9 8 5 4
6 7
M0557SWR
Figure 8. Fuel Filter Assembly Disassembly. END OF TASK CLEANING Wipe off all parts with a cleaning cloth. END OF TASK
0127-10
TM 5-3895-379-23-1
0127
INSPECTION 1. 2. 3. 4. 5. 6. Inspect fuel filter assembly for cracks, nicks, dents, and stripped threads. If damage is found, replace fuel filter assembly. Inspect that spring washer (Figure 9, Item 1) is firmly seated in nylon retainer (Figure 9, Item 2) in fuel filter assembly. Inspect nylon retainer (Figure 9, Item 2) for cracking and hardening. Inspect plug, barrel nut, and ring for cracks, nicks, dents, and stripped threads. Replace all damaged parts. Inspect screw and connector for cracks, nicks, dents, and stripped threads. Replace all damaged parts. Inspect hoses and fittings for cracks, bends, nicks, dents, stripped threads, and cuts. Replace all damaged parts.
1 2
M0558SWR
Fuel Filter Assembly Inspection.
0127-11
TM 5-3895-379-23-1
0127
FUEL FILTER ASSEMBLY ASSEMBLY
CAUTION
Area around filter element must be very clean. Any contaminants entering fuel filter assembly will cause damage to equipment. 1. 2. 3. Place fuel filter assembly (Figure 10, Item 6) on a clean work bench. Remove shipping plug from filter element (Figure 10, Item 4). Install new seal (Figure 10, Item 5), filter element (Figure 10, Item 4), and ring (Figure 10, Item 3) on fuel filter (Figure 10, Item 6).
NOTE
Note position of connector before installation. 4. 5. 6. Install bolt (Figure 10, Item 1), washer (Figure 10, Item 11), connector (Figure 10, Item 2), and washer (Figure 10, Item 11) in fuel filter assembly (Figure 10, Item 6). Install plug (Figure 10, Item 10) in fuel filter assembly (Figure 10, Item 6). Install preformed packing (Figure 10, Item 9), cap (Figure 10, Item 7), and barrel nut (Figure 10, Item 8) on fuel filter assembly (Figure 10, Item 6).
1 2 11 3
10 9 8 5 4
6 7
M0559SWR
Figure 10. Fuel Filter Assembly Assembly. END OF TASK FUEL FILTER ASSEMBLY INSTALLATION 1. 2. If removed, install bracket (Figure 11, Item 6) with two screws (Figure 11, Item 4) on engine block (Figure 11, Item 5). Install fuel filter assembly (Figure 11, Item 8), clip (Figure 11, Item 1), and hose (Figure 11, Item 3) on bracket (Figure 11, Item 6) with two screws (Figure 11, Item 2) and nuts (Figure 11, Item 7).
0127-12
TM 5-3895-379-23-1
0127
FUEL FILTER ASSEMBLY INSTALLATION - Continued

1 2 3
8 7 6
5 4
M0560SWR
Figure 11. 3. 4. 5.
Install damper (Figure 12, Item 4), connector (Figure 12, Item 7), and tube (Figure 12, Item 8) on connector (Figure 12, Item 9) and tighten nut (Figure 12, Item 5). Install hose (Figure 12, Item 6) on tube (Figure 12, Item 8) and tighten connector (Figure 12, Item 7). Install new sleeve (Figure 12, Item 3) and tube (Figure 12, Item 1) on connector (Figure 12, Item 9) and tighten nut (Figure 12, Item 2).
1 2 3 4 5 6
M0561SWR
Figure 12.
0127-13
TM 5-3895-379-23-1
0127
FUEL FILTER ASSEMBLY INSTALLATION - Continued 6. Install two new bushings (Figure 13, Items 2 and 7) and tubes (Figure 13, Items 4 and 5) in fuel filter assembly (Figure 13, Item 1) and tighten two nuts (Figure 13, Items 3 and 6).
M0562SWR
Figure 13. Fuel Filter Assembly Installation. 7. 8. 9. Ensure that drain valve (Figure 14, Item 4) on bottom of filter element (Figure 14, Item 3) is closed. If drain valve is open, close drain valve. If removed, install two new washers (Figure 14, Item 8) and adapters (Figure 14, Item 7) in fuel injection pump (Figure 14, Item 5). Install two new bushings (Figure 14, Items 16 and 17), two new bushings (Figure 14, Item 6), and two tubes (Figure 14, Items 12 and 13) in fuel filter assembly (Figure 14, Item 18) and on two adapters (Figure 14, Item 7). Tighten two nuts (Figure 14, Items 14 and 15) and two nuts (Figure 14, Item 9). Slide clamp (Figure 14, Item 10) up and tighten nut (Figure 14, Item 11). For CB534B Roller, open fuel supply valves (Figure 14, Item 1). For CB534C Roller, open fuel supply valves (Figure 14, Item 2).
10. 11. 12.
0127-14
TM 5-3895-379-23-1
0127
1 2
CB534B ROLLER
CB534C ROLLER
14 15 16 17
18
13 12 11 3 10 9 6 7 5 8 7
M0563SWR
Figure 14.
0127-15
TM 5-3895-379-23-1
0127
CAUTION
The fuel injection pump needs fuel for lubrication. The precision parts of the pump are easily damaged. For this reason, engine must NOT be started until lubrication pump is full of fuel that is free of air. The system must be primed any time any part of system is drained of fuel. For example, when fuel system is changed or a fuel line is removed or when inspection cover on fuel injection pump is removed for service or repair, fuel system must be primed (air removed). 13. Prime fuel system (WP 0128).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Lower operator platform assembly. (Volume 2, WP 0235) Start engine and check for leaks. (TM 5-3895-379-10)
0127-16
TM 5-3895-379-23-1
0128
FIELD MAINTENANCE PRIMING FUEL SYSTEM
INITIAL SETUP: Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-10 Equipment Condition Engine off. (TM 5-3895-379-10) Equipment Condition (cont.) Drums chocked. (TM 5-3895-379-10) Left-side door assembly opened. (TM 5-3895-379-10)
0128-1
TM 5-3895-379-23-1
0128
WARNING
DO NOT perform fuel system checks, inspections or maintenance while smoking or near fire, flames or sparks. Fuel may ignite, causing injury or death, or damage to machine. Fuel is very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury. Use caution and allow engine to cool before removal of components. Failure to follow this warning may cause injury. PRIMING
NOTE
Fuel lift pump is located above engine starter. To prime pump, reach up from under engine and around starter. If fuel system components have recently been serviced or replaced, perform Step (2) while performing Step (1); otherwise, Step (2) may be skipped. Fuel system priming is performed the same way for CB534B and CB534C Rollers. CB534B Roller is shown. 1. Operate fuel lift pump handle (Figure 1, Item 1) for approximately two minutes or until resistance is felt.
0128-2
TM 5-3895-379-23-1
0128
PRIMING - Continued
M0564SWR
Figure 1.
Priming Fuel System.
0128-3
TM 5-3895-379-23-1
0128
PRIMING - Continued 2. Loosen cap (Figure 2, Item 1) on fuel filter or fuel/water separator to allow air to escape while performing Step (1). Close cap when all air is replaced with fuel.
M0565SWR
Figure 2. Priming Fuel System.
0128-4
TM 5-3895-379-23-1
0128
PRIMING - Continued
CAUTION
The fuel injection pump needs fuel for lubrication. The precision parts of the pump are easily damaged. For this reason, the engine must NOT be started until the lubrication pump is full of fuel that is free of air. The system must be primed any time the fuel system has been sealed or repaired. 3. 4. Insert key (Figure 3, Item 2) in engine start switch (Figure 3, Item 1) and turn key to start (full right) position. Crank engine for 30 seconds. If engine is not started after 30 seconds, release key (Figure 3, Item 2) and wait two minutes for starter to cool.
OFF
ON START
1
n/min
2
M0566SWR
Figure 3. 5. 6.
Priming Fuel System.
Repeat Steps (3) and (4) until engine starts. If engine does not start after three tries, the high pressure fuel lines must be bled. If engine starts, but runs rough, continue running engine at low idle (TM 5-3895-379-10) until engine runs smoothly.
END OF TASK
0128-5
TM 5-3895-379-23-1
0128
FOLLOW-ON MAINTENANCE 1. 2. 3. Close left-side door assembly. (TM 5-3895-379-10) Start engine and check for leaks. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0128-6
TM 5-3895-379-23-1
0129
FIELD MAINTENANCE FUEL/WATER SEPARATOR ASSEMBLY SERVICE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (Volume 2, WP 0289, Table 1, Item 23) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Cloth, Cleaning (Volume 2, WP 0288, Table 1, Item 16) Diesel Fuel Oil DF1 B (Volume 2, WP 0288, Table 1, Item 18, 19, 20) OR Diesel Fuel Oil DF2 B (Volume 2, WP 0288, Table 1, Item 21, 22, 23) OR Turbine Fuel, Aviation (Volume 2, WP 0288, Table 1, Item 73) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Packing, Preformed (Volume 2, WP 0290, Table 1, Item 11) Qty: 1 Materials/Parts (cont.) Packing, Preformed (Volume 2, WP 0290, Table 1, Item 35) Qty: 1 Gasket (Volume 2, WP 0290, Table 1, Item 76) Qty: 7 Seal (Volume 2, WP 0290, Table 1, Item 4) Qty: 1 Seal (Volume 2, WP 0290, Table 1, Item 12) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 33 and 34 WP 0128 Equipment Condition Engine off. (TM 5-3895-379-10) Operator platform assembly raised. (Volume 2, WP 0235) Drums chocked. (TM 5-3895-379-10)
0129-1
TM 5-3895-379-23-1
0129
ELEMENT REMOVAL
WARNING
NOTE
Fuel/water separator assembly service is performed the same way for CB534B and CB534C Rollers. CB534B Roller is shown. 1. For CB534B Roller, close fuel supply valves (Figure 1, Item 1). For CB534C Roller, close fuel supply valves (Figure 1, Item 2).
CB534B ROLLER CB534C ROLLER
M0567SWR
Figure 1.
Fuel/Water Separator Element Removal.
0129-2
TM 5-3895-379-23-1
0129
ELEMENT REMOVAL - Continued
NOTE
Place a drain pan beneath fuel/water separator to catch any fuel/water that may drain from system. Dispose of fuel/water IAW local policy and ordinances. Ensure all spills are cleaned up. 2. 3. 4. 5. Open drain valve (Figure 2, Item 5), loosen nut (Figure 2, Item 1), and drain fuel/water separator into drain pan. Remove water separator bowl (Figure 2, Item 6) from fuel/water separator element (Figure 2, Item 4). Remove and discard washer (Figure 2, Item 7) from water separator bowl (Figure 2, Item 6). Remove ring (Figure 2, Item 8) from fuel/water separator head (Figure 2, Item 2).
CAUTION
Area around filter must be very clean. Any contaminants entering filter head will damage equipment. Wipe area with cleaning cloth. 6. Remove fuel/water separator element (Figure 2, Item 4) and seal (Figure 2, Item 3) from fuel/water separator head (Figure 2, Item 2). Discard seal and element.
1
2 3
8 7 6
5
M0568SWR
Fuel/Water Separator Element Removal.
0129-3
TM 5-3895-379-23-1
0129
ELEMENT INSTALLATION
CAUTION
Area around filter must be very clean. Any contaminant entering filter element or filter assembly will damage equipment. 1. Remove plug (Figure 3, Item 1) and drain (Figure 3, Item 3) from new element (Figure 3, Item 2).
3
M0569SWR
Figure 3. Fuel/Water Separator Element Installation.
0129-4
TM 5-3895-379-23-1
0129
ELEMENT INSTALLATION - Continued 2. 3. 4. 5. 6. 7. Apply fuel oil on new seal (Figure 4, Item 3) and install on fuel/water separator head (Figure 4, Item 2). Install fuel/water separator element (Figure 4, Item 4) on fuel/water separator head (Figure 4, Item 2). Install ring (Figure 4, Item 8) on fuel/water separator head (Figure 4, Item 2). Apply fuel oil on washer (Figure 4, Item 7) and install on water separator bowl (Figure 4, Item 6). Install water separator bowl (Figure 4, Item 6) on fuel/water separator element (Figure 4, Item 4). Tighten nut (Figure 4, Item 1) and close drain valve (Figure 4, Item 5) on water separator bowl (Figure 4, Item 6).
2 3
8 7 6
M0570SWR
Figure 4. Fuel/Water Separator Element Installation.
0129-5
TM 5-3895-379-23-1
0129
ELEMENT INSTALLATION - Continued 8. On the CB534B Roller, open fuel supply valves (Figure 5, Item 1). On the CB534C Roller, open fuel supply valves (Figure 5, Item 2).
M1313SWR
Figure 5. Fuel/Water Separator Element Installation. END OF TASK
0129-6
TM 5-3895-379-23-1
0129
FUEL/WATER SEPARATOR ASSEMBLY REMOVAL 1. For CB534B Roller, close fuel supply valves (Figure 6, Item 1). For the CB534C Roller, close fuel supply valves (Figure 6, Item 2).
M0571SWR
Figure 6.
Fuel/Water Separator Assembly Removal.
0129-7
TM 5-3895-379-23-1
0129
FUEL/WATER SEPARATOR ASSEMBLY REMOVAL - Continued
NOTE
Place a drain pan beneath fuel/water separator to catch any fuel/water that may drain from system. Dispose of fuel/water IAW local policy and ordinances. Ensure all spills are cleaned up. 2. 3. Place drain pan under drain valve (Figure 7, Item 4). Open drain valve (Figure 7, Item 4), loosen nut (Figure 7, Item 3), and drain fuel/water separator into drain pan.
NOTE
Tag and mark all hoses prior to removal. Inspect all hoses, lines, and fittings for cracks, bends, nicks, dents, stripped threads, and cuts. Replace all damaged parts. 4. Remove two hoses (Figure 7, Items 1 and 6) from connectors (Figure 7, Items 2 and 5).
6 5 4
M0572SWR
Figure 7.
0129-8
TM 5-3895-379-23-1
0129
FUEL/WATER SEPARATOR ASSEMBLY REMOVAL - Continued 5. Remove two nuts (Figure 8, Item 2), screws (Figure 8, Item 4), washers (Figure 8, Item 3), and fuel/water separator assembly (Figure 8, Item 5) from support (Figure 8, Item 1).
5
Figure 8. END OF TASK FUEL/WATER SEPARATOR ASSEMBLY DISASSEMBLY 1. 2. 3.
M0573SWR
Place fuel/water separator assembly (Figure 9, Item 2) on a clean work bench. Remove nut (Figure 9, Item 6), cap (Figure 9, Item 5), and preformed packing (Figure 9, Item 4) from fuel/water separator head (Figure 9, Item 1). Discard preformed packing. Remove plug (Figure 9, Item 3) from fuel/water separator head (Figure 9, Item 1).
3 4 5 6
M0574SWR
Figure 9.
Fuel/Water Separator Disassembly.
0129-9
TM 5-3895-379-23-1
0129
FUEL/WATER SEPARATOR ASSEMBLY DISASSEMBLY - Continued 4. 5. 6. 7. 8. 9. 10. 11. Remove drain valve (Figure 10, Item 2) and preformed packing (Figure 10, Item 1) from water separator bowl (Figure 10, Item 9). Discard preformed packing. Remove water separator bowl (Figure 10, Item 9) from fuel/water separator element (Figure 10, Item 5). Remove and discard preformed packing (Figure 10, Item 8) from water separator bowl (Figure 10, Item 9). Remove screw (Figure 10, Item 3) from water separator bowl (Figure 10, Item 9). Remove and discard preformed packing (Figure 10, Item 1) from screw (Figure 10, Item 3). Remove collar (Figure 10, Item 4) from fuel/water separator head (Figure 10, Item 7). Remove fuel/water separator element (Figure 10, Item 5) and seal (Figure 10, Item 6) from fuel/water separator head (Figure 10, Item 7). Discard seal. Place fuel/water separator head (Figure 10, Item 7) in a soft-jawed vise.
2 1
9 3 1
7 4 5
M0575SWR
Figure 10. Fuel/Water Separator Disassembly. 12. 13. 14. 15. 16. Remove two plugs (Figure 11, Item 1) and gaskets (Figure 11, Item 9) from fuel/water separator head (Figure 11, Item 4). Discard gaskets. Remove plug (Figure 11, Item 2) and preformed packing (Figure 11, Item 3) from fuel/water separator head (Figure 11, Item 4). Discard preformed packing. Remove two connectors (Figure 11, Items 6 and 8) and gaskets (Figure 11, Item 5) from fuel/water separator head (Figure 11, Item 4). Discard gaskets. Remove two preformed packings (Figure 11, Item 7) from connectors (Figure 11, Items 6 and 8). Discard preformed packings. Remove fuel/water separator head (Figure 11, Item 4) from soft-jawed vise.
0129-10
TM 5-3895-379-23-1
0129
FUEL/WATER SEPARATOR ASSEMBLY DISASSEMBLY - Continued

1 2 3 9 4 5 6
5 8
M0576SWR
Figure 11. END OF TASK CLEANING Wipe off all parts with cleaning cloth. END OF TASK INSPECTION 1. 2. 3. 4. 5.
Fuel/Water Separator Disassembly.
Inspect fuel/water separator head fittings for cracks, nicks, dents, and stripped threads. If damage is found, replace fuel/water separator head. Inspect all plugs and washers for cracks, nicks, dents, and stripped threads. Replace all damaged parts. Inspect nut, screw, cap, and collar for cracks, nicks, dents, and stripped threads. Replace all damaged parts. Inspect water separator bowl for cracks, nicks, and dents. Replace if necessary. Inspect hoses and fittings for cracks, bends, nicks, dents, stripped threads, and cuts. Replace all damaged parts.
END OF TASK
0129-11
TM 5-3895-379-23-1
0129
FUEL/WATER SEPARATOR ASSEMBLY ASSEMBLY
CAUTION
Area around filter must be very clean. Any contaminant entering filter element or filter assembly will damage equipment. 1. 2. 3. 4. 5. Place fuel/water separator head (Figure 12, Item 4) in a soft-jawed vise. Install two new preformed packings (Figure 12, Item 7) into connectors (Figure 12, Items 6 and 8). Install two gaskets (Figure 12, Item 5) and connectors (Figure 12, Items 6 and 8) in fuel/water separator head (Figure 12, Item 4). Install new preformed packing (Figure 12, Item 3) and plug (Figure 12, Item 2) in fuel/water separator head (Figure 12, Item 4). Tighten plug securely. Install two gaskets (Figure 12, Item 9) and plugs (Figure 12, Item 1) in fuel/water separator head (Figure 12, Item 4). Tighten plugs securely.
1 2 3 9 4 5 6
5 8
M0577SWR
Figure 12.
Fuel/Water Separator Assembly.
0129-12
TM 5-3895-379-23-1
0129
FUEL/WATER SEPARATOR ASSEMBLY ASSEMBLY - Continued 6. 7. 8. 9. 10. 11. 12. Remove fuel/water separator head (Figure 13, Item 7) from soft-jawed vise. Apply fuel on seal (Figure 13, Item 6) and install on fuel/water separator head (Figure 13, Item 7). Install fuel/water separator element (Figure 13, Item 5) on fuel/water separator head (Figure 13, Item 7). Install ring (Figure 13, Item 4) on fuel/water separator head (Figure 13, Item 7). Apply fuel on preformed packing (Figure 13, Item 1) and install on screw (Figure 13, Item 3). Install screw (Figure 13, Item 3) through water separator bowl (Figure 13, Item 9). Apply fuel on preformed packing (Figure 13, Item 8) and install on water separator bowl (Figure 13, Item 9).
CAUTION
Area around filter must be very clean. Any contaminant entering filter element or filter assembly will damage equipment. 13. 14. 15. Install water separator bowl (Figure 13, Item 9) on fuel/water separator element (Figure 13, Item 5). Install new preformed packing (Figure 13, Item 1) on drain valve (Figure 13, Item 2). Install drain valve (Figure 13, Item 2) on water separator bowl (Figure 13, Item 9). Tighten securely.
1 2
9 3 1
7 4 5
6
M0578SWR
Figure 13.
0129-13
TM 5-3895-379-23-1
0129
FUEL/WATER SEPARATOR ASSEMBLY ASSEMBLY - Continued 16. 17. 18. 19. Install plug (Figure 14, Item 3) in fuel/water separator head (Figure 14, Item 1). Apply fuel on preformed packing (Figure 14, Item 4). Install new preformed packing (Figure 14, Item 4), cap (Figure 14, Item 5), and nut (Figure 14, Item 6) on fuel/water separator head (Figure 14, Item 1). Tighten nut securely. Remove fuel/water separator assembly (Figure 14, Item 2) from work bench.
3 4 5 6
M0579SWR
FUEL/WATER SEPARATOR ASSEMBLY INSTALLATION 1. Install fuel/water separator assembly (Figure 15, Item 5) on support (Figure 15, Item 1) with two washers (Figure 15, Item 3), screw (Figure 15, Item 4), and nuts (Figure 15, Item 2). Tighten screws to 25 lb-ft (34 Nm).
M0580SWR
Figure 15. Fuel/Water Separator Assembly Installation.
0129-14
TM 5-3895-379-23-1
0129
FUEL/WATER SEPARATOR ASSEMBLY INSTALLATION - Continued 2. Install two hoses (Figure 16, Items 1 and 4) on fittings (Figure 16, Items 2 and 3).
4 3
M0581SWR
Figure 16. Fuel/Water Separator Assembly Installation. 3. For CB534B Roller, open fuel supply valves (Figure 17, Item 1). For CB534C Roller, open fuel supply valves (Figure 17, Item 2).
M0582SWR
Figure 17. Fuel/Water Separator Assembly Installation.
0129-15
TM 5-3895-379-23-1
0129
FUEL/WATER SEPARATOR ASSEMBLY INSTALLATION - Continued
CAUTION
The fuel injection pump needs fuel for lubrication. The precision parts of pump are easily damaged. For this reason, engine must NOT be started until lubrication pump is full of fuel that is free of air. The system must be primed any time any part of system is drained of fuel. For example, when fuel system is changed or a fuel line is removed or when inspection cover on fuel injection pump is removed for service or repair, fuel system must be primed (air removed). 4. Prime fuel system (WP 0128).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Lower operator platform assembly. (Volume 2, WP 0235) Start engine and check for leaks. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0129-16
TM 5-3895-379-23-1
0130
FIELD MAINTENANCE COLD START HEATER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 0-300 in-lb (Volume 2, WP 0289, Table 1, Item 41) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 2, WP 0288, Table 1, Item 12) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 16 and 34 Equipment Condition Engine off. (TM 5-3895-379-10) Operator platform assembly raised. (Volume 2, WP 0235)
0130-1
TM 5-3895-379-23-1
0130
REMOVAL
WARNING
DO NOT perform fuel system checks, inspections or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing injury or death, or damage to machine. Fuel is very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury. 1. Disconnect wire (Figure 1, Item 1) from cold start heater connector (Figure 1, Item 2).
M0583SWR
Figure 1. Cold Start Heater Removal.
CAUTION
Cap fuel line to prevent foreign material from entering lines to prevent damage to equipment.
NOTE
Inspect all hoses, lines, and fittings for cracks, bends, breaks, nicks, dents, stripped threads, and cuts. Replace all damaged parts. 2. 3. Loosen nut (Figure 2, Item 5) and remove fuel line (Figure 2, Item 1) from cold start heater nipple (Figure 2, Item 4). Remove cold start heater (Figure 2, Item 3) from intake manifold elbow (Figure 2, Item 2).
0130-2
TM 5-3895-379-23-1
0130
REMOVAL - Continued
5
M0584SWR
Cold Start Heater Removal.
Install cold start heater (Figure 3, Item 3) into intake manifold elbow (Figure 3, Item 2). Tighten to 204-337 lb-in. (23-38 Nm). Install fuel line (Figure 3, Item 1) into cold start heater nipple (Figure 3, Item 4) and tighten nut (Figure 3, Item 5) to 35-71 lb-ft (47-96 Nm).
5
Figure 3.
M1110SWR
Cold Start Heater Installation.
0130-3
TM 5-3895-379-23-1
0130
INSTALLATION - Continued 3. Connect wire (Figure 4, Item 1) to cold start heater connection (Figure 4, Item 2).
M1308SWR
Cold Start Heater Installation.
Lower operator platform assembly. (Volume 2, WP 0235) Start engine and check for leaks. (TM 5-3895-379-10)
0130-4
TM 5-3895-379-23-1
0131
FIELD MAINTENANCE THROTTLE CABLE REPLACEMENT/ADJUSTMENT (CB534B)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 0-300 in-lb (Volume 2, WP 0289, Table 1, Item 41) Materials/Parts Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Personnel Required Construction Equipment Repairer 91L Equipment Condition Engine off. (TM 5-3895-379-10) Right-side door assembly opened. (TM 5-3895-379-10) Operator platform assembly raised. (Volume 2, WP 0235)
0131-1
TM 5-3895-379-23-1
0131
REMOVAL 1. Slide spring-loaded sheath (Figure 1, Item 2) away from governor lever (Figure 1, Item 4) and disconnect ball joint assembly (Figure 1, Item 1) on throttle cable (Figure 1, Item 3) from governor lever.
1 2
3 4
M0585SWR
Figure 1. Throttle Cable Removal.
0131-2
TM 5-3895-379-23-1
0131
REMOVAL - Continued 2. Loosen nut (Figure 2, Item 1) and remove throttle cable (Figure 2, Item 3) from bracket (Figure 2, Item 2).
3
Figure 2.
2
M0586SWR
Throttle Cable Removal.
NOTE
Tag and mark clamp position of all cables and hoses prior to removal. 3. 4. Remove two nuts (Figure 3, Item 5), washers (Figure 3, Item 4), and one plate (Figure 3, Item 3) from clamp (Figure 3, Item 2). Remove throttle cable (Figure 3, Item 1) from clamp (Figure 3, Item 2).
2 3 4 5
M0587SWR
Figure 3.
0131-3
TM 5-3895-379-23-1
0131
REMOVAL - Continued 5. Remove throttle cable (Figure 4, Item 1) from sock (Figure 4, Item 2).
M0588SWR
NOTE
Tag and mark clamp position of all cables and hoses prior to removal. 6. 7. Remove two nuts (Figure 5, Item 3), washers (Figure 5, Item 2), and plate (Figure 5, Item 1) from clamp (Figure 5, Item 4). Remove throttle cable (Figure 5, Item 5) from clamp (Figure 5, Item 4).
1 2 3
4 5
M0589SWR
0131-4
TM 5-3895-379-23-1
0131
REMOVAL - Continued 8. 9. 10. 11. Lower operator platform assembly (Volume 2, WP 0235). Remove two shoulder screws (Figure 6, Item 1), washers (Figure 6, Item 2), and vandal guard (Figure 6, Item 3) from instrument box assembly (Figure 6, Item 4). Remove four screws (Figure 6, Item 8), washers (Figure 6, Item 9), and cover (Figure 6, Item 10) from operator station (Figure 6, Item 7). Remove three screws (Figure 6, Item 6) and washers (Figure 6, Item 5) from operator station (Figure 6, Item 7) and instrument box assembly (Figure 6, Item 4).
4
6 10 8 9
M0590SWR
Figure 6.
0131-5
TM 5-3895-379-23-1
0131
REMOVAL - Continued 12. Lift and tilt back instrument box assembly (Figure 7, Item 1) to gain access to throttle cable (Figure 7, Item 2).
M0591SWR
Figure 7. Throttle Cable Removal. 13. 14. Remove locknut (Figure 8, Item 3), clamp (Figure 8, Item 2), and throttle cable (Figure 8, Item 4) from operator station (Figure 8, Item 1). Discard locknut. Pull throttle cable (Figure 8, Item 4) free.
M0592SWR
0131-6
TM 5-3895-379-23-1
0131
REMOVAL - Continued 15. 16. 17. 18. 19. 20. 21. 22. Push button (Figure 9, Item 2) and throttle cable handle (Figure 9, Item 3) down as far as possible. Turn friction lock (Figure 9, Item 1) to left until it is loose on throttle cable handle (Figure 9, Item 3). Loosen locking nut (Figure 9, Item 5) and lockwasher (Figure 9, Item 4) on throttle cable handle (Figure 9, Item 3). Loosen knurled nut (Figure 9, Item 7) on throttle cable (Figure 9, Item 6) and allow knurled nut to drop free on throttle cable. Remove throttle cable handle (Figure 9, Item 3) from throttle cable (Figure 9, Item 6). Remove locking nut (Figure 9, Item 5) and lockwasher (Figure 9, Item 4) from throttle cable handle (Figure 9, Item 3). Discard lockwasher. Remove throttle cable handle (Figure 9, Item 3) from operator station (Figure 9, Item 8). Remove throttle cable (Figure 9, Item 6) from operator station (Figure 9, Item 8).
1 2 3
5 7
M0593SWR
0131-7
TM 5-3895-379-23-1
0131
INSTALLATION 1. 2. 3. 4. Guide throttle cable (Figure 10, Item 6) through operator station (Figure 10, Item 8). Position throttle cable handle (Figure 10, Item 3) on operator station (Figure 10, Item 8). Position new lockwasher (Figure 10, Item 4) and new locking nut (Figure 10, Item 5) on throttle cable handle (Figure 10, Item 3). Install throttle cable handle (Figure 10, Item 3) on throttle cable (Figure 10, Item 6) and tighten knurled nut (Figure 10, Item 7).
CAUTION
Do not tighten locking nut more than 120 lb-in. (14 Nm) or damage will occur to throttle cable handle. 5. 6. Tighten locking nut (Figure 10, Item 5) and lockwasher (Figure 10, Item 4) on throttle cable handle (Figure 10, Item 3). Tighten friction lock (Figure 10, Item 1) on throttle cable handle (Figure 10, Item 3) with throttle cable handle pushed down as far as possible.
1 2 3
5 7
M1265SWR
Figure 10. Throttle Cable Installation.
0131-8
TM 5-3895-379-23-1
0131
INSTALLATION - Continued 7. 8. Guide throttle cable (Figure 11, Item 5) through operator platform (Figure 11, Item 1). Install throttle cable (Figure 11, Item 5) and clamp (Figure 11, Item 3) on operator station (Figure 11, Item 2) and tighten locknut (Figure 11, Item 4).
M0594SWR
Figure 11.
Throttle Cable Installation.
0131-9
TM 5-3895-379-23-1
0131
INSTALLATION - Continued 9. 10. 11. Install instrument box assembly (Figure 12, Item 4) on operator station (Figure 12, Item 7) with three washers (Figure 12, Item 5) and screws (Figure 12, Item 6). Install cover (Figure 12, Item 10) on operator station (Figure 12, Item 7) with four washers (Figure 12, Item 9) and screws (Figure 12, Item 8). Install vandal guard (Figure 12, Item 3) on box assembly (Figure 12, Item 4) with two washers (Figure 12, Item 2) and shoulder screws (Figure 12, Item 1).
4
5 6
10 8 9
M0595SWR
0131-10
TM 5-3895-379-23-1
0131
INSTALLATION - Continued 12. 13. 14. Raise operator platform assembly (Volume 2, WP 0235). Position throttle cable (Figure 13, Item 5) in clamp (Figure 13, Item 4). Install plate (Figure 13, Item 1) on clamp (Figure 13, Item 4) with two washers (Figure 13, Item 2) and nuts (Figure 13, Item 3).
1 2 3
4 5
M0596SWR
Figure 13. 15.
Guide throttle cable (Figure 14, Item 1) through sock (Figure 14, Item 2).
M0597SWR
Figure 14.
0131-11
TM 5-3895-379-23-1
0131
INSTALLATION - Continued 16. 17. Position throttle cable (Figure 15, Item 1) in clamp (Figure 15, Item 2). Install plate (Figure 15, Item 3) on clamp (Figure 15, Item 2) with two washers (Figure 15, Item 4) and nuts (Figure 15, Item 5).
2 3 4 5
M0598SWR
Figure 15. Throttle Cable Installation. 18. Install throttle cable (Figure 16, Item 3) on bracket (Figure 16, Item 2) and tighten nut (Figure 16, Item 1).
2
M0599SWR
0131-12
TM 5-3895-379-23-1
0131
INSTALLATION - Continued 19. Connect ball joint assembly (Figure 17, Item 1) on throttle cable (Figure 17, Item 3) and slide spring-loaded sheath (Figure 17, Item 2) onto governor lever (Figure 17, Item 4).
1 2
3 4
M0600SWR
Figure 17. 20.
Lower operator platform assembly (Volume 2, WP 0235).
END OF TASK
0131-13
TM 5-3895-379-23-1
0131
ADJUSTMENT The objective is to adjust the linkage so the measured high idle of the engine is the same as measured high idle without the linkage. Proper use of the over-travel spring on the governor will cause this to happen. 1. 2. Start engine (TM 5-3895-379-10) and allow to operate at low idle for five minutes to warm up. Turn engine off (TM 5-3895-379-10).
CAUTION
Governor lever can be pushed past the contact point between the high idle adjustment screw and the idle screw adjustment stop. Ensure that the throttle linkage adjustment is made such that high idle position is between the first contact point of the high idle screw and the idle screw stop and the maximum lever rotation angle. Too little angle will result in decreased engine power.
NOTE
Adjust throttle cable linkage by turning the lock to the left to lengthen cable and clockwise to shorten cable. 3. 4. Slide spring-loaded sheath (Figure 18, Item 3) away from governor lever (Figure 18, Item 2) and disconnect ball joint assembly (Figure 18, Item 6) on throttle cable (Figure 18, Item 4) from governor lever. Lock throttle cable handle (Figure 18, Item 9) at full throttle by pushing down on button (Figure 18, Item 1), pulling throttle handle up as far as possible, and turning friction lock (Figure 18, Item 10) clockwise until handle is held in position. Push governor lever (Figure 18, Item 2) until it is half-way between where the high idle adjustment screw (Figure 18, Item 8) makes contact with idle screw adjustment stop (Figure 18, Item 7) and the maximum point at which the lever will rotate. This is half-way through the over-travel adjustment of the spring. Loosen locking nut (Figure 18, Item 5) at throttle cable ball joint assembly (Figure 18, Item 6) and adjust linkage until ball on governor lever (Figure 18, Item 2) is aligned with cavity in spring-loaded sheath (Figure 18, Item 3).
5.
6.
0131-14
TM 5-3895-379-23-1
0131
ADJUSTMENT - Continued
1 3
2 5 6 4
8 10
7
M0601SWR
Figure 18. 7.
Throttle Cable Adjustment.
Slide spring-loaded sheath (Figure 19, Item 2) back and connect ball joint assembly (Figure 19, Item 1) on governor lever. Release lock and allow lock to return to locked position.
1 2
M0602SWR
Figure 19.
Throttle Cable Adjustment.
0131-15
TM 5-3895-379-23-1
0131
ADJUSTMENT - Continued 8. Loosen friction lock (Figure 20, Item 3) by turning friction lock to left and push button (Figure 20, Item 1) and throttle cable handle (Figure 20, Item 2) fully down. Release button.
1
3
M1314SWR
Figure 20. Throttle Cable Adjustment. 9. 10. Start engine (TM 5-3895-379-10) and ensure that governor lever is still in the over-travel position when the throttle control is moved to the high idle position. Turn engine off (TM 5-3895-379-10).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Lower operator platform assembly. (Volume 2, WP 0235) Close right-side door assembly. (TM 5-3895-379-10) Operate roller and check for proper operation. (TM 5-3895-379-10)
0131-16
TM 5-3895-379-23-1
0132
FIELD MAINTENANCE LOW IDLE SPEED ADJUSTMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Test Set, Electronic Systems (Volume 2, WP 0289, Table 1, Item 37) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 35 TM 9-4910-571-12&P Equipment Condition Engine off. (TM 5-3895-379-10) Equipment Condition (cont.) Drums chocked. (TM 5-3895-379-10) Right and left-side door assemblies opened. (TM 5-3895-379-10)
0132-1
TM 5-3895-379-23-1
0132
ADJUSTMENT 1. 2. Remove plug (Figure 1, Item 2) from flywheel housing (Figure 1, Item 1). Attach Test Set to flywheel housing (Figure 1, Item 1) per TM 9-4910-571-12&P, Test No. 10.
VIEW LOOKING UP FROM UNDER ROLLER
M0603SWR
Figure 1. Low Idle Speed Adjustment. 3. Start and run engine until it reaches normal operating temperature (TM 5-3895-379-10).
NOTE
Engine low idle speed is 1075 to 1125 rpm. Turning adjustment screw clockwise increases engine speed. Turning adjustment screw to the left decreases engine speed. Throttle control must be set at the lowest speed position (pushed down) before adjusting engine low idle speed. 4. 5. Loosen locknut (Figure 2, Item 1) and turn screw (Figure 2, Item 2) to adjust idle speed. Use Test Set, Test No. 10 to monitor idle speed (TM 9-4910-571-12&P). When idle speed of 1075 to 1125 rpm is obtained, hold screw (Figure 2, Item 2) in place and tighten locknut (Figure 2, Item 1).
0132-2
TM 5-3895-379-23-1
0132
ADJUSTMENT - Continued
M0604SWR
Figure 2. 6.
Low Idle Speed Adjustment.
Remove Test Set and install plug (Figure 3, Item 2) in flywheel housing (Figure 3, Item 1).
M0605SWR
Low Idle Speed Adjustment.
0132-3
TM 5-3895-379-23-1
0132
FOLLOW-ON MAINTENANCE 1. 2. Close right and left-side door assemblies. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0132-4
TM 5-3895-379-23-1
0133
FIELD MAINTENANCE THROTTLE CONTROL REPLACEMENT (CB534C)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 35 Equipment Condition Engine off. (TM 5-3895-379-10) Equipment Condition (cont.) Battery disconnect switch in OFF position. (TM 5-3895-379-10) Operator platform assembly raised. (Volume 2, WP 0235) Right-side door assembly opened. (TM 5-3895-379-10)
0133-1
TM 5-3895-379-23-1
0133
REMOVAL 1. 2. 3. 4. Disconnect electrical connector (Figure 1, Item 4) from engine wiring harness (Figure 1, Item 5). Remove nut (Figure 1, Item 10) and washer (Figure 1, Item 11) from ball joint (Figure 1, Item 2). Remove ball joint (Figure 1, Item 2) from governor control shaft (Figure 1, Item 1). Remove four nuts (Figure 1, Item 7), washers (Figure 1, Item 8), bolts (Figure 1, Item 3), and engine speed control solenoid (Figure 1, Item 6) from bracket (Figure 1, Item 9).
5 4
11 10 9 8 7
M0606SWR
Figure 1. Throttle Control Removal. END OF TASK
0133-2
TM 5-3895-379-23-1
0133
INSTALLATION 1. 2. 3. 4. Install four bolts (Figure 2, Item 3), washers (Figure 2, Item 8), nuts (Figure 2, Item 7), and engine speed control solenoid (Figure 2, Item 6) to bracket (Figure 2, Item 9). Install the ball joint (Figure 2, Item 2) onto the governor control shaft (Figure 2, Item 1). Install washer (Figure 2, Item 11) and nut (Figure 2, Item 10) on ball joint (Figure 2, Item 2). Connect electrical connector (Figure 2, Item 4) to engine wiring harness (Figure 2, Item 5).
5 4
11 10 9 8 7
M1300SWR
Throttle Control Installation.
0133-3
TM 5-3895-379-23-1
0133
ADJUSTMENT
CAUTION
Make sure rod linkage is attached before connecting the engine speed control solenoid to prevent damage to the engine speed control solenoid. 1. 2. 3. 4. 5. 6. 7. 8. 9. Align the engine speed control solenoid (Figure 3, Item 7) with governor control shaft (Figure 3, Item 1). Move the engine speed switch to HIGH position (TM 5-3895-379-10). Battery disconnect switch in OFF position (TM 5-3895-379-10). Move the key switch to ON position to energize engine speed control solenoid (Figure 3, Item 7). Do not start engine. Loosen locknuts (Figure 3, Item 3) on rod linkage (Figure 3, Item 11). Adjust rod linkage (Figure 3, Item 11) until lever (Figure 3, Item 14) on governor control shaft (Figure 3, Item 1) contacts stop for HIGH idle. Tighten locknuts (Figure 3, Item 3) on rod linkage (Figure 3, Item 11). Cycle the engine speed switch to ensure lever (Figure 3, Item 14) contacts HIGH idle stop. Manually move plunger of engine speed control solenoid (Figure 3, Item 7) and check for binding of linkage. Adjust linkage as needed.
6 5
4 2 3
14
13 12
11 10 9 8
M1301SWR
Throttle Control Adjustment.
0133-4
TM 5-3895-379-23-1
0133
FOLLOW-ON MAINTENANCE 1. 2. 3. Close right-side door assembly. (TM 5-3895-379-10) Lower operator platform assembly. (Volume 2, WP 0235) Start engine and check for proper operation. (TM 5-3895-379-10)
0133-5/6 blank
TM 5-3895-379-23-1
0134
FIELD MAINTENANCE MUFFLER AND TAILPIPE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 0-300 in-lb (Volume 2, WP 0289, Table 1, Item 41) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Gasket (Volume 2, WP 0290, Table 1, Item 64) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 36 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)
0134-1
TM 5-3895-379-23-1
0134
REMOVAL
WARNING
Use caution and allow muffler and tailpipe to cool before removal. Failure to follow this warning may cause injury. 1. 2. Loosen two nuts (Figure 1, Item 1) and remove clamp (Figure 1, Item 5) and exhaust tube (Figure 1, Item 6) from muffler (Figure 1, Item 4). Loosen two nuts (Figure 1, Item 2) and allow clamp (Figure 1, Item 3) to slide down onto muffler (Figure 1, Item 4).
3 1
4
M0607SWR
Figure 1. Muffler and Tailpipe Removal.
WARNING
Use caution when handling heavy parts. Provide adequate support and use assistance during procedure. Failure to follow this warning may cause injury.
NOTE
Muffler weighs 19 lb (8.6 kg). 3. Remove nut (Figure 2, Item 6), washer (Figure 2, Item 3), screw (Figure 2, Item 2), washer (Figure 2, Item 3), and clamp (Figure 2, Item 4) from plate assembly (Figure 2, Item 5) and muffler (Figure 2, Item 7).
0134-2
TM 5-3895-379-23-1
0134
REMOVAL - Continued 4. Remove muffler (Figure 2, Item 7) from tube assembly (Figure 2, Item 1).
3 2 1
5 6 3 7 4
M0608SWR
Figure 2. 5. 6. 7.
Muffler and Tailpipe Removal.
Remove two nuts (Figure 3, Item 4) and clamp (Figure 3, Item 6) from bracket (Figure 3, Item 5). Remove three nuts (Figure 3, Item 3), tube assembly (Figure 3, Item 7), and gasket (Figure 3, Item 1) from turbocharger assembly (Figure 3, Item 2). Discard gasket. Remove two screws (Figure 3, Item 8), washers (Figure 3, Item 9), and bracket (Figure 3, Item 5) from engine (Figure 3, Item 10).
1 2 10 9 8 7 6 5 4 3
M0609SWR
Figure 3.
Muffler and Tailpipe Removal.
0134-3
TM 5-3895-379-23-1
0134
REMOVAL - Continued 8. Remove two screws (Figure 4, Item 3), washers (Figure 4, Item 4), clamps (Figure 4, Item 2), cables (Figure 4, Item 5), and plate assembly (Figure 4, Item 6) from flywheel housing (Figure 4, Item 1).
2 1 3 4
2
M0610SWR
Figure 4. Muffler and Tailpipe Removal. END OF TASK INSTALLATION 1. Install plate assembly (Figure 5, Item 6), two clamps (Figure 5, Item 2), and cables (Figure 5, Item 5) on flywheel housing (Figure 5, Item 1) with two washers (Figure 5, Item 4) and screws (Figure 5, Item 3). Tighten screws to 60-90 lb-ft (81-122 Nm).
2 1 3 4
2
M1252SWR
Figure 5. Muffler and Tailpipe Installation.
0134-4
TM 5-3895-379-23-1
0134
INSTALLATION - Continued 2. 3. 4. Install bracket (Figure 6, Item 5) on engine (Figure 6, Item 10) with two washers (Figure 6, Item 9) and screws (Figure 6, Item 8). Tighten screws to 60-90 lb-ft (81-122 Nm). Install new gasket (Figure 6, Item 1) and tube assembly (Figure 6, Item 7) on turbocharger assembly (Figure 6, Item 2) three nuts (Figure 6, Item 3). Tighten nuts to 33-47 lb-ft (45-64 Nm) Install clamp (Figure 6, Item 6) on tube assembly (Figure 6, Item 2) and in bracket (Figure 6, Item 5) with two nuts (Figure 6, Item 4). Tighten nuts (Figure 6, Item 4) to 203-328 lb-in. (23-37 Nm).
1 2 10 9 8 7 6 5 4 3
M0611SWR
Figure 6.
Muffler and Tailpipe Installation.
0134-5
TM 5-3895-379-23-1
0134
WARNING
Use caution when handling heavy parts. Provide adequate support and use assistance during procedure. Failure to follow this warning may cause injury. 5. 6. 7. Position clamp (Figure 7, Item 3) on top port of muffler (Figure 7, Item 8) and install muffler in tube assembly (Figure 7, Item 1). Hold muffler in place. Position clamp (Figure 7, Item 5) over end of muffler (Figure 7, Item 8). Install clamp (Figure 7, Item 5) on plate assembly (Figure 7, Item 6) with washer (Figure 7, Item 4), screw (Figure 7, Item 3), washer (Figure 7, Item 4), and nut (Figure 7, Item 7). Tighten nut to 33-47 lb-ft (45-64 Nm).
2 1
4 3
6 7 4 8 5
M0612SWR
Figure 7. Muffler and Tailpipe Installation.
0134-6
TM 5-3895-379-23-1
0134
INSTALLATION - Continued 8. 9. 10. Position clamp (Figure 8, Item 3) on overlap of top port of muffler (Figure 8, Item 4) and tube assembly (Figure 7, Item 1) and tighten nuts (Figure 8, Item 2) to 203-328 lb-in (23-37 Nm). Position clamp (Figure 8, Item 5) on side port of muffler (Figure 8, Item 4) and install exhaust tube (Figure 8, Item 6) in muffler. Position clamp (Figure 8, Item 5) on overlap of side port of muffler (Figure 8, Item 4) and exhaust tube (Figure 8, Item 6) and tighten nuts (Figure 8, Item 1) to 203-328 lb-in. (23-37 Nm).
2
3 1
M0613SWR
Muffler and Tailpipe Installation.
Close right and left-side door assemblies. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0134-7/8 blank
TM 5-3895-379-23-1
0135
FIELD MAINTENANCE COOLANT SYSTEM PRESSURE TEST
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Goggles (Volume 2, WP 0289, Table 1, Item 13) Indicator, Point Set, Group (Volume 2, WP 0289, Table 1, Item 16) Pan, Drain, 5 Gal Cap. (Volume 2, WP 0289, Table 1, Item 23) Pump, GP Cool SYS (Volume 2, WP 0289, Table 1, Item 28) Resistor, Thermal (Volume 2, WP 0289, Table 1, Item 30) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 37 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Right-side door assembly opened. (TM 5-3895-379-10) Coolant at proper level. (WP 0139)
0135-1
TM 5-3895-379-23-1
0135
PRESSURE TEST
WARNING
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 burns. DO NOT remove cooling system 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 burns. Wear effective eye, glove, and skin protection when handling coolants. Failure to do so may cause injury. 1. 2. 3. Push down on radiator cap (Figure 1, Item 1) and slowly turn 1/2 turn counterclockwise to relieve pressure from radiator (Figure 1, Item 3). Turn radiator cap (Figure 1, Item 1) additional 1/2 turn left and remove radiator cap from radiator (Figure 1, Item 3). Install radiator cap (Figure 1, Item 1) on coolant system pressure tester (Figure 1, Item 2) and pressurized radiator cap.
NOTE
Pressure valve on radiator cap must start to open between 7-10 psi (48-69 kPa). If pressure valve does not open, replace cap. 4. 5. Remove radiator cap (Figure 1, Item 1) from coolant system pressure tester (Figure 1, Item 2). Install coolant system pressure tester (Figure 1, Item 2) on radiator (Figure 1, Item 3) and pressurize coolant system to 7-10 psi (48-69 kPa). If pressure does not hold for two minutes, check for coolant leaks and replace or repair as necessary. Slowly remove coolant system pressure tester (Figure 1, Item 2) from radiator (Figure 1, Item 3). Install radiator cap (Figure 1, Item 1) on radiator (Figure 1, Item 3).
6. 7.
0135-2
TM 5-3895-379-23-1
0135
PRESSURE TEST - Continued
1 2
M0614SWR
Coolant System Pressure Test.
Close right-side door assembly. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0135-3/4 blank
TM 5-3895-379-23-1
0136
FIELD MAINTENANCE RADIATOR ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Lifting Device, Minimum Capacity 90 lb (41 kg) Link (Volume 2, WP 0289, Table 1, Item 22) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Antifreeze: Permanent, Ethylene Glycol, Inhibited (Volume 2, WP 0288, Table 1, Item 5, 6, 7) Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figure 37 WP 0135 Equipment Condition Right-side door assembly opened. (TM 5-3895-379-10) Operator platform assembly raised. (Volume 2, WP 0235) Coolant system drained. (WP 0139)
0136-1
TM 5-3895-379-23-1
0136
REMOVAL
NOTE
Inspect all hoses, lines, and fittings for cracks, bends, nicks, dents, stripped threads, and cuts. Replace all damaged parts. 1. 2. Loosen clamp (Figure 1, Item 1) and remove top radiator hose (Figure 1, Item 2) from radiator (Figure 1, Item 5). Loosen clamp (Figure 1, Item 4) and remove bottom radiator hose (Figure 1, Item 3) from radiator (Figure 1, Item 5).
1
3 4
M0615SWR
Figure 1. Radiator Assembly Removal.
0136-2
TM 5-3895-379-23-1
0136
REMOVAL - Continued 3. 4. Remove overflow hose (Figure 2, Item 1) form radiator (Figure 2, Item 6). Mark location and direction of two clips (Figure 2, Item 5).
WARNING
NOTE
Weight of radiator is 90 lb (41 kg). 5. 6. Attach lifting device to radiator (Figure 2, Item 6). With assistance, remove eight bolts (Figure 2, Item 3), washers (Figure 2, Item 4), two clips (Figure 2, Item 5), overflow hose (Figure 2, Item 1), and radiator (Figure 2, Item 6) from oil cooler (Figure 2, Item 2). Remove lifting device. Remove drain cock from radiator (Figure 2, Item 4). Loosen clamp and remove cap from radiator (Figure 2, Item 4).
1 6
7. 8.
M0616SWR
Radiator Assembly Removal.
0136-3
TM 5-3895-379-23-1
0136
INSTALLATION 1. 2. Install cap and clamp on radiator (Figure 3, Item 6). Tighten clamp until secure. Install drain cock on radiator (Figure 3, Item 6).
WARNING
NOTE
Weight of radiator is 90 lb (41 kg). 3. 4. Attach lifting device to radiator (Figure 3, Item 6). With assistance, install radiator (Figure 3, Item 6) on oil cooler (Figure 3, Item 2) with six washers (Figure 3, Item 4) and bolts (Figure 3, Item 3) leaving two holes open for clips (Figure 3, Item 5). Remove lifting device. Position two clips (Figure 3, Item 5) on overflow hose (Figure 3, Item 1). Install two clips (Figure 3, Item 5) and overflow hose (Figure 3, Item 1) on oil cooler (Figure 3, Item 2) with two washers (Figure 3, Item 4) and bolts (Figure 3, Item 3). Install overflow hose (Figure 3, Item 1) on radiator (Figure 3, Item 6).
5. 6. 7.
NOTE
Bottom four bolts on backside cannot be measurably tightened due to location. Torque wrench will not fit between oil cooler and frame. 8. Tighten eight bolts (Figure 3, Item 3) to 33-47 lb-ft (45-64 Nm). Ensure two clips (Figure 3, Item 5) do not turn and restrict overflow hose (Figure 3, Item 1).
0136-4
TM 5-3895-379-23-1
0136
1 6
M1064SWR
Figure 3.
Radiator Assembly Installation.
0136-5
TM 5-3895-379-23-1
0136
INSTALLATION - Continued 9. 10. 11. 12. Slide clamp (Figure 4, Item 4) over bottom radiator hose (Figure 4, Item 3). Position bottom radiator hose (Figure 4, Item 3) on radiator (Figure 4, Item 5) and tighten clamp (Figure 4, Item 4). Slide clamp (Figure 4, Item 1) over top radiator hose (Figure 4, Item 2). Position top radiator hose (Figure 4, Item 2) on radiator (Figure 4, Item 5) and tighten clamp (Figure 4, Item 1).
1
3 4
M0617SWR
Figure 4. Radiator Assembly Installation. END OF TASK
0136-6
TM 5-3895-379-23-1
0136
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Fill coolant system. (WP 0139) Lower operator platform assembly. (Volume 2, WP 0235) Start engine. Allow engine to idle until coolant reaches normal operating temperature. Run engine five minutes. Check for leaks. (TM 5-3895-379-10) Turn engine off. (TM 5-3895-379-10) Close right-side door assembly. (TM 5-3895-379-10)
0136-7/8 blank
TM 5-3895-379-23-1
0137
FIELD MAINTENANCE RADIATOR ASSEMBLY REPAIR
INITIAL SETUP: Personnel Required Construction Equipment Repairer 91L References TM 750-254
Refer to TM 750-254 for information on radiator repair. Includes Radiator Assembly Repair (Test) Man Hours. END OF TASK END OF WORK PACKAGE
0137-1/2 blank
TM 5-3895-379-23-1
0138
FIELD MAINTENANCE RADIATOR HOSES REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References TM 5-3896-379-23P, Figure 37 Equipment Condition Engine off and cool. (TM 5-3895-379-10) Equipment Condition (cont.) Drums chocked. (TM 5-3895-379-10) Cooling system drained. (WP 0139)
0138-1
TM 5-3895-379-23-1
0138
REMOVAL 1. 2. 3. 4. 5. 6. Loosen two clamps (Figure 1, Item 1). Remove hose (Figure 1, Item 2) from radiator (Figure 1, Item 6) and thermostat housing (Figure 1, Item 3). Remove two clamps (Figure 1, Item 1) from hose (Figure 1, Item 2). Loosen two clamps (Figure 1, Item 1). Remove hose (Figure 1, Item 5) from radiator (Figure 1, Item 6) and water pump (Figure 1, Item 4). Remove two clamps (Figure 1, Item 1) from hose (Figure 1, Item 5).
2 1 3 4
1 5 6 1
M0618SWR
Figure 1. Radiator Hoses Removal. END OF TASK INSTALLATION 1. 2. 3. 4. Position two clamps (Figure 2, Item 1) on hose (Figure 2, Item 5). Position hose (Figure 2, Item 5) on radiator (Figure 2, Item 6) and water pump (Figure 2, Item 4) and tighten two clamps (Figure 2, Item 1). Position two clamps (Figure 2, Item 1) on hose (Figure 2, Item 2). Position hose (Figure 2, Item 2) on radiator (Figure 2, Item 6) and thermostat housing (Figure 2, Item 3) and tighten two clamps (Figure 2, Item 1).
0138-2
TM 5-3895-379-23-1
0138
2 1 3 4
1 5 6 1
M0619SWR
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Fill cooling system. (WP 0139)
Radiator Hoses Installation.
Start engine and allow engine to idle until coolant reaches normal operating temperature. Run engine for five minutes. Check for leaks. (TM 5-3895-379-10) Turn engine off. (TM 5-3895-379-10) Start engine and check for leaks. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0138-3/4 blank
TM 5-3895-379-23-1
0139
FIELD MAINTENANCE COOLANT SYSTEM SERVICE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Goggles (Volume 2, WP 0289, Table 1, Item 13) Pan, Drain, 5 Gal Cap. (Volume 2, WP 0289, Table 1, Item 23) Tester, Electrolyte and Antifreeze (Volume 2, WP 0289, Table 1, Item 38) Materials/Parts Antifreeze: Permanent, Ethylene Glycol, Inhibited (Volume 2, WP 0288, Table 1, Item 5, 6, 7) Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Sodium Carbonate Tech (Volume 2, WP 0288, Table 1, Item 65) Personnel Required Construction Equipment Repairer 91L References TB 750-651 TM 5-3895-379-23P, Figure 37 WP 0135 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Right-side door assembly opened. (TM 5-3895-379-10)
0139-1
TM 5-3895-379-23-1
0139
CHECK
WARNING
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 burns. DO NOT remove cooling system 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 burns. Wear effective eye, glove, and skin protection when handling coolants. Failure to do so may cause injury.
NOTE
Refer to (WP 0135) for the test procedure. 1. 2. 3. 4. 5. 6. Pull lever (Figure 1, Item 4) and open access door (Figure 1, Item 1). Release lever. Remove radiator cap (Figure 1, Item 2) from radiator (Figure 1, Item 5). Using antifreeze tester, check coolant protection level (TB 750-651). If protection level is not within needs of environmental conditions, add or change coolant. Install radiator cap (Figure 1, Item 2) on radiator (Figure 1, Item 5). Pull lever (Figure 1, Item 5) and close access door (Figure 1, Item 1). Release lever.
0139-2
TM 5-3895-379-23-1
0139
CHECK - Continued
1
2 5
4 3
M0620SWR
Coolant System Check.
0139-3
TM 5-3895-379-23-1
0139
DRAIN
NOTE
Place drain pan with a 6 gal (22.7 Liters) capacity under radiator to catch draining coolant. 1. 2. 3. 4. 5. 6. 7. 8. 9. Pull lever (Figure 2, Item 4) and open access door (Figure 2, Item 1). Release lever. Remove radiator cap (Figure 2, Item 2) from radiator (Figure 2, Item 5). Open drain cock (Figure 2, Item 3) on radiator (Figure 2, Item 5) and drain coolant. Dispose of drained fluid in accordance with local regulations. Close drain cock (Figure 2, Item 3). Fill radiator (Figure 2, Item 5) with 5.8 gal (22 Liters) clean water and 0.75 lb (0.4 kg) sodium carbonate. Install radiator cap (Figure 2, Item 2) on radiator (Figure 2, Item 5). Pull lever (Figure 2, Item 4) and close access door (Figure 2, Item 1). Release lever. Start engine (TM 5-3895-379-10) and allow engine to idle until coolant reaches normal operating temperature. Run engine five minutes. Turn engine off (TM 5-3895-379-10) and allow radiator to cool. Open drain cock (Figure 2, Item 3) on radiator (Figure 2, Item 5) and drain fluid. Dispose of drained fluid in accordance with local regulations. Close drain cock (Figure 2, Item 3).
1
2 5
4 3
M1213SWR
Figure 2. Coolant System Drain.
0139-4
TM 5-3895-379-23-1
0139
DRAIN - Continued
NOTE
Place drain pan with a 6 gal (22.7 Liters) capacity under radiator to catch draining fluid. 10. 11. Loosen clamp (Figure 3, Item 2) and remove hose (Figure 3, Item 1) from radiator (Figure 3, Item 3). Drain remaining water. Dispose of drained fluid in accordance with local regulations. Install hose (Figure 3, Item 1) on radiator (Figure 3, Item 3) and tighten clamp (Figure 3, Item 2).
M0621SWR
Figure 3. 12. 13.
Coolant System Drain.
Repeat Steps (5) through (9), using clean water only to flush coolant system. Do not add sodium carbonate. If water drained still appears dirty, repeat Steps (5) through (9) until water appears clean.
END OF TASK
0139-5
TM 5-3895-379-23-1
0139
FILL
CAUTION
Do not fill coolant system with water only. Use a 50/50 mixture of ethylene glycol (antifreeze) and water. Failure to do so will result in damage to engine. 1. 2. 3. 4. Pull lever (Figure 4, Item 3) and open access door (Figure 4, Item 1). Release lever. Remove radiator cap (Figure 4, Item 2) from radiator (Figure 4, Item 4) and fill radiator with a 50/50 mixture of water and antifreeze. The radiator is full when coolant level is 3 inches below top of fill hose. Check radiator cap (Figure 4, Item 2) for missing or damaged gasket. Replace cap if gasket is damaged or missing. Install radiator cap (Figure 4, Item 2) on radiator (Figure 4, Item 4), pull lever (Figure 4, Item 1) and close access door (Figure 4, Item 1). Release lever.
1
2 4
M0622SWR
Figure 4. Coolant System Fill. 5. 6. Start engine (TM 5-3895-379-10) and allow engine to idle until coolant reaches normal operating temperature. Run engine five minutes. Check for leaks. Turn engine off (TM 5-3895-379-10).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Close right-side door assembly. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0139-6
TM 5-3895-379-23-1
0140
FIELD MAINTENANCE THERMOSTAT MAINTENANCE (CB534B)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Resistor, Thermal (Volume 2, WP 0289, Table 1, Item 30) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Sealing Compound, Loctite 271 (Volume 2, WP 0288, Table 1, Item 62) Packing, Preformed (Volume 2, WP 0290, Table 1, Item 62) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 39 Equipment Condition Operator platform assembly raised. (Volume 2, WP 0235) Cooling system drained. (WP 0139)
0140-1
TM 5-3895-379-23-1
0140
REMOVAL 1. 2. 3. 4. Loosen clamp (Figure 1, Item 4) and remove radiator hose (Figure 1, Item 3) from connector (Figure 1, Item 9). Remove bolts (Figure 1, Items 1 and 5) from thermostat housing (Figure 1, Item 6). Remove four screws (Figure 1, Item 2) and connector (Figure 1, Item 9) from thermostat housing (Figure 1, Item 6). Remove thermostat (Figure 1, Item 8) and preformed packing (Figure 1, Item 7) from thermostat housing (Figure 1, Item 6). Discard preformed packing.
1 2 3 4 9 5
7 6
M0623SWR
Figure 1. Thermostat Removal. END OF TASK TESTING 1. 2. 3. Hang thermostat in pan of water so that thermostat is completely under water. Do not allow thermostat to make contact with pan. Place thermal digital resistor (thermometer) in water. Heat water with propane torch and stir to allow for consistent temperature.
NOTE
Opening temperature should be 170F to 185F (77C to 85C). Full open temperature should be 198F to 208F (92C to 98C). 4. Observe temperature at which thermostat opens. Replace thermostat if temperatures are not as specified.
END OF TASK
0140-2
TM 5-3895-379-23-1
0140
INSTALLATION
NOTE
Thermostat is replaced as a kit with preformed packing. 1. 2. 3. Position thermostat (Figure 2, Item 8) and new preformed packing (Figure 2, Item 7) in thermostat housing (Figure 2, Item 6). Install connector (Figure 2, Item 9) on thermostat housing (Figure 2, Item 6) with four screws (Figure 2, Item 2) and bolts (Figure 2, Items 1 and 5). Tighten screws to 25-41 lb-ft (34-56 Nm). Install radiator hose (Figure 2, Item 3) on connector (Figure 2, Item 9) and tighten clamp (Figure 2, Item 4).
1 2 3 4 9 5
7 6
M0624SWR
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Fill cooling system. (WP 0139)
Thermostat Installation.
Lower operator platform assembly. (Volume 2, WP 0235) Start engine and allow engine to idle until coolant reaches normal operating temperature. Run engine five minutes. Check for leaks. (TM 5-3895-379-10) Turn engine off. (TM 5-3895-379-10)
0140-3/4 blank
TM 5-3895-379-23-1
0141
FIELD MAINTENANCE THERMOSTAT MAINTENANCE (CB534C)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Resistor, Thermal (Volume 2, WP 0289, Table 1, Item 30) Soldering Torch (Volume 2, WP 0289, Table 1, Item 34) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Cloth, Cleaning (Volume 2, WP 0288, Table 1, Item 16) Sealing Compound, Loctite 271 (Volume 2, WP 0288, Table 1, Item 62) O-ring (Volume 2, WP 0290, Table 1, Item 13) Qty: 1 Materials/Parts (cont.) Ring (Volume 2, WP 0290, Table 1, Item 19) Qty: 1 Seal (Volume 2, WP 0290, Table 1, Item 15) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 39 Equipment Condition Operator platform assembly raised. (Volume 2, WP 0235) Cooling system drained. (WP 0139)
0141-1
TM 5-3895-379-23-1
0141
REMOVAL 1. 2. 3. Loosen clamp (Figure 1, Item 3) and remove radiator hose (Figure 1, Item 2) from connector (Figure 1, Item 1). Remove four screws (Figure 1, Item 4) and connector (Figure 1, Item 1) from thermostat housing (Figure 1, Item 5). Remove thermostat (Figure 1, Item 7), ring (Figure 1, Item 6), seal (Figure 1, Item 9), and O-ring (Figure 1, Item 8) from thermostat housing (Figure 1, Item 5). Discard ring, seal, and O-ring.
2 3 4
9 8 7 6 5
M0625SWR
Figure 1. Thermostat Removal. END OF TASK TESTING 1. 2. 3. Hang thermostat in pan of water so that thermostat is completely under water. Do not allow thermostat to make contact with pan. Place thermal digital resistor (thermometer) in water. Heat water with propane torch and stir to allow for consistent temperature.
0141-2
TM 5-3895-379-23-1
0141
TESTING - Continued
NOTE
Opening temperature should be 170F to 185F (77C to 85C). Full open temperature should be 198F to 208F (92C to 98C). 4. Observe temperature at which thermostat opens. Replace thermostat if temperatures are not as specified.
END OF TASK INSTALLATION 1. 2. 3. Install thermostat (Figure 2, Item 7), new ring (Figure 2, Item 6), new seal (Figure 2, Item 9), and new O-ring (Figure 2, Item 8) in thermostat housing (Figure 2, Item 5). Install connector (Figure 2, Item 1) on thermostat housing (Figure 2, Item 5) with four screws (Figure 2, Item 4). Tighten screws to 25-41 lb-ft (34-56 Nm). Position radiator hose (Figure 2, Item 2) on connector (Figure 2, Item 1) and tighten clamp (Figure 2, Item 3).
2 3 4
9 8 7 6 5
M1063SWR
Thermostat Installation.
0141-3
TM 5-3895-379-23-1
0141
FOLLOW-ON MAINTENANCE 1. 2. 3. Fill cooling system. (WP 0139) Lower operator platform assembly. (Volume 2, WP 0235) Start engine and allow engine to idle until coolant reaches normal operating temperature. Run engine five minutes. Check for leaks. (TM 5-3895-379-10)
0141-4
TM 5-3895-379-23-1
0142
FIELD MAINTENANCE THERMOSTAT HOUSING REPLACEMENT (CB534B)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 0-300 in-lb (Volume 2, WP 0289, Table 1, Item 41) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Gasket (Volume 2, WP 0290, Table 1, Item 57) Qty: 1 Packing, Preformed (Volume 2, WP 0290, Table 1, Item 62) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-10 TM 5-3895-379-23P, Figure 39 Equipment Condition Operator platform assembly raised. (Volume 2, WP 0235) Cooling system drained. (WP 0139)
0142-1
TM 5-3895-379-23-1
0142
REMOVAL
NOTE
Inspect all hoses, lines, and fittings for cracks, bends, nicks, dents, stripped threads, and cuts. Replace all damaged parts. 1. 2. 3. 4. 5. Loosen clamps (Figure 1, Item 1) and remove top radiator hose (Figure 1, Item 2) from thermostat housing assembly (Figure 1, Item 10). Disconnect connector (Figure 1, Item 4) from temperature sensor connector (Figure 1, Item 5). Remove temperature sensor (Figure 1, Item 7) from thermostat housing assembly (Figure 1, Item 10). Remove screw (Figure 1, Item 6) and clip (Figure 1, Item 3) from thermostat housing assembly (Figure 1, Item 10). Loosen clamp (Figure 1, Item 9) around hose (Figure 1, Item 8).
1 2 3 4 5
10 6
9 8
7
M0626SWR
Figure 1. Thermostat Housing Removal.
0142-2
TM 5-3895-379-23-1
0142
REMOVAL - Continued 6. 7. 8. 9. 10. 11. Remove two bolts (Figure 2, Item 4) from thermostat housing assembly (Figure 2, Item 1). Remove two screws (Figure 2, Item 7) from thermostat housing assembly (Figure 2, Item 1). Remove two bolts (Figure 2, Item 5) from thermostat housing assembly (Figure 2, Item 1). Remove bolt (Figure 2, Item 6) from thermostat housing assembly (Figure 2, Item 1). Pull thermostat housing assembly (Figure 2, Item 1) away from engine (Figure 2, Item 2). Slide hose (Figure 2, Item 3) off thermostat housing assembly.
1 7 2
6 5 4 3
M0627SWR
Figure 2.
Thermostat Housing Removal.
0142-3
TM 5-3895-379-23-1
0142
REMOVAL - Continued
NOTE
Ensure that all gasket material is removed from thermostat housing assembly and engine block. 12. 13. 14. 15. 16. 17. Remove gasket (Figure 3, Item 5) from thermostat housing assembly (Figure 3, Item 6). Discard gasket. Remove four screws (Figure 3, Item 2) from thermostat housing assembly (Figure 3, Item 6). Remove bolt (Figure 3, Item 1) from thermostat housing assembly (Figure 3, Item 6). Remove bolt (Figure 3, Item 3) from thermostat housing assembly (Figure 3, Item 6). Remove connector (Figure 3, Item 4), preformed packing (Figure 3, Item 8), and thermostat (Figure 3, Item 9) from thermostat housing assembly (Figure 3, Item 6). Discard preformed packing. Remove two pipe plugs (Figure 3, Item 7) from thermostat housing assembly (Figure 3, Item 6).
2 3
4 9 8 5
6
M0628SWR
Figure 3. Thermostat Housing Removal. END OF TASK
0142-4
TM 5-3895-379-23-1
0142
INSTALLATION 1. 2. 3. Install two pipe plugs (Figure 4, Item 7) in thermostat housing assembly (Figure 4, Item 6). Install thermostat (Figure 4, Item 9), new preformed packing (Figure 4, Item 8), and connector (Figure 4, Item 4) in thermostat housing assembly (Figure 4, Item 6). Install bolts (Figure 4, Items 1 and 3) in thermostat housing assembly (Figure 4, Item 6). Tighten bolt to 177-301 lb-in. (20-34 Nm). Install bolt (Figure 4, Item 1) in thermostat housing assembly (Figure 4, Item 6). Tighten bolt to 177-301 lb-in. (20-34 Nm). Install four screws (Figure 4, Item 2) in thermostat housing assembly (Figure 4, Item 6). Tighten screws to 177-301 lb-in. (20-34 Nm). Position new gasket (Figure 4, Item 5) on thermostat housing assembly (Figure 4, Item 6).
4. 5.
2 3
4 9 8 5
6
M1251SWR
Figure 4.
Thermostat Housing Installation.
0142-5
TM 5-3895-379-23-1
0142
INSTALLATION - Continued 6. 7. Position hose (Figure 5, Item 3) onto thermostat housing assembly (Figure 5, Item 1). Install two bolts (Figure 5, Item 5) and bolt (Figure 5, Item 6) in thermostat housing assembly (Figure 5, Item 1). Tighten bolt to 177-301 lb-in. (20-34 Nm). Install two screws (Figure 5, Item 7) in thermostat housing assembly (Figure 5, Item 6). Tighten screws to 33-47 lb-ft (45-64 Nm). Install two bolts (Figure 5, Item 4) in thermostat housing assembly (Figure 5, Item 1). Tighten bolts to 33-47 lb-ft (45-64 Nm).
8.
1 7 2
6 5 4 3
M1070SWR
Figure 5. Thermostat Housing Installation. 9. 10. 11. 12. 13. Install clamp (Figure 6, Item 9) on hose (Figure 6, Item 8) and thermostat housing assembly (Figure 6, Item 10). Tighten clamp until secure. Install clip (Figure 6, Item 3) and screw (Figure 6, Item 6) in thermostat housing assembly (Figure 6, Item 10). Tighten screw to 177-301 lb-in. (20-34 Nm). Install temperature sensor (Figure 6, Item 7) in thermostat housing assembly (Figure 6, Item 10). Connect temperature sensor connector (Figure 6, Item 5) to connector (Figure 6, Item 4). Install top radiator hose (Figure 6, Item 2) and clamp (Figure 6, Item 1) on thermostat housing assembly (Figure 6, Item 10). Tighten clamp securely.
0142-6
TM 5-3895-379-23-1
0142
1 2 3 4 5
10 6
9 8
7
M1068SWR
Figure 6. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Fill coolant system. (WP 0139)
Lower operator platform assembly. (Volume 2, WP 0235) Start engine and allow engine to idle until coolant reaches normal operating temperature. Run engine five minutes. Check for leaks. (TM 5-3895-379-10)
0142-7/8 blank
TM 5-3895-379-23-1
0143
FIELD MAINTENANCE THERMOSTAT HOUSING REPLACEMENT (CB534C)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts O-ring (Volume 2, WP 0290, Table 1, Item 21) Qty: 1 O-ring (Volume 2, WP 0290, Table 1, Item 73) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-10 References (cont.) TM 5-3895-379-23P, Figures 39 and 52 WP 0139 Equipment Condition Operator platform assembly raised. (Volume 2, WP 0235) Thermostat removed. (WP 0141)
0143-1
TM 5-3895-379-23-1
0143
REMOVAL
NOTE
Inspect hoses, lines, and fittings for cracks, bends, nicks, dents, stripped threads, and cuts. Replace all damaged parts. 1. 2. 3. 4. 5. 6. 7. 8. Disconnect connector (Figure 1, Item 6) from temperature sensor connector (Figure 1, Item 5). Remove temperature sensor (Figure 1, Item 8) and O-ring (Figure 1, Item 9) from thermostat housing assembly (Figure 1, Item 10). Remove screw (Figure 1, Item 7) and clip (Figure 1, Item 2) from thermostat housing assembly (Figure 1, Item 10). Loosen clamp (Figure 1, Item 12) around hose (Figure 1, Item 11). Remove two bolts (Figure 1, Item 13) from thermostat housing assembly (Figure 1, Item 10). Remove three bolts (Figure 1, Item 14) from thermostat housing assembly (Figure 1, Item 10). Pull thermostat housing assembly (Figure 1, Item 10) away from engine (Figure 1, Item 4). Slide hose (Figure 1, Item 11) off thermostat housing assembly (Figure 1, Item 10).
CAUTION
Ensure that all O-ring material is removed from thermostat housing assembly and engine. 9. 10. Remove O-ring (Figure 1, Item 3) from thermostat housing assembly (Figure 1, Item 10). Discard O-ring. Remove pipe plug (Figure 1, Item 1) from thermostat housing assembly (Figure 1, Item 10).
4 2 1 3
14 8 7 6 5
10 13 12 11
M0629SWR
Figure 1. Thermostat Housing Removal. END OF TASK
0143-2
TM 5-3895-379-23-1
0143
INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. Install pipe plug (Figure 2, Item 1) in thermostat housing assembly (Figure 2, Item 10). Position new O-ring (Figure 2, Item 3) on thermostat housing assembly (Figure 2, Item 10). Position hose (Figure 2, Item 11) onto thermostat housing assembly (Figure 2, Item 10). Install three bolts (Figure 2, Item 14) and two bolts (Figure 2, Item 13) in thermostat housing assembly (Figure 2, Item 10). Tighten bolts to 33-47 lb-ft (45-64 Nm). Install clamp (Figure 2, Item 12) on hose (Figure 2, Item 11) and thermostat housing assembly (Figure 2, Item 10). Tighten clamp until secure. Install clip (Figure 2, Item 2) on thermostat housing assembly (Figure 2, Item 10) with screw (Figure 2, Item 7). Install O-ring (Figure 2, Item 9) and temperature sensor (Figure 2, Item 8) in thermostat housing assembly (Figure 2, Item 10). Connect temperature sensor connector (Figure 2, Item 5) to connector (Figure 2, Item 6).
4 2 1 3
14 8 7 6 5
10 13 12 11
M1108SWR
0143-3
TM 5-3895-379-23-1
0143
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Fill cooling system. (WP 0139) Lower operator platform assembly. (Volume 2, WP 0235) Start engine and allow engine to idle until coolant reaches normal operating temperature. Run engine five minutes. Check for leaks. (TM 5-3895-379-10) Turn engine off. (TM 5-3895-379-10)
0143-4
TM 5-3895-379-23-1
0144
FIELD MAINTENANCE WATER PUMP REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 0-300 in-lb (Volume 2, WP 0289, Table 1, Item 41) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Gasket (CB534C Roller) (Volume 2, WP 0290, Table 1, Item 26) Qty: 1 Packing, Preformed (CB534B Roller) (Volume 2, WP 0290, Table 1, Item 32) Qty: 2 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 40 Equipment Condition Engine off and cool. (TM 5-3895-379-10) Operator platform assembly raised. (Volume 2, WP 0235) Cooling system drained. (WP 0139)
0144-1
TM 5-3895-379-23-1
0144
REMOVAL
NOTE
Water pump is replaced the same way for CB534B and CB534C Rollers except where noted. CB534B Roller is shown. Inspect all hoses, lines, and fittings for cracks, bends, nicks, dents, stripped threads, and cuts. Replace all damaged parts. 1. Loosen clamp (Figure 1, Item 2) and remove hose (Figure 1, Item 3) from water pump (Figure 1, Item 1).
2 3
M0630SWR
Figure 1. Water Pump Removal. 2. 3. Remove two bolts (Figure 2, Item 5) and washers (Figure 2, Item 4) from front fan guard assembly (Figure 2, Item 3). Remove two bolts (Figure 2, Item 2), washers (Figure 2, Item 1), and front fan guard assembly (Figure 2, Item 3) from fan shroud (Figure 2, Item 6).
2 3
4 5
M0631SWR
Figure 2. Water Pump Removal. 4. 5. For CB534B Roller, remove two bolts (Figure 3, Item 2) from connector (Figure 3, Item 3). For CB534B Roller, remove bolts (Figure 3, Items 1 and 5) from water pump (Figure 3, Item 4).
0144-2
TM 5-3895-379-23-1
0144
REMOVAL - Continued
5 4
M0632SWR
Figure 3. 6. 7.
Water Pump Removal.
For CB534B Roller, remove bolt (Figure 4, Item 4) from engine (Figure 4, Item 3). For CB534B Roller, remove three bolts (Figure 4, Item 5), water pump (Figure 4, Item 7), preformed packing (Figure 4, Item 6), gasket (Figure 4, Item 1), and preformed packing (Figure 4, Item 2) from engine (Figure 4, Item 3). Discard preformed packings and gasket.
1 2 3
5 6 7
CB534B
Figure 4. Water Pump Removal.
M1087SWR
0144-3
TM 5-3895-379-23-1
0144
REMOVAL - Continued 8. For CB534C Roller, remove bolts (Figure 5, Items 2, 3, 4, 5, and 6), water pump (Figure 5, Item 7), and gasket (Figure 5, Item 8) from engine (Figure 5, Item 1). Discard gasket.
8 7 6 5
4 3
M0633SWR
CB534C
Figure 5. Water Pump Removal.
END OF TASK
0144-4
TM 5-3895-379-23-1
0144
INSTALLATION 1. For CB534C Roller, install new gasket (Figure 6, Item 8) and water pump (Figure 6, Item 7), to engine (Figure 6, Item 1) with bolts (Figure 6, Items 2, 3, 4, 5, and 6).
8 7 6 5
4 3
M1206SWR
CB534C
Figure 6. Water Pump Installation.
0144-5
TM 5-3895-379-23-1
0144
INSTALLATION - Continued 2. For CB534B Roller, install new preformed packing (Figure 7, Item 2), new gasket (Figure 7, Item 1), new preformed packing (Figure 7, Item 6), and water pump (Figure 7, Item 7) on engine (Figure 7, Item 3) with three bolts (Figure 7, Item 5). Tighten bolts to 177-301 lb-in. (20-34 Nm). For CB534B Roller, install bolt (Figure 7, Item 4) in engine (Figure 7, Item 3). Tighten bolt to 177-301 lb-in. (20-34 Nm).
3.
1 2 3
5 6 7
CB534B
Figure 7. Water Pump Installation. 4. 5.
M1207SWR
For CB534B Roller, install bolts (Figure 8, Items 1 and 5) in water pump (Figure 8, Item 4). Tighten bolts to 15-25 lb-ft (20-34 Nm). For CB534B Roller, install two bolts (Figure 8, Item 2) in connector (Figure 8, Item 3). Tighten bolts to 177-301 lb-in (20-34 Nm).
5 4
M0634SWR
Figure 8. Water Pump Installation.
0144-6
TM 5-3895-379-23-1
0144
INSTALLATION - Continued 6. 7. Install front fan guard assembly (Figure 9, Item 3) on fan shroud (Figure 9, Item 6) with two washers (Figure 9, Item 1) and bolts (Figure 9, Item 2). Tighten bolts to 177-301 lb-in (20-34 Nm). Install two washers (Figure 9, Item 4) and bolts (Figure 9, Item 5) in front fan guard assembly (Figure 9, Item 3). Tighten bolts to 177-301 lb-in (20-34 Nm).
2 3
4 5
M0635SWR
Figure 9. 8.
Water Pump Installation.
Install hose (Figure 10, Item 3) on water pump (Figure 10, Item 1) and tighten clamp (Figure 10, Item 2).
2 3
M0636SWR
Water Pump Installation.
0144-7
TM 5-3895-379-23-1
0144
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Fill cooling system. (WP 0139) Lower operator platform assembly. (Volume 2, WP 0235) Start engine and allow engine to idle until coolant reaches normal operating temperature. Run engine five minutes. Check for leaks. (TM 5-3895-379-10) Turn engine off. (TM 5-3895-379-10)
0144-8
TM 5-3895-379-23-1
0145
FIELD MAINTENANCE FAN DRIVE HOUSING ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 41 Equipment Condition Operator platform assembly raised. (Volume 2, WP 0235) Fan pulley removed. (WP 0146)
REMOVAL Remove four screws (Figure 1, Item 3) and fan drive housing assembly (Figure 1, Item 1) from engine assembly (Figure 1, Item 2).
M0637SWR
Figure 1. Fan Drive Housing Assembly Removal. END OF TASK
0145-1
TM 5-3895-379-23-1
0145
INSTALLATION Install fan drive housing assembly (Figure 2, Item 1) on engine assembly (Figure 2, Item 2) with four screws (Figure 2, Item 3). Tighten screws to 33-47 lb-ft (45-64 Nm).
2
M1286SWR
Figure 2. Fan Drive Housing Assembly Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install fan pulley. (WP 0146) Lower operator platform assembly. (Volume 2, WP 0235)
0145-2
TM 5-3895-379-23-1
0146
FIELD MAINTENANCE FAN ASSEMBLY AND GUARD REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 0-300 in-lb (Volume 2, WP 0289, Table 1, Item 41) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 41 WP 0147 Equipment Condition Operator platform assembly raised. (Volume 2, WP 0235)
0146-1
TM 5-3895-379-23-1
0146
REMOVAL
WARNING
Use caution while working under operator platform assembly. Falling platform may cause injury or death. 1. 2. Remove two bolts (Figure 1, Item 8) and washers (Figure 1, Item 7) from front fan guard assembly (Figure 1, Item 6). Remove two bolts (Figure 1, Item 2), washers (Figure 1, Item 1), and front fan guard assembly (Figure 1, Item 6) from fan shroud (Figure 1, Item 9).
NOTE
Remove both fan guard assemblies only when replacing fan shroud. 3. Remove two bolts (Figure 1, Item 4), washers (Figure 1, Item 5), and rear fan guard assembly (Figure 1, Item 3) from fan shroud (Figure 1, Item 9).
3 1 2
5 6 7 8 9
M0638SWR
Figure 1. Fan Assembly and Guard Removal.
0146-2
TM 5-3895-379-23-1
0146
REMOVAL - Continued 4. Remove four nuts (Figure 2, Item 1), washers (Figure 2, Item 2), fan (Figure 2, Item 5), and spacer (Figure 2, Item 3) from fan pulley (Figure 2, Item 4).
1 2 3 4
5
M0639SWR
Figure 2.
Fan Assembly and Guard Removal.
0146-3
TM 5-3895-379-23-1
0146
REMOVAL - Continued 5. 6. 7. 8. Loosen nut (Figure 3, Item 9) holding alternator (Figure 3, Item 1) to alternator bracket (Figure 3, Item 10). Loosen screw (Figure 3, Item 7) holding alternator (Figure 3, Item 8) to alternator strap (Figure 3, Item 6). Slide alternator (Figure 3, Item 8) towards engine (Figure 3, Item 2) and remove two V-belts (Figure 3, Item 3) from fan pulley (Figure 3, Item 4). Remove fan pulley (Figure 3, Item 5) from fan drive housing assembly (Figure 3, Item 4).
1 2 10 9 3 4
8 5
6
M0640SWR
Figure 3. Fan Assembly and Guard Removal. END OF TASK
0146-4
TM 5-3895-379-23-1
0146
INSTALLATION 1. Position fan pulley (Figure 4, Item 5) on fan drive housing assembly (Figure 4, Item 4).
1 2 10 9 3 4
8 5
6
M1229SWR
Figure 4. 2.
Fan Assembly and Guard Installation.
Install spacer (Figure 5, Item 3) and fan (Figure 5, Item 5) to fan pulley (Figure 5, Item 4) with four washers (Figure 5, Item 2) and nuts (Figure 5, Item 1). Tighten nuts to 177-301 lb-in. (20-34 Nm).
1 2 3 4
5
M1230SWR
Figure 5.
0146-5
TM 5-3895-379-23-1
0146
INSTALLATION - Continued 3. 4. 5. 6. Install fan V-belts (WP 0147). Install rear fan guard assembly (Figure 6, Item 3) on fan shroud (Figure 6, Item 9) with two washers (Figure 6, Item 5) and bolts (Figure 6, Item 4). Tighten bolts to 33-47 lb-ft (45-64 Nm). Install front fan guard assembly (Figure 6, Item 6) on fan shroud (Figure 6, Item 9) with two washers (Figure 6, Item 1) and bolts (Figure 6, Item 2). Tighten bolts to 33-47 lb-ft (45-64 Nm). Install two washers (Figure 6, Item 7) and bolts (Figure 6, Item 8) in front fan guard assembly (Figure 6, Item 6). Tighten bolts to 177-301 lb-in. (20-34 Nm).
3 1 2 4
5 6 7 8 9
M0641SWR
0146-6
TM 5-3895-379-23-1
0147
FIELD MAINTENANCE FAN V-BELTS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Plug Assembly, Sealing (Volume 2, WP 0289, Table 1, Item 26) Tensiometer, Dial Indication (Volume 2, WP 0289, Table 1, Item 36) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 41 Equipment Condition Operator platform assembly raised. (Volume 2, WP 0235) Fan guard removed. (WP 0146)
0147-1
TM 5-3895-379-23-1
0147
REMOVAL 1. 2. 3. 4. Loosen nut (Figure 1, Item 8) holding alternator (Figure 1, Item 1) to alternator bracket (Figure 1, Item 9). Loosen screw (Figure 1, Item 5) holding alternator (Figure 1, Item 1) to alternator strap (Figure 1, Item 4). Slide alternator (Figure 1, Item 1) toward engine (Figure 1, Item 2) and remove two V-belts (Figure 1, Item 7) from three pulleys (Figure 1, Item 3). Move two V-belts (Figure 1, Item 7) around fan (Figure 1, Item 6) and remove two V-belts.
1 2
9 8 7
6 3 5 4
M0642SWR
Figure 1. END OF TASK CLEANING AND INSPECTION
Fan V-Belts Removal.
Check V-belts (Figure 2, Item 7) for any cracks that go to belt fiber, cracks 1/8 in. in depth or 50% of belt thickness, grease build-up, peeling, glazing, or frays more than 2 in. long. END OF TASK
0147-2
TM 5-3895-379-23-1
0147
INSTALLATION
NOTE
Always replace V-belts as a set, even if only one is found to be damaged. 1. Position two V-belts (Figure 2, Item 7) around fan (Figure 2, Item 6) and three pulleys (Figure 2, Item 3).
1 2
9 8 7
6 3 5 4
M0643SWR
Figure 2. 2. Perform Adjustment.
Fan V-Belts Installation.
END OF TASK
0147-3
TM 5-3895-379-23-1
0147
ADJUSTMENT 1. Attach belt tension gauge (Figure 3, Item 1) to V-belts (Figure 4, Item 7).
M0644SWR
Figure 3. Fan V-Belts Adjustment. 2. 3. Slide alternator (Figure 4, Item 1) away from or toward engine (Figure 4, Item 2) to adjust belt tension. Maintain 80 lb (355 Nm) of belt tension while tightening screw (Figure 4, Item 5) and nut (Figure 4, Item 8).
1 2
9 8 7
6 3 5 4
M1231SWR
Figure 4. Fan V-Belts Adjustment. 4. Check belt tension.
END OF TASK
0147-4
TM 5-3895-379-23-1
0147
FOLLOW-ON MAINTENANCE 1. 2. Install fan guard. (WP 0146) Lower operator platform assembly. (Volume 2, WP 0235)
0147-5/6 blank
TM 5-3895-379-23-1
0148
FIELD MAINTENANCE ALTERNATOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figures 42, 43, and 44 Equipment Condition Operator platform assembly raised. (Volume 2, WP 0235) Fan V-belts removed. (WP 0147) Battery cables disconnected. (WP 0192)
REMOVAL 1. 2. Remove nut (Figure 1, Item 7), washer (Figure 1, Item 8), and wire (Figure 1, Item 9) from D+ terminal (Figure 1, Item 1) of alternator (Figure 1, Item 2). Remove nut (Figure 1, Item 6), washer (Figure 1, Item 5), and wire (Figure 1, Item 4) from B- terminal (Figure 1, Item 3) of alternator (Figure 1, Item 2).
VIEW FROM REAR OF ALTERNATOR 1
7 6
8 9 4 5 3
M0828SWR
Figure 1.
Alternator Removal.
0148-1
TM 5-3895-379-23-1
0148
REMOVAL - Continued 3. Remove nut (Figure 2, Item 5), lockwasher (Figure 2, Item 4), and two wires (Figure 2, Item 1) from B+ terminal (Figure 2, Item 3) of alternator (Figure 2, Item 2). Discard lockwasher.
2 3 5 4
M0829SWR
Figure 2.
Alternator Removal.
0148-2
TM 5-3895-379-23-1
0148
REMOVAL - Continued 4. 5. Remove screw (Figure 3, Item 10), washer (Figure 3, Item 11), spacer (Figure 3, Item 8), and welded nut (Figure 3, Item 7) from alternator (Figure 3, Item 6) and alternator strap (Figure 3, Item 9). With assistance, remove nut (Figure 3, Item 1), washer (Figure 3, Item 2), alternator (Figure 3, Item 6), washer (Figure 3, Item 2), spacer (Figure 3, Item 3), washer (Figure 3, Item 2), and screw (Figure 3, Item 4) from alternator bracket (Figure 3, Item 5).
4 3 2 1 5 2
6 7 11
10
8 9
M0830SWR
Alternator Removal.
0148-3
TM 5-3895-379-23-1
0148
INSTALLATION
NOTE
Ensure alternator pulley is aligned with crankshaft pulley to within 3/32 in. (2.4 mm). If alternator pulley is removed, install alternator pulley on alternator and tighten alternator nut to 48-55 lb-ft (65-75 Nm). 1. With assistance, install alternator (Figure 4, Item 6) on alternator bracket (Figure 4, Item 5) with screw (Figure 4, Item 4), washer (Figure 4, Item 2), spacer (Figure 4, Item 3), washer (Figure 4, Item 2), and nut (Figure 4, Item 1). Do not tighten nut. Install alternator (Figure 4, Item 6) on alternator strap (Figure 4, Item 9), and welded nut (Figure 4, Item 7) with spacer (Figure 4, Item 8), washer (Figure 4, Item 11), and screw (Figure 4, Item 10). Do not tighten nut.
4 3 2 1 5 2
2.
6 7 11
10
8 9
M0831SWR
Figure 4. 3.
Alternator Installation.
Install two wires (Figure 5, Item 1), new lockwasher (Figure 5, Item 4), and nut (Figure 5, Item 5) on terminal B+ (Figure 5, Item 3) of alternator (Figure 5, Item 2).
0148-4
TM 5-3895-379-23-1
0148
2 3 5 4
M0832SWR
Figure 5. 4. 5.
Install wire (Figure 6, Item 9), washer (Figure 6, Item 8), and nut (Figure 6, Item 7) on B- terminal (Figure 6, Item 6) of alternator (Figure 6, Item 5). Install wire (Figure 6, Item 3), washer (Figure 6, Item 2), and nut (Figure 6, Item 1) to D+ terminal (Figure 6, Item 4) of alternator (Figure 6, Item 5).
4 3 1 2
6 7
M0833SWR
0148-5
TM 5-3895-379-23-1
0148
FOLLOW-ON MAINTENANCE 1. 2. 3. Install V-belts. (WP 0147) Connect battery cables. (WP 0192) Lower operator platform assembly. (Volume 2, WP 0235)
0148-6
TM 5-3895-379-23-1
0149
FIELD MAINTENANCE ALTERNATOR TEST
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References WP 0148 Equipment Condition Engine off. (TM 5-3895-379-10) Equipment Condition (cont.) Drums chocked. (TM 5-3895-379-10) Right-side door assembly opened. (TM 5-3895-379-10)
TEST 1. 2. Place positive (+) lead of multimeter on alternator BAT terminal. Place negative (-) lead on ground terminal or frame of alternator. Place ammeter around positive output wire of alternator. Turn off all electrical accessories. Turn off fuel to engine. Crank engine for 30 seconds. Wait for two minutes to cool starting motor. If electrical system appears to operate correctly, crank engine again for 30 seconds.
NOTE
Cranking engine for 30 seconds partially discharges batteries to perform charging test. If battery has a low charge, do not perform this step. Jump start engine or charge battery before engine is started. 3. 4. Start engine and run at full throttle (TM 5-3895-379-10). Check output current of the alternator. Initial charging current should be equal to minimum full load current or greater than minimum full load current. Minimum full load current at 5000 rpm = 47 amps and at 1500 rpm = 13.5 amps. a. b. After approximately 10 minutes of operating engine at full throttle, output voltage of alternator should be 28.0 +/-1 volt for a 24-volt system. After 10 minutes of engine operation, charging current should decrease to approximately 10 amps. Actual length of time for charging current to decrease to 10 amps depends on battery charge, ambient temperature, and rpm of engine.
5.
Replace alternator (WP 0148) if voltage is below specification, decreases after matching specification or is consistently above specification after 10 minutes of operation.
END OF TASK
0149-1
TM 5-3895-379-23-1
0149
FOLLOW-ON MAINTENANCE 1. 2. Close right-side door assembly. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0149-2
TM 5-3895-379-23-1
0150
FIELD MAINTENANCE ALTERNATOR BRACKET REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Locknut (Volume 2, WP 0290, Table 1, Item 29) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 42 Equipment Condition Operator platform assembly raised. (Volume 2, WP 0235) Alternator removed. (WP 0148)
REMOVAL 1. 2. Remove three screws (Figure 1, Item 1), washers (Figure 1, Item 2), and alternator bracket (Figure 1, Item 3) from engine (Figure 1, Item 4) and bracket (Figure 1, Item 6). Remove two screws (Figure 1, Item 5) and bracket (Figure 1, Item 6) from engine (Figure 1, Item 4).
1 2
4 6 5
M0834SWR
Figure 1.
Alternator Bracket Removal.
0150-1
TM 5-3895-379-23-1
0150
REMOVAL - Continued 3. 4. Remove locknut (Figure 2, Item 4), washer (Figure 2, Item 3), screw (Figure 2, Item 7), washer (Figure 2, Item 3), and alternator strap (Figure 2, Item 1) from bracket (Figure 2, Item 2). Discard locknut. Remove three screws (Figure 2, Item 6) and bracket (Figure 2, Item 2) from engine (Figure 2, Item 5).
3 1 2
3 5 6 7
Figure 2. Alternator Bracket Removal. END OF TASK INSTALLATION 1. 2. Install bracket (Figure 3, Item 2) on engine (Figure 3, Item 5) with three screws (Figure 3, Item 6). Install alternator strap (Figure 3, Item 1) on bracket (Figure 3, Item 2) with washer (Figure 3, Item 3), screw (Figure 3, Item 7), washer (Figure 3, Item 3), and new locknut (Figure 3, Item 4).
M1065SWR
3 1 2
3 5 6 7
Figure 3. Alternator Bracket Installation.
M0835SWR
0150-2
TM 5-3895-379-23-1
0150
INSTALLATION - Continued 3. 4. Install bracket (Figure 4, Item 6) on engine (Figure 4, Item 4) with two screws (Figure 4, Item 5). Install alternator bracket (Figure 4, Item 3) on engine (Figure 4, Item 4) and bracket (Figure 4, Item 6) with three washers (Figure 4, Item 2) and screws (Figure 4, Item 1).
1 2
4 6 5
M0836SWR
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install alternator. (WP 0148)
Alternator Bracket Installation.
Lower operator platform assembly. (Volume 2, WP 0235)
0150-3/4 blank
TM 5-3895-379-23-1
0151
FIELD MAINTENANCE ALTERNATOR CIRCUIT BREAKER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 0-300 in-lb (Volume 2, WP 0289, Table 1, Item 41) Materials/Parts Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Washer, Lock (Volume 2, WP 0290, Table 1, Item 128) Qty: 2 Lockwasher (Volume 2, WP 0290, Table 1, Item 23) Qty: 2 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 52 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Left-side door assembly opened. (TM 5-3895-379-10)
0151-1
TM 5-3895-379-23-1
0151
REMOVAL
NOTE
Tag and mark wires prior to removal. 1. 2. 3. Position cable boots (Figure 1, Item 9) to expose two terminals (Figure 1, Item 6) and terminal (Figure 1, Item 5). Remove two screws (Figure 1, Item 8), lockwashers (Figure 1, Item 7), and terminals (Figure 1, Item 6) and terminal (Figure 1, Item 5) from circuit breaker assembly (Figure 1, Item 4). Discard lockwashers. Remove two screws (Figure 1, Item 1), lockwashers (Figure 1, Item 2), and circuit breaker assembly (Figure 1, Item 4) from air cleaner support assembly (Figure 1, Item 3). Discard lockwashers.
1 2 3 4
5 6 7
9 VIEW FROM BACK SIDE OF ALTERNATOR CIRCUIT BREAKER
M0837SWR
Figure 1. Alternator Circuit Breaker Removal. END OF TASK
0151-2
TM 5-3895-379-23-1
0151
INSTALLATION 1. 2. Install circuit breaker (Figure 2, Item 4) on air cleaner support assembly (Figure 2, Item 3) with two new lockwashers (Figure 2, Item 2) and screws (Figure 2, Item 1). Install two terminals (Figure 2, Item 6) and terminal (Figure 2, Item 5) on circuit breaker assembly (Figure 2, Item 4) with two new lockwashers (Figure 2, Item 7) and screws (Figure 2, Item 8). Tighten screws to 24-48 lb-in (3-5 Nm). Position cable boots (Figure 2, Item 9) to cover two terminals (Figure 2, Item 6) and terminal (Figure 2, Item 5).
1 2 3 4
3.
5 6 7
9 VIEW FROM BACK SIDE OF ALTERNATOR CIRCUIT BREAKER
M0838SWR
Figure 2. Alternator Circuit Breaker Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Close left-side door assembly. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0151-3/4 blank
TM 5-3895-379-23-1
0152
FIELD MAINTENANCE STARTER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Lockwasher (Volume 2, WP 0290, Table 1, Item 2) Qty: 3 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 46 and 47 Equipment Condition Operator platform assembly raised. (Volume 2, WP 0235) Muffler removed. (WP 0134) Battery cables disconnected. (WP 0192)
0152-1
TM 5-3895-379-23-1
0152
REMOVAL
NOTE
Tag and mark all wires prior to removal. Inspect all hoses, lines, and fittings for cracks, bends, nicks, dents, stripped threads, and cuts. Replace all damaged parts. 1. Loosen two clamps (Figure 1, Item 2) and remove hose (Figure 1, Item 3) from air cleaner assembly (Figure 1, Item 4) and turbocharger (Figure 1, Item 1).
VIEW FROM REAR OF AIR CLEANER ASSEMBLY 1
3 2 4
M0839SWR
Figure 1.
Starter Removal.
0152-2
TM 5-3895-379-23-1
0152
REMOVAL - Continued 2. 3. Pull back rubber cover (Figure 2, Item 4) from terminal (Figure 2, Item 3). Remove nut (Figure 2, Item 6), lockwasher (Figure 2, Item 1), and two cables (Figure 2, Items 2 and 5) from terminal (Figure 2, Item 3). Discard lockwasher.
3 2 1
6 5 4

M0840SWR
Figure 2.
Starter Removal.
0152-3
TM 5-3895-379-23-1
0152
REMOVAL - Continued 4. 5. Pull back rubber cover (Figure 3, Item 1) from terminal (Figure 3, Item 6). Remove nut (Figure 3, Item 3), washer (Figure 3, Item 2), cable (Figure 3, Item 4), and wire (Figure 3, Item 5) from terminal (Figure 3, Item 6).
1 2 3
4 6 5
M0841SWR
Figure 3.
Starter Removal.
0152-4
TM 5-3895-379-23-1
0152
REMOVAL - Continued
WARNING
CAUTION
Support weight of starter while wire is still attached to starter. Do not allow wire to be stretched or broken by weight of starter. Allowing wire to stretch or break will cause damage to equipment.
NOTE
Starter weighs 19 lb (8.6 kg). 6. 7. 8. Remove three screws (Figure 4, Item 6), washers (Figure 4, Item 5), cable (Figure 4, Item 4), and starter (Figure 4, Item 2) from flywheel housing (Figure 4, Item 3). Open cover (Figure 4, Item 8) on terminal (Figure 4, Item 7). Remove screw (Figure 4, Item 10), lockwasher (Figure 4, Item 9), and cable (Figure 4, Item 1) from terminal (Figure 4, Item 7). Discard lockwasher.
1 1
10 9
7 6 5
M0842SWR
Starter Removal.
0152-5
TM 5-3895-379-23-1
0152
INSTALLATION
WARNING
CAUTION
Support weight of starter while wire is still attached to starter. Do not allow wire to be stretched or broken by weight of starter. Allowing wire to stretch or break will cause damage to equipment.
NOTE
Starter weighs 19 lb (8.6 kg). 1. 2. 3. Install cable (Figure 5, Item 1) on terminal (Figure 5, Item 7) with new lockwasher (Figure 5, Item 9) and screw (Figure 5, Item 10). Close cover (Figure 5, Item 8) on terminal (Figure 5, Item 7). Install starter (Figure 5, Item 2) and cable (Figure 5, Item 4) on flywheel housing (Figure 5, Item 3) with three washers (Figure 5, Item 5) and screws (Figure 5, Item 6). Tighten screws to 33-47 lb-ft (45-64 Nm).
1 1
10 9
7 6 5
M0843SWR
Figure 5.
Starter Installation.
0152-6
TM 5-3895-379-23-1
0152
INSTALLATION - Continued 4. 5. Install wire (Figure 6, Item 5) and cable (Figure 6, Item 4) on terminal (Figure 6, Item 6) with washer (Figure 6, Item 2) and nut (Figure 6, Item 3). Tighten nut securely. Install rubber cover (Figure 6, Item 1) on terminal (Figure 6, Item 6).
1 2 3
4 6 5
M0844SWR
Figure 6.
0152-7
TM 5-3895-379-23-1
0152
INSTALLATION - Continued 6. 7. Install two cables (Figure 7, Items 2 and 5) on terminals (Figure 7, Item 3) with new lockwasher (Figure 7, Item 1) and nut (Figure 7, Item 3). Tighten nut securely. Install rubber cover (Figure 7, Item 4) on terminal (Figure 7, Item 3).
3 1 2
6 5 4

M0845SWR
Figure 7.
0152-8
TM 5-3895-379-23-1
0152
INSTALLATION - Continued 8. Install hose (Figure 8, Item 3) and two clamps (Figure 8, Item 2) on air cleaner assembly (Figure 8, Item 4) and turbocharger (Figure 8, Item 1). Tighten clamps securely.
VIEW FROM REAR OF AIR CLEANER ASSEMBLY 1
3 2 4
M0846SWR
Figure 8. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables. (WP 0192) Install muffler. (WP 0134)
Lower operator platform assembly. (Volume 2, WP 0235)
0152-9/10 blank
TM 5-3895-379-23-1
0153
FIELD MAINTENANCE STARTER RELAY SWITCH ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Strap, Tiedown, Electrical (Volume 2, WP 0288, Table 1, Item 67, 68, 69) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 45 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 and left-side door assemblies opened. (TM 5-3895-379-10)
0153-1
TM 5-3895-379-23-1
0153
REMOVAL
NOTE
Tag and mark all wires prior to removal. Remove electrical tiedown straps as required. 1. 2. Disconnect starter relay switch assembly connector (Figure 1, Item 5) from connector (Figure 1, Item 6). Remove two screws (Figure 1, Item 1), washers (Figure 1, Item 2), and starter relay switch assembly (Figure 1, Item 4) from frame assembly (Figure 1, Item 3).
3 2 1
4 6 5
M0847SWR
Figure 1. 3.
Starter Relay Switch Removal.
Position boot (Figure 2, Item 4) so that end of cable (Figure 2, Item 1) can be seen and remove two nuts (Figure 2, Item 6), washers (Figure 2, Item 5), and two cables from starter relay switch assembly (Figure 2, Item 2).
6 5
M0848SWR
Starter Relay Switch Removal.
0153-2
TM 5-3895-379-23-1
0153
INSTALLATION
NOTE
Install electrical tiedown straps as needed. 1. 2. Install two cables (Figure 3, Item 1) on starter relay switch assembly (Figure 3, Item 2) with two washers (Figure 3, Item 5) and nuts (Figure 3, Item 6). Reposition boot (Figure 3, Item 4) on end of cover cable (Figure 3, Item 1).
6 5
Figure 3.
M1077SWR
Starter Relay Switch Installation.
0153-3
TM 5-3895-379-23-1
0153
INSTALLATION - Continued 3. 4. Install starter relay switch assembly (Figure 4, Item 4) on frame assembly (Figure 4, Item 3) with two washers (Figure 4, Item 2) and screws (Figure 4, Item 1). Connect starter relay switch assembly connector (Figure 4, Item 5) to connector (Figure 4, Item 6).
3 2 1
4 6 5
M1076SWR
Figure 4. Starter Relay Switch Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Connect batteries. (TM 5-3895-379-10) Close right and left-side door assemblies. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0153-4
TM 5-3895-379-23-1
0154
FIELD MAINTENANCE MAIN RELAY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 50 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)
0154-1
TM 5-3895-379-23-1
0154
REMOVAL 1. 2. 3. Remove two screws (Figure 1, Item 1) and washers (Figure 1, Item 5) from operator station (Figure 1, Item 4). Remove seven screws (Figure 1, Item 1) and washers (Figure 1, Item 2) from operator station (Figure 1, Item 4). Lift panel assembly (Figure 1, Item 3) and pull away from operator station (Figure 1, Item 4).
1 2 1 2 3 4
5
M0849SWR
Figure 1. Main Relay Removal. 4. Disconnect main relay connector (Figure 2, Item 6) from connector (Figure 2, Item 7).
NOTE
Tag and mark all wires prior to removal. 5. 6. Remove two nuts (Figure 2, Item 3) and two wires (Figure 2, Items 1 and 2) from main relay (Figure 2, Item 5). Remove two nuts (Figure 2, Item 8), washers (Figure 2, Item 9), and main relay (Figure 2, Item 5) from operator station (Figure 2, Item 4).
0154-2
TM 5-3895-379-23-1
0154
REMOVAL - Continued
2 3
8 9 5 7 6 4
M0850SWR
Figure 2. END OF TASK INSTALLATION 1. 2. 3.
Main Relay Removal.
Install main relay (Figure 3, Item 5) on operator station (Figure 3, Item 4) with two washers (Figure 3, Item 9) and nuts (Figure 3, Item 8). Tighten nuts. Install two wires (Figure 3, Items 1 and 2) on main relay (Figure 3, Item 5) with two nuts (Figure 3, Item 3). Connect main relay connector (Figure 3, Item 6) with connector (Figure 3, Item 7).
2 3
8 9 5 7 6 4
M1082SWR
Figure 3.
Main Relay Installation.
0154-3
TM 5-3895-379-23-1
0154
INSTALLATION - Continued 4. Install panel assembly (Figure 4, Item 3) on operator station (Figure 4, Item 4) with two washers (Figure 4, Item 5), seven washers (Figure 4, Item 2), and nine screws (Figure 4, Item 1).
1 2 1 2 3 4
5
M0851SWR
Main Relay Installation.
0154-4
TM 5-3895-379-23-1
0155
FIELD MAINTENANCE RELAY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Locknut (Volume 2, WP 0290, Table 1, Item 114) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 49 and 50 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)
0155-1
TM 5-3895-379-23-1
0155
1 2 4
5
M0852SWR
Figure 1.
Relay Removal.
0155-2
TM 5-3895-379-23-1
0155
REMOVAL - Continued 4. Refer to the following tables when replacing relays. The relays may be positively identified by their attached wires. Table 1. Relay Functional Light (Figure 2, Item 8) Hydraulic Temperature (Figure 2, Item 9) Warning Light (Figure 2, Item 10) Coolant Temperature (Figure 2, Item 11) Position 1 123-WH Wire and Relay Connections (CB534B). Position 2 200-BK Position 3 C930-BR Position 4 C938-BR Position 5 C938-BR
428-OR
123-WH
200-BK
226-BK
C931-OR
200-BK
200-BK
C930-BR
406-PU
123-WH
200-BK
211-BK
Engine Oil Pressure 405-GY (Figure 2, Item 12) Hydraulic Charge (Figure 2, Item 1) RR Intermittent (Figure 2, Item 7) Front Intermittent (Figure 2, Item 6) Neutral Start #1 (Figure 2, Item 2) Neutral Start #2 (Figure 2, Item 3) Brake #1 (Figure 2, Item 5) Brake #2 (Figure 2, Item 4) 461-OR
123-WH
200-BK
200-BK
123-WH
200-BK
276-BK
C936-GY
C937-WH
C923-OR
C936-GY
C935-PU
C937-WH
C922-BK
C935-GY
306-GR
200-BK
307-OR
300-YL
155-PK
330-YL
C720-PU
200-BK
765-BR
419-YL
777-PU
200-BK
C720-PU
419-YL
419-YL
200-BK
Legend: BK=Black BR=Brown GR=Green GY=Gray OR=Orange PK=Pink PU=Purple WH=White YL=Yellow
0155-3
TM 5-3895-379-23-1
0155
REMOVAL - Continued
2 3
5 6 7
12 11
10 9 8
Figure 2. Relay Removal.
M0853SWR
0155-4
TM 5-3895-379-23-1
0155
REMOVAL - Continued
Table 2. Relay Functional Light (Figure 3, Item 7) Hydraulic Temperature (Figure 3, Item 8) Warning Light (Figure 3, Item 9) Coolant Temperature (Figure 3, Item 10) Position 1 123-WH
Wire and Relay Connections (CB534C). Position 2 200-BK Position 3 C930-BR Position 4 C938-BR Position 5 C938-BR
428-OR
123-WH
200-BK
226-BK
C931-OR
200-BK
200-BK
C930-BR
406-PU
123-WH
200-BK
211-BK
Engine Oil Pressure 405-GY (Figure 3, Item 11) Hydraulic Charge (Figure 3, Item 1) Intermittent (Figure 3, Item 6) Neutral Start #1 (Figure 3, Item 2) Neutral Start #2 (Figure 3, Item 3) Brake #1 (Figure 3, Item 5) Brake #2 (Figure 3, Item 4) 465-OR
123-WH
200-BK
220-BK
123-WH
200-BK
276-BK
C935-PU
C937-WH
C936-GY
C935-PU
306-GR
200-BK
307-OR
300-YL
155-PK
330-YL
C720-PU
200-BK
765-BR
419-YL
777-PU
200-BK
C720-PU
419-YL
419-YL
200-BK
Legend: BK=Black BR=Brown GR=Green GY=Gray OR=Orange PK=Pink PU=Purple WH=White YL=Yellow
0155-5
TM 5-3895-379-23-1
0155
REMOVAL - Continued
2 3
11 10
9 8 7
Figure 3. Relay Removal.
M0854SWR
0155-6
TM 5-3895-379-23-1
0155
REMOVAL - Continued 5. Remove connector (Figure 4, Item 6) from relay (Figure 4, Item 4).
NOTE
There are two methods of removing the relays. Perform Step (5) or Step (6) as the relay requires. 6. 7. Remove screw (Figure 4, Item 5), washer (Figure 4, Item 3), and relay (Figure 4, Item 4) from the panel assembly (Figure 4, Item 2). Remove locknut (Figure 4, Item 1), washer (Figure 4, Item 8), and relay (Figure 4, Item 4) from operator station (Figure 4, Item 7). Discard locknut.
1 2 3 4 8 5 6 6 4 7
M0855SWR
Relay Removal.
0155-7
TM 5-3895-379-23-1
0155
INSTALLATION
NOTE
There are two methods of installing relays. Perform Step (1) or Step (2) as relay requires. 1. 2. 3. Install relay (Figure 5, Item 4) on operator station (Figure 5, Item 7) with washer (Figure 5, Item 8) and new locknut (Figure 5, Item 1). Install relay (Figure 5, Item 4) on panel assembly (Figure 5, Item 2) with washer (Figure 5, Item 3) and screw (Figure 5, Item 5). Install connector (Figure 5, Item 6) on relay (Figure 5, Item 4).
1 2 3 4 8 5 6 6 4 7
M1173SWR
Figure 5.
Relay Installation.
0155-8
TM 5-3895-379-23-1
0155
1 2 4
5
M0856SWR
Relay Installation.
0155-9/10 blank
TM 5-3895-379-23-1
0156
FIELD MAINTENANCE PARKING BRAKE SWITCH REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 49 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)
0156-1
TM 5-3895-379-23-1
0156
1 1 2 3 2 4
5
M0857SWR
Figure 1. Parking Brake Switch Removal.
0156-2
TM 5-3895-379-23-1
0156
REMOVAL - Continued 4. 5. 6. Remove cap (Figure 2, Item 1) by turning cap counterclockwise. Remove nut (Figure 2, Item 2), parking brake switch (Figure 2, Item 4), and seal (Figure 2, Item 5) from panel assembly (Figure 2, Item 6). Push lamp (Figure 2, Item 3) down and counterclockwise and remove lamp from parking brake switch (Figure 2, Item 4).
REMOVE 1 INSTALL 2 3
VIEW FROM DRIVERS SEAT

M0858SWR
Figure 2.
Parking Brake Switch Removal.
0156-3
TM 5-3895-379-23-1
0156
REMOVAL - Continued
NOTE
Tag and mark all wires prior to removal. 7. 8. Loosen two screw assemblies (Figure 3, Item 1) and remove two wires (Figure 3, Items 3 and 4) from parking brake switch (Figure 3, Item 5). Loosen four screw assemblies (Figure 3, Item 1) and remove four wires (Figure 3, Items 2, 6, 7, and 8) from parking brake switch (Figure 3, Item 5).
3 2 1 1
8 4 5
6
M0859SWR
Figure 3. Parking Brake Switch Removal. END OF TASK INSTALLATION 1. 2. Install four wires (Figure 4, Items 2, 6, 7, and 8) in parking brake switch (Figure 4, Item 5) and tighten four screw assemblies (Figure 4, Item 1). Install two wires (Figure 4, Items 3 and 4) in parking brake switch (Figure 4, Item 5) and tighten two screws assemblies (Figure 4, Item 1).
0156-4
TM 5-3895-379-23-1
0156
3 2 1 1
8 4 5
6
M1162SWR
Figure 4.
Parking Brake Switch Installation.
NOTE
Tab of switch must fit in notch in panel assembly to properly align switch. 3. 4. 5. Install parking brake switch (Figure 5, Item 4) and seal (Figure 5, Item 5) in panel assembly (Figure 5, Item 6) with nut (Figure 5, Item 2). Tighten nut. Push lamp (Figure 5, Item 3) down, turn clockwise and install lamp in parking brake switch (Figure 5, Item 4). Install cap (Figure 5, Item 1) on parking brake switch (Figure 5, Item 4) by turning clockwise.
REMOVE 1 INSTALL 2 3

M1161SWR
Figure 5.
Parking Brake Switch Installation.
0156-5
TM 5-3895-379-23-1
0156
1 1 2 3 2 4
5
M0860SWR
Figure 6. Parking Brake Switch Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Close right-side door assembly. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0156-6
TM 5-3895-379-23-1
0157
FIELD MAINTENANCE WATER SPRAY SWITCH REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Lockwasher (Volume 2, WP 0290, Table 1, Item 17) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 49 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)
1 2 4
5
M0861SWR
Figure 1.
Water Spray Switch Removal.
0157-1
TM 5-3895-379-23-1
0157
REMOVAL - Continued 4. Remove nut (Figure 2, Item 1), ring (Figure 2, Item 2), water spray switch (Figure 2, Item 4), and lockwasher (Figure 2, Item 5) from panel assembly (Figure 2, Item 3). Discard lockwasher.
1 2 3
4 VIEW FROM DRIVERS SEAT 5

M0862SWR
Figure 2. Water Spray Switch Removal.
NOTE
Tag and mark all wires prior to removal. 5. 6. Remove three screws (Figure 3, Item 3) and wires (Figure 3, Items 1, 2, and 8) from water spray switch (Figure 3, Item 7). Remove three screws (Figure 3, Item 3) and wires (Figure 3, Items 4, 5, and 6) from water spray switch (Figure 3, Item 7).
0157-2
TM 5-3895-379-23-1
0157
REMOVAL - Continued
1
7 6
2 5 3 4
M0863SWR
Water Spray Switch Removal.
Install three wires (Figure 4, Items 4, 5, and 6) on water spray switch (Figure 4, Item 7) with three screws (Figure 4, Item 3). Install three wires (Figure 4, Items 1, 2, and 8) on water spray switch (Figure 4, Item 7) with three screws (Figure 4, Item 3).
1
7 6
2 5 3 4
M1245SWR
Figure 4.
Water Spray Switch Installation.
0157-3
TM 5-3895-379-23-1
0157
NOTE
Tab of ring (Figure 5, Item 7) must fit in notch (Figure 5, Item 6) in panel assembly to properly align switch in panel assembly. 3. Install water spray switch (Figure 5, Item 4) on panel assembly (Figure 5, Item 3) with new lockwasher (Figure 5, Item 5), ring (Figure 5, Item 2), and nut (Figure 5, Item 1).
1 2 3
4 5
M1244SWR
Figure 5. Water Spray Switch Installation.
0157-4
TM 5-3895-379-23-1
0157
1 2 4
5
M0864SWR
Water Spray Switch Installation.
0157-5/6 blank
TM 5-3895-379-23-1
0158
FIELD MAINTENANCE DRUM SELECT SWITCH REPLACEMENT
1 2 4
5
M0865SWR
Figure 1.
Drum Select Switch Removal.
0158-1
TM 5-3895-379-23-1
0158
REMOVAL - Continued 4. Remove nut (Figure 2, Item 2), lockwasher (Figure 2, Item 1), drum select switch (Figure 2, Item 4), and ring (Figure 2, Item 5) from panel assembly (Figure 2, Item 3). Discard lockwasher.
2 3
4 5

M0866SWR
Figure 2. Drum Select Switch Removal.
NOTE
Tag and mark all wires prior to removal. 5. 6. Remove three screws (Figure 3, Item 3) and wires (Figure 3, Items 1, 2, and 8) from drum select switch (Figure 3, Item 7). Remove three screws (Figure 3, Item 3) and wires (Figure 3, Items 4, 5, and 6) from drum select switch (Figure 3, Item 7). Discard screw assemblies.
0158-2
TM 5-3895-379-23-1
0158
REMOVAL - Continued
1
7 6
2 5 3 4
M0867SWR
Drum Select Switch Removal.
Install three wires (Figure 4, Items 4, 5, and 6) on drum select switch (Figure 4, Item 7) with three screws (Figure 4, Item 3). Install three wires (Figure 4, Items 1, 2, and 8) on drum select switch (Figure 4, Item 7) with three screws (Figure 4, Item 3).
1
7 6
2 5 3 4
M1306SWR
Figure 4.
Drum Select Switch Installation.
0158-3
TM 5-3895-379-23-1
0158
NOTE
Tab of ring (Figure 5, Item 7) fits in notch (Figure 5, Item 6) of panel assembly to properly align drum select switch in panel assembly. 3. Install drum select switch (Figure 5, Item 4) on panel assembly (Figure 5, Item 3) with ring (Figure 5, Item 5), new lockwasher (Figure 5, Item 1), and nut (Figure 5, Item 2).
2 3
4 5

M1090SWR
Figure 5.
0158-4
TM 5-3895-379-23-1
0158
1 2 4
5
M0868SWR
0158-5/6 blank
TM 5-3895-379-23-1
0159
FIELD MAINTENANCE VIBRATION CONTROL SWITCH REPLACEMENT
0159-1
TM 5-3895-379-23-1
0159
1 2 4
5
M0869SWR
Figure 1. 4.
Vibration Control Switch Removal.
Remove nut (Figure 2, Item 1), lockwasher (Figure 2, Item 2), vibration control switch (Figure 2, Item 5), and ring (Figure 2, Item 4) from panel assembly (Figure 2, Item 3). Discard lockwasher.
0159-2
TM 5-3895-379-23-1
0159
REMOVAL - Continued
1 2
4 5

M0870SWR
Figure 2.
NOTE
Tag and mark all wires prior to removal. 5. Remove three screws (Figure 3, Item 1) and wires (Figure 3, Items 2, 3, and 5) from vibration control switch (Figure 3, Item 4).
2
M0871SWR
0159-3
TM 5-3895-379-23-1
0159
INSTALLATION 1. Install three wires (Figure 4, Items 2, 3, and 5) on vibration control switch (Figure 4, Item 4) with three screws (Figure 4, Item 1).
2
M1221SWR
Figure 4.
Vibration Control Switch Installation.
NOTE
Tab of ring (Figure 5, Item 7) fits in notch (Figure 5, Item 6) of panel assembly to properly align vibration control switch in panel assembly. 2. Install vibration control switch (Figure 5, Item 5) on panel assembly (Figure 5, Item 3) with ring (Figure 5, Item 4), new lockwasher (Figure 5, Item 2), and nut (Figure 5, Item 1).
1 2
4 5

M1304SWR
Figure 5.
0159-4
TM 5-3895-379-23-1
0159
1 2 4
5
M0872SWR
0159-5/6 blank
TM 5-3895-379-23-1
0160
FIELD MAINTENANCE AMPLITUDE SELECT SWITCH REPLACEMENT
0160-1
TM 5-3895-379-23-1
0160
1 2 4
5
M0873SWR
Figure 1. Amplitude Select Switch Removal. 4. Remove nut (Figure 2, Item 1), lockwasher (Figure 2, Item 2), amplitude select switch (Figure 2, Item 5), and ring (Figure 2, Item 4) from panel assembly (Figure 2, Item 3). Discard lockwasher.
0160-2
TM 5-3895-379-23-1
0160
REMOVAL - Continued
1 2
4 5

M0874SWR
Figure 2.
Amplitude Select Switch Removal.
NOTE
Tag and mark all wires prior to removal. 5. Remove three screws (Figure 3, Item 1) and wires (Figure 3, Items 2, 3, and 5) from amplitude select switch (Figure 3, Item 4).
2
M0875SWR
Amplitude Select Switch Removal.
0160-3
TM 5-3895-379-23-1
0160
INSTALLATION 1. Install three wires (Figure 4, Items 2, 3, and 5) on amplitude select switch (Figure 4, Item 4) with three screws (Figure 4, Item 1).
2
M1107SWR
Figure 4.
Amplitude Select Switch Installation.
NOTE
Tag of ring (Figure 5, Item 7) fits in notch (Figure 5, Item 6) of panel assembly to properly align amplitude select switch in panel assembly. 2. Install amplitude select switch (Figure 5, Item 5) on panel assembly (Figure 5, Item 3) with ring (Figure 5, Item 4), new lockwasher (Figure 5, Item 2), and nut (Figure 5, Item 1).
1 2
4 5

M1056SWR
Figure 5.
Amplitude Select Switch Installation.
0160-4
TM 5-3895-379-23-1
0160
1 2 4
5
M0876SWR
Figure 6. Amplitude Select Switch Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Close right-side door assembly. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0160-5/6 blank
TM 5-3895-379-23-1
0161
FIELD MAINTENANCE PROPEL SPEED RANGE SWITCH REPLACEMENT
0161-1
TM 5-3895-379-23-1
0161
1 2 4
5
M0877SWR
Figure 1.
Propel Speed Range Switch Removal.
0161-2
TM 5-3895-379-23-1
0161
REMOVAL - Continued 4. Remove nut (Figure 2, Item 1), lockwasher (Figure 2, Item 2), propel speed range switch (Figure 2, Item 4), and ring (Figure 2, Item 5) from panel assembly (Figure 2, Item 3). Discard lockwasher.
4
M0878SWR
Figure 2.
0161-3
TM 5-3895-379-23-1
0161
REMOVAL - Continued
NOTE
Tag and mark all wires prior to removal. 5. Remove two screws (Figure 3, Item 1), lockwashers (Figure 3, Item 5), and wires (Figure 3, Items 2 and 4) from propel speed range switch (Figure 3, Item 3). Discard lockwashers.
1
5 4
2 3
M0879SWR
Figure 3. END OF TASK INSTALLATION 1.
Install two wires (Figure 4, Items 2 and 4) on propel speed range switch (Figure 4, Item 3) with new lockwashers (Figure 4, Item 5) and screws (Figure 4, Item 1).
1
5 4
2 3
M1227SWR
Figure 4. Propel Speed Range Switch Installation.
0161-4
TM 5-3895-379-23-1
0161
NOTE
Tab of ring (Figure 5, Item 5) fits in notch (Figure 5, Item 4) of panel assembly to properly align propel speed range switch in panel assembly. 2. Install propel speed range switch (Figure 5, Item 6) on panel assembly (Figure 5, Item 3) with ring (Figure 5, Item 7), new lockwasher (Figure 5, Item 2), and nut (Figure 5, Item 1).
5 4 VIEW FROM DRIVERS SEAT
6
M1083SWR
Figure 5. Propel Speed Range Switch Installation.
0161-5
TM 5-3895-379-23-1
0161
1 2 4
5
M0880SWR
Figure 6. Propel Speed Range Switch Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Close right-side door assembly. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0161-6
TM 5-3895-379-23-1
0162
FIELD MAINTENANCE WORK LIGHT CONTROL SWITCH REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Strap, Tiedown, Electrical (Volume 2, WP 0288, Table 1, Item 67, 68, 69) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Lockwasher (Volume 2, WP 0290, Table 1, Item 124) Qty: 2 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 51 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)
1 2 1 2 3 4
5
M0881SWR
Figure 1. Work Light Control Switch Removal.
0162-1
TM 5-3895-379-23-1
0162
REMOVAL - Continued
NOTE
Tag and mark all wires prior to removal. 4. 5. 6. 7. Remove screw (Figure 2, Item 10), lockwasher (Figure 2, Item 11), and wire (Figure 2, Item 9) from light switch (Figure 2, Item 6). Discard lockwasher. Loosen three screws (Figure 2, Item 8) and remove three wires (Figure 2, Item 7) from light switch (Figure 2, Item 6). Remove screw (Figure 2, Item 1) and knob (Figure 2, Item 2) from light switch (Figure 2, Item 6). Remove nut (Figure 2, Item 3), light switch (Figure 2, Item 6), and lockwasher (Figure 2, Item 5) from panel assembly (Figure 2, Item 4). Discard lockwasher.
1 2 3 4
5 6 7 8 9 11 VIEW FROM DRIVERS SEAT 10

M0882SWR
Figure 2. Work Light Control Switch Removal. END OF TASK
0162-2
TM 5-3895-379-23-1
0162
INSTALLATION
NOTE
Post on light switch is positioned in notch of panel assembly to properly align light switch on panel assembly. 1. Install light switch (Figure 3, Item 6) on panel assembly (Figure 3, Item 4) with new lockwasher (Figure 3, Item 5) and nut (Figure 3, Item 3). Tighten nut.
NOTE
Knob indicator is positioned on switch to point at lights selection icons. To find correct position, turn switch to full-right position and position indicator to point toward icon furthest to the right. 2. 3. 4. Install knob (Figure 3, Item 2) on light switch (Figure 3, Item 6) with screw (Figure 3, Item 1). Tighten screw. Install three wires (Figure 3, Item 7) on light switch (Figure 3, Item 6) and tighten three screws (Figure 3, Item 8). Install wire (Figure 3, Item 9) on light switch (Figure 3, Item 6) with screw (Figure 3, Item 10) and new lockwasher (Figure 3, Item 11).
1 2 3 4
5 6 7 8 9 11 VIEW FROM DRIVERS SEAT 10

M1250SWR
Figure 3. Work Light Control Switch Installation.
0162-3
TM 5-3895-379-23-1
0162
1 2 1 2 3 4
5
M0883SWR
Figure 4. Work Light Control Switch Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Close right-side door assembly. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0162-4
TM 5-3895-379-23-1
0163
FIELD MAINTENANCE INTERMITTENT WATER SPRAY TIMER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Locknut (Volume 2, WP 0290, Table 1, Item 114) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 50 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)
0163-1
TM 5-3895-379-23-1
0163
1 2 1 2 3 4
5
M0884SWR
Figure 1.
Intermittent Water Spray Timer Removal.
0163-2
TM 5-3895-379-23-1
0163
REMOVAL - Continued
NOTE
Tag and mark wires prior to removal. 4. 5. Remove three wires (Figure 2, Items 1, 2, and 3) from timer (Figure 2, Item 5). Remove locknut (Figure 2, Item 6), washer (Figure 2, Item 7), and timer (Figure 2, Item 5) from operator station (Figure 2, Item 4). Discard locknut.
1 2 5 6 7 3

Figure 2. END OF TASK Intermittent Water Spray Timer Removal.
M0885SWR
0163-3
TM 5-3895-379-23-1
0163
INSTALLATION 1. 2. Install timer (Figure 3, Item 5) on operator station (Figure 3, Item 4) with washer (Figure 3, Item 7) and new locknut (Figure 3, Item 6). Tighten locknut. Install three wires (Figure 3, Items 1, 2, and 3) on timer (Figure 3, Item 5).
1 2 5 6 7 3

Figure 3. 3. Intermittent Water Spray Timer Installation.
M1242SWR
Install panel assembly (Figure 4, Item 3) on operator station (Figure 4, Item 4) with two washers (Figure 4, Item 5), seven washers (Figure 4, Item 2), and nine screws (Figure 4, Item 1).
1 2 1 2 3 4
5
M0886SWR
Intermittent Water Spray Timer Installation.
0163-4
TM 5-3895-379-23-1
0163
0163-5/6 blank
TM 5-3895-379-23-1
0164
FIELD MAINTENANCE FUSE AND FUSE HOLDER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Solder Tin Alloy (WI) (Volume 2, WP 0288, Table 1, Item 66) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 48 and 103 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)
REMOVAL
NOTE
All fuse and fuse holders are replaced the same way. One fuse and fuse holder is shown. 1. 2. Remove fuse holder assembly cap (Figure 1, Item 1) from fuse holder assembly (Figure 1, Item 4). Remove fuse (Figure 1, Item 3) and seal (Figure 1, Item 2) from fuse holder assembly cap (Figure 1, Item 1). Discard seal.
2 3
STEERING WHEEL SHOWN REMOVED FOR CLARITY

Figure 1. Fuse and Fuse Holder Removal.
M0887SWR
0164-1
TM 5-3895-379-23-1
0164
REMOVAL - Continued 3. 4. 5. Remove two shoulder screws (Figure 2, Item 1), washers (Figure 2, Item 2), and vandal guard (Figure 2, Item 3) from instrument box assembly (Figure 2, Item 7). Remove three screws (Figure 2, Item 6) and washers (Figure 2, Item 5) from operator station (Figure 2, Item 4). Lift and tilt back instrument box assembly (Figure 2, Item 7) to gain access to back of instrument box assembly.
3 2 1
6 5 4
M0888SWR
Figure 2. Fuse and Fuse Holder Removal.
NOTE
Tag and mark all wires prior to removal. 6. 7. 8. Cut two wires (Figure 3, Item 2) and remove from fuse holder assembly (Figure 3, Item 1). Remove nut (Figure 3, Item 4) from fuse holder assembly (Figure 3, Item 1). Remove fuse holder assembly (Figure 3, Item 1) and seal (Figure 3, Item 5) from instrument box assembly (Figure 3, Item 3). Discard seal.
0164-2
TM 5-3895-379-23-1
0164
REMOVAL - Continued
1
5 2 3 4
M0889SWR
Figure 3. END OF TASK INSTALLATION 1. 2. 3.
Fuse and Fuse Holder Removal.
Install new seal (Figure 4, Item 5) on fuse holder assembly (Figure 4, Item 1). Install fuse holder assembly (Figure 4, Item 1) on instrument box assembly (Figure 4, Item 3) with nut (Figure 4, Item 4). Solder two wires (Figure 4, Item 2) on fuse holder assembly (Figure 4, Item 1).
1
5 2 3 4
M1293SWR
Figure 4.
Fuse and Fuse Holder Installation.
0164-3
TM 5-3895-379-23-1
0164
INSTALLATION - Continued 4. 5. Install instrument box assembly (Figure 5, Item 7) on operator station (Figure 5, Item 4) with three washers (Figure 5, Item 5) and screws (Figure 5, Item 6). Install vandal guard (Figure 5, Item 3) on instrument box assembly (Figure 5, Item 7) with two washers (Figure 5, Item 2) and shoulder screws (Figure 5, Item 1).
3 2 1
6 5 4
M1086SWR
Figure 5. Fuse and Fuse Holder Installation.
0164-4
TM 5-3895-379-23-1
0164
INSTALLATION - Continued 6. 7. Install new seal (Figure 6, Item 2) and fuse (Figure 6, Item 3) in fuse holder assembly cap (Figure 6, Item 1). Install fuse holder assembly cap (Figure 6, Item 1) on fuse holder assembly (Figure 6, Item 4).
2 3

Figure 6. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Close right-side door assembly. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10) Fuse and Fuse Holder Installation.
M0890SWR
0164-5/6 blank
TM 5-3895-379-23-1
0165
FIELD MAINTENANCE STARTING AID SWITCH REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Lockwasher (Volume 2, WP 0290, Table 1, Item 9) Qty: 2 Lockwasher (Volume 2, WP 0290, Table 1, Item 17) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 48 and 103 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)
0165-1
TM 5-3895-379-23-1
0165
REMOVAL 1. 2. 3. 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). Remove three screws (Figure 1, Item 5) and washers (Figure 1, Item 6) from operator station (Figure 1, Item 7). Lift and tilt back instrument box assembly (Figure 1, Item 4) to gain access to back of instrument box assembly.
3 2 1
7 6 5
4
M0891SWR
Figure 1. Starting Aid Switch Removal.
0165-2
TM 5-3895-379-23-1
0165
REMOVAL - Continued
NOTE
Tag and mark all wires prior to removal. 4. 5. 6. 7. Remove two screws (Figure 2, Item 1), wires (Figure 2, Item 2), and lockwashers (Figure 2, Item 3) from starting aid switch (Figure 2, Item 8). Discard lockwasher. Remove nut (Figure 2, Item 4) and lockwasher (Figure 2, Item 5) from starting aid switch (Figure 2, Item 8). Discard lockwasher. Remove starting aid switch (Figure 2, Item 8) and ring (Figure 2, Item 7) from instrument box assembly (Figure 2, Item 6). Remove locking ring (Figure 2, Item 7) from starting aid switch (Figure 2, Item 8).
4 1 2 3 5
6 2 8 7
8
M0892SWR
Starting Aid Switch Removal.
0165-3
TM 5-3895-379-23-1
0165
INSTALLATION
NOTE
Tab of ring (Figure 3, Item 7) fits in notch (Figure 3, Item 6) of instrument box assembly to properly align starting aid switch. 1. 2. 3. 4. Position ring (Figure 3, Item 9) on starting aid switch (Figure 3, Item 8). Position ring (Figure 3, Item 9) and starting aid switch (Figure 3, Item 8) on instrument box assembly (Figure 3, Item 10). Install new lockwasher (Figure 3, Item 4) and nut (Figure 3, Item 5) on starting aid switch (Figure 3, Item 8). Install two new lockwashers (Figure 3, Item 3) and wires (Figure 3, Item 2) on starting aid switch (Figure 3, Item 8) with screws (Figure 3, Item 1).
5 4 1 2 3 6
7 10 2 8 9
8
M1283SWR
Figure 3. Starting Aid Switch Installation.
0165-4
TM 5-3895-379-23-1
0165
3 2 1
7 6 5
4
M0893SWR
Starting Aid Switch Installation.
0165-5/6 blank
TM 5-3895-379-23-1
0166
FIELD MAINTENANCE ENGINE START SWITCH REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Lockwasher (Volume 2, WP 0290, Table 1, Item 124) Qty: 3 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 48 and 103 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)
0166-1
TM 5-3895-379-23-1
0166
3 2 1
7 6 5
4
M0894SWR
Figure 1. Engine Start Switch Removal. 4. 5. Remove nut (Figure 2, Item 1) from lock assembly (Figure 2, Item 3). Remove lock assembly (Figure 2, Item 3) from instrument box assembly (Figure 2, Item 2).
0166-2
TM 5-3895-379-23-1
0166
REMOVAL - Continued
2 3

Figure 2. Engine Start Switch Removal.
M0895SWR
NOTE
Tag and mark all wires prior to removal. 6. 7. 8. Remove screw (Figure 3, Item 6), wire (Figure 3, Item 7), and lockwasher (Figure 3, Item 5) from START terminal (Figure 3, Item 4). Discard lockwasher. Remove screw (Figure 3, Item 1), wire (Figure 3, Item 12), and lockwasher (Figure 3, Item 2) from BATTERY terminal (Figure 3, Item 3). Discard lockwasher. Remove screw (Figure 3, Item 11), wire (Figure 3, Item 10), and lockwasher (Figure 3, Item 9) from RELAY terminal (Figure 3, Item 8). Discard lockwasher.
4 6 5
2 3
7 8 9 12 11 10
M0896SWR
Engine Start Switch Removal.
0166-3
TM 5-3895-379-23-1
0166
INSTALLATION 1. 2. 3. Install new lockwasher (Figure 4, Item 9) and wire (Figure 4, Item 10) on RELAY terminal (Figure 4, Item 8) with screw (Figure 4, Item 11). Install new lockwasher (Figure 4, Item 2) and wire (Figure 4, Item 12) on BATTERY terminal (Figure 4, Item 3) with screw (Figure 4, Item 1). Install new lockwasher (Figure 4, Item 5) and wire (Figure 4, Item 7) on START terminal (Figure 4, Item 4) with screw (Figure 4, Item 6).
4 6 5
2 3
7 8 9 12
Figure 4.
11 10
M1224SWR
Engine Start Switch Installation.
NOTE
Tab of starter switch fits in notch of instrument box assembly to properly align start switch in instrument box assembly. 4. 5. Position lock assembly (Figure 5, Item 3) in instrument box assembly (Figure 5, Item 2). Install nut (Figure 5, Item 1) on lock assembly (Figure 5, Item 3).
0166-4
TM 5-3895-379-23-1
0166
2 3

Figure 5. 6. 7. Engine Start Switch Installation.
M1223SWR
Install instrument box assembly (Figure 6, Item 4) on operator station (Figure 6, Item 7) with three washers (Figure 6, Item 6) and screws (Figure 6, Item 5). Install vandal guard (Figure 6, Item 3) on instrument box assembly (Figure 6, Item 4) with two washers (Figure 6, Item 2) and shoulder screws (Figure 6, Item 1).
3 2 1
7 6 5
4
M0897SWR
Engine Start Switch Installation.
0166-5
TM 5-3895-379-23-1
0166
0166-6
TM 5-3895-379-23-1
0167
FIELD MAINTENANCE VIBRATION PUSH SWITCH REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Gasket (Volume 2, WP 0290, Table 1, Item 5) Qty: 2 Packing, Preformed (Volume 2, WP 0290, Table 1, Item 93) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 78 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)
0167-1
TM 5-3895-379-23-1
0167
REMOVAL 1. Remove retainer ring (Figure 1, Item 1) and cap (Figure 1, Item 2) from grip housing (Figure 1, Items 3 and 5).
CAUTION
Do not turn handle more than one full turn. Handle cannot be removed by unscrewing and should not be forced or turned more than needed to allow access to screws and nuts. 2. Loosen grip housings (Figure 1, Items 3 and 5) on handle pipe (Figure 1, Item 4) by turning grip housings counterclockwise not more than one full turn.
1 2
3 5
M0898SWR
Figure 1. Vibration Push Switch Removal.
0167-2
TM 5-3895-379-23-1
0167
REMOVAL - Continued
NOTE
Nuts are small and easily lost. Take extra care to not lose nuts. Nuts may stay with grip housing. 3. 4. 5. 6. 7. Remove two screws (Figure 2, Item 4), four screws (Figure 2, Item 6), and six nuts (Figure 2, Item 10) from grip housings (Figure 2, Items 9 and 14). Remove two grip housings (Figure 2, Items 9 and 14) from handle pipe (Figure 2, Item 7) and vibration push switch (Figure 2, Item 3). Remove two gaskets (Figure 2, Item 5) from grip housing (Figure 2, Item 14). Discard gaskets. Remove two screws (Figure 2, Item 11) and wires (Figure 2, Item 12) from vibration push switch (Figure 2, Item 3). Remove nut (Figure 2, Item 13) and preformed packing (Figure 2, Item 7) from handle pipe (Figure 2, Item 8). Discard preformed packing.
1 2 3 4
11 10 12 5 13 14 5
6 7 10 9 8
M0899SWR
Vibration Push Switch Removal.
0167-3
TM 5-3895-379-23-1
0167
INSTALLATION 1. 2. 3. Install new preformed packing (Figure 3, Item 7) and nut (Figure 3, Item 13) on handle pipe (Figure 3, Item 8). Turn nut onto handle pipe until top of nut is flush with top of handle pipe. Install two wires (Figure 3, Item 12) on vibration push switch (Figure 3, Item 3) with two screws (Figure 3, Item 4). Install two new gaskets (Figure 3, Item 5) in grip housing (Figure 3, Item 14).
NOTE
Grip housings will not fit together if any threads of handle pipe are showing on top side of nut while nut is installed. Mate flat sides of nut with cavity on grip housing. 4. 5. 6. Install grip housing (Figure 3, Item 14) on handle pipe (Figure 3, Item 8), nut (Figure 3, Item 13), and new preformed packing (Figure 3, Item 7). Install vibration push switch (Figure 3, Item 3) in grip housing (Figure 3, Item 14). Install grip housing (Figure 3, Item 9) on grip housing (Figure 3, Item 14) with two screws (Figure 3, Item 4), four screws (Figure 3, Item 6), and six nuts (Figure 3, Item 10).
1 2 3 4
11 10 12 5 13 14 5
6 7 10 9 8
M1228SWR
Figure 3.
Vibration Push Switch Installation.
0167-4
TM 5-3895-379-23-1
0167
INSTALLATION - Continued 7. 8. Tighten grip housings (Figure 4, Items 3 and 5) on handle pipe (Figure 4, Item 4) by turning grip housings to right until snug. Do not over-tighten. Install cap (Figure 4, Item 2) and retaining ring (Figure 4, Item 1) on grip housings (Figure 4, Items 3 and 5).
1 2
3 5
M0900SWR
Vibration Push Switch Installation.
0167-5/6 blank
TM 5-3895-379-23-1
0168
FIELD MAINTENANCE FUEL LEVEL GAUGE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Solder Tin Alloy (WI) (Volume 2, WP 0288, Table 1, Item 66) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Lockwasher (Volume 2, WP 0290, Table 1, Item 124) Qty: 2 Lockwasher (Volume 2, WP 0290, Table 1, Item 78) Qty: 3 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 48 and 103 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)
0168-1
TM 5-3895-379-23-1
0168
3 2 1
7 6 5
4
M0901SWR
Figure 1. Fuel Level Gauge Removal. 4. 5. 6. 7. Pull light fixture (Figure 2, Item 6) and remove light fixture from fuel level gauge (Figure 2, Item 1). Remove retainer clip (Figure 2, Item 7) from light fixture (Figure 2, Item 6). Push and twist light bulb (Figure 2, Item 2) counterclockwise and remove light bulb from light fixture (Figure 2, Item 6). If damaged, cut wire (Figure 2, Item 5) below contact (Figure 2, Item 8) and remove contact, cap (Figure 2, Item 3), spring (Figure 2, Item 4), and light fixture (Figure 2, Item 6) from wire.
0168-2
TM 5-3895-379-23-1
0168
REMOVAL - Continued
1 2
7 6 5
M0902SWR
Figure 2. 8.
Fuel Level Gauge Removal.
Remove two nuts (Figure 3, Item 3), lockwashers (Figure 3, Item 2), and fuel level gauge bracket (Figure 3, Item 1) from fuel level gauge studs (Figure 3, Item 4). Discard lockwashers.
4 3
M0903SWR
Figure 3.
0168-3
TM 5-3895-379-23-1
0168
REMOVAL - Continued
NOTE
Tag and mark all wires prior to removal. 9. 10. 11. Remove nut (Figure 4, Item 3), wire (Figure 4, Item 4), and lockwasher (Figure 4, Item 2) from fuel level gauge terminal S (Figure 4, Item 5). Discard lockwasher. Remove nut (Figure 4, Item 10), wire (Figure 4, Item 11), and lockwasher (Figure 4, Item 12) from fuel level gauge terminal T (Figure 4, Item 1). Discard lockwasher. Remove nut (Figure 4, Item 6), wire (Figure 4, Item 7), and lockwasher (Figure 4, Item 9) from fuel level gauge terminal G (Figure 4, Item 8). Discard lockwasher.
12 11 2
10
8 7 6 5 4 3
M0904SWR
Figure 4. Fuel Level Gauge Removal.
0168-4
TM 5-3895-379-23-1
0168
REMOVAL - Continued 12. Remove fuel level gauge (Figure 5, Item 1) from instrument box assembly (Figure 5, Item 2).
1
M0905SWR
Figure 5. END OF TASK INSTALLATION 1.
Position fuel level gauge (Figure 6, Item 1) in instrument box assembly (Figure 6, Item 2).
1
M1261SWR
Figure 6.
Fuel Level Gauge Installation.
0168-5
TM 5-3895-379-23-1
0168
INSTALLATION - Continued 2. 3. 4. Install new lockwasher (Figure 7, Item 9) and wire (Figure 7, Item 7) on fuel level gauge terminal G (Figure 7, Item 8) with nut (Figure 7, Item 6). Install new lockwasher (Figure 7, Item 12) and wire (Figure 7, Item 11) on fuel level gauge terminal T (Figure 7, Item 1) with nut (Figure 7, Item 10). Install new lockwasher (Figure 7, Item 2) and wire (Figure 7, Item 4) on fuel level gauge terminal S (Figure 7, Item 5) with nut (Figure 7, Item 3).
12 11 2
10
8 7 6 5 4 3
M1262SWR
Figure 7. Fuel Level Gauge Installation.
NOTE
Before installing fuel level gauge bracket on fuel level gauge, ensure that fuel level gauge is positioned so needle will point up when instrument box assembly is installed. 5. Install fuel level gauge bracket (Figure 8, Item 1) on fuel level gauge studs (Figure 8, Item 4) with two new lockwashers (Figure 8, Item 2) and nuts (Figure 8, Item 3).
4 3
M0906SWR
Figure 8. Fuel Level Gauge Installation.
0168-6
TM 5-3895-379-23-1
0168
NOTE
Perform Steps (6) and (7) only if wire was cut. 6. 7. 8. 9. 10. Install light fixture (Figure 9, Item 6), spring (Figure 9, Item 4), and cap (Figure 9, Item 3) on wire (Figure 9, Item 5). Solder contact (Figure 9, Item 8) on wire (Figure 9, Item 5). Push and twist light bulb (Figure 9, Item 2) clockwise and install light bulb in light fixture (Figure 9, Item 6). Install retainer clip (Figure 9, Item 7) on light fixture (Figure 9, Item 6). Push light fixture (Figure 9, Item 6) and install light fixture in fuel level gauge (Figure 9, Item 1).
1 2
7 6 5
M1055SWR
Figure 9.
0168-7
TM 5-3895-379-23-1
0168
3 2 1
7 6 5
4
M0907SWR
0168-8
TM 5-3895-379-23-1
0169
FIELD MAINTENANCE SERVICE METER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 48 and 103 Equipment Condition Engine off. (TM 5-3895-379-10) Equipment Condition (cont.) 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)
0169-1
TM 5-3895-379-23-1
0169
3 2 1
7 6 5
4
M0908SWR
Figure 1. Service Meter Removal. 4. Disconnect plug connector (Figure 2, Item 2) from service meter (Figure 2, Item 1).
0169-2
TM 5-3895-379-23-1
0169
REMOVAL - Continued
1 2

Figure 2. 5. 6. Service Meter Removal.
M0909SWR
Remove two thumb nuts (Figure 3, Item 5), clip (Figure 3, Item 4), and service meter bracket (Figure 3, Item 3) from service meter studs (Figure 3, Item 6). Lift service meter (Figure 3, Item 1) from instrument box assembly (Figure 3, Item 2).
3 6
4 5
M0910SWR
Service Meter Removal.
0169-3
TM 5-3895-379-23-1
0169
INSTALLATION 1. Position service meter (Figure 4, Item 1) in instrument box assembly (Figure 4, Item 2).
NOTE
Make sure service meter is positioned so numbers are right-side up when box assembly is installed. 2. Install service meter bracket (Figure 4, Item 3) and clip (Figure 4, Item 4) on service meter studs (Figure 4, Item 6) with two thumb nuts (Figure 4, Item 5).
3 6
4 5
M1298SWR
Figure 4. Service Meter Installation. 3. Connect plug connector (Figure 5, Item 2) to service meter (Figure 5, Item 1).
1 2

Figure 5. Service Meter Installation.
M1297SWR
0169-4
TM 5-3895-379-23-1
0169
3 2 1
7 6 5
4
M0911SWR
Service Meter Installation.
0169-5/6 blank
TM 5-3895-379-23-1
0170
FIELD MAINTENANCE VIBRATIONS PER MINUTE (VPM) TACHOMETER AND FEET PER MINUTE (FPM) METER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Solder Tin Alloy (WI) (Volume 2, WP 0288, Table 1, Item 66) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Lockwasher (Volume 2, WP 0290, Table 1, Item 124) Qty: 11 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 48, 103, and 139 WP 0195 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)
0170-1
TM 5-3895-379-23-1
0170
REMOVAL
NOTE
Vibrations Per Minute (VPM) tachometer for the CB534B and CB534C Rollers are replaced in the same way. CB534C Roller is equipped with a Feet Per Minute (FPM) meter. 1. 2. 3. 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). Remove three screws (Figure 1, Item 5) and washers (Figure 1, Item 6) from operator station (Figure 1, Item 7). Lift and tilt back instrument box assembly (Figure 1, Item 4) to gain access to back of instrument box assembly.
3 2 1
7 6 5
4
M0912SWR
Figure 1. 4. 5. 6. 7.
VPM Tachometer and FPM Meter Removal.
Remove light fixture (Figure 2, Item 2) from VPM tachometer (Figure 2, Item 1). Remove retainer clip (Figure 2, Item 3) from light fixture (Figure 2, Item 2). Push and twist light bulb (Figure 2, Item 4) counterclockwise and remove light bulb from light fixture (Figure 2, Item 2). If damaged, cut wire and install new light fixture (Figure 2, Item 2) using general wiring repair (WP 0195).
0170-2
TM 5-3895-379-23-1
0170
REMOVAL - Continued
1
2 3 4
M0913SWR
Figure 2. 8.
Remove two nuts (Figure 3, Item 2), lockwashers (Figure 3, Item 3), and VPM tachometer bracket (Figure 3, Item 4) from VPM tachometer studs (Figure 3, Item 1). Discard lockwashers.
2
M0914SWR
Figure 3.
0170-3
TM 5-3895-379-23-1
0170
REMOVAL - Continued
NOTE
Tag and mark all wires prior to removal. 9. 10. 11. 12. Remove nut (Figure 4, Item 2), wire (Figure 4, Item 3), and lockwasher (Figure 4, Item 13) from VPM tachometer terminal S (Figure 4, Item 14). Discard lockwasher. Remove nut (Figure 4, Item 1), wire (Figure 4, Item 12), and lockwasher (Figure 4, Item 11) from VPM tachometer terminal I (Figure 4, Item 10). Discard lockwasher. Remove nut (Figure 4, Item 4), wire (Figure 4, Item 5), and lockwasher (Figure 4, Item 6) from VPM tachometer terminal G (Figure 4, Item 8). Discard lockwasher. Remove VPM tachometer (Figure 4, Item 7) from instrument box assembly (Figure 4, Item 9).
1 2 3 13 12 11 6 10 14 5 4
9 8 7
M0915SWR
Figure 4.
0170-4
TM 5-3895-379-23-1
0170
REMOVAL - Continued
NOTE
Perform Steps (13) through (22) for the CB534C Roller. 13. 14. 15. 16. 17. Pull light fixture (Figure 5, Item 6) and remove light fixture from FPM meter. Remove retainer clip (Figure 5, Item 7) from light fixture (Figure 5, Item 6). Push and twist light bulb (Figure 5, Item 8) counterclockwise and remove light. If damaged, cut wire (Figure 5, Item 5) and install new light fixture (Figure 5, Item 6) using general wiring repair (WP 0195). Remove two nuts (Figure 5, Item 4), lockwashers (Figure 5, Item 3), and FPM meter bracket (Figure 5, Item 2) from FPM meter studs (Figure 5, Item 1). Discard lockwashers.
3 4
6 8 7
M0916SWR

Figure 5. VPM Tachometer and FPM Meter Removal.
0170-5
TM 5-3895-379-23-1
0170
REMOVAL - Continued 18. 19. 20. 21. 22. Remove nut (Figure 6, Item 2), wire (Figure 6, Item 1), and lockwasher (Figure 6, Item 17) from FPM meter terminal (Figure 6, Item 16). Discard lockwasher. Remove nut (Figure 6, Item 4), wire (Figure 6, Item 3), and lockwasher (Figure 6, Item 5) from FPM meter terminal (Figure 6, Item 18). Discard lockwasher. Remove nut (Figure 6, Item 7), wire (Figure 6, Item 6), and lockwasher (Figure 6, Item 8) from FPM meter terminal (Figure 6, Item 15). Discard lockwasher. Remove nut (Figure 6, Item 10), wire (Figure 6, Item 9), and lockwasher (Figure 6, Item 11) from FPM meter terminal (Figure 6, Item 14). Discard lockwasher. Remove FPM meter (Figure 6, Item 14) from instrument box assembly.
4 8 3 17 5 9 10
16
11
15 12 14 13
M0917SWR
0170-6
TM 5-3895-379-23-1
0170
INSTALLATION
NOTE
Perform Steps (1) through (9) for the CB534C Roller. 1. 2. 3. 4. 5. Install FPM meter (Figure 7, Item 14) to instrument box assembly. Install nut (Figure 7, Item 10), wire (Figure 7, Item 9), and lockwasher (Figure 7, Item 11) to FPM meter terminal (Figure 7, Item 13). Install nut (Figure 7, Item 7), wire (Figure 7, Item 6), and lockwasher (Figure 7, Item 8) to FPM meter terminal (Figure 7, Item 15). Install nut (Figure 7, Item 4), wire (Figure 7, Item 3), and lockwasher (Figure 7, Item 5) to FPM meter terminal (Figure 7, Item 18). Install nut (Figure 7, Item 2), wire (Figure 7, Item 1), and lockwasher (Figure 7, Item 17) to FPM meter terminal (Figure 7, Item 16).
4 8 3 17 5 9 10
16
11
15 12 14 13
M1210SWR
Figure 7.
VPM Tachometer and FPM Meter Installation.
0170-7
TM 5-3895-379-23-1
0170
INSTALLATION - Continued 6. 7. 8. 9. Install two nuts (Figure 8, Item 4), new lockwashers (Figure 8, Item 3), and FPM meter bracket (Figure 8, Item 2) to FPM meter studs (Figure 8, Item 1). Install light bulb (Figure 8, Item 8) to light fixture (Figure 8, Item 5). Push and twist bulb clockwise. Install retainer clip (Figure 8, Item 7) to light fixture (Figure 8, Item 5). Install light fixtures (Figure 8, Item 5) to FPM meter.
3 4
6 8 7
M0918SWR

Figure 8. 10. 11. 12. 13. VPM Tachometer and FPM Meter Installation.
Position VPM tachometer (Figure 9, Item 7) in instrument box assembly (Figure 9, Item 9). Install new lockwasher (Figure 9, Item 6) and wire (Figure 9, Item 5) on VPM tachometer terminal G (Figure 9, Item 8) with nut (Figure 9, Item 4). Install new lockwasher (Figure 9, Item 11) and wire (Figure 9, Item 12) on VPM tachometer terminal I (Figure 9, Item 10) with nut (Figure 9, Item 1). Install new lockwasher (Figure 9, Item 13) and wire (Figure 9, Item 3) on VPM tachometer terminal S (Figure 9, Item 14) with nut (Figure 9, Item 2).
0170-8
TM 5-3895-379-23-1
0170
1 2 3 13 12 11 6 10 14 5 4
9 8 7
M0919SWR
Figure 9.
VPM Tachometer and FPM Meter Installation.
NOTE
Before installing VPM tachometer bracket on VPM tachometer, ensure VPM tachometer is positioned so numbers are right-side up when instrument box assembly is installed. 14. 15. 16. 17. Install VPM tachometer bracket (Figure 10, Item 2) on VPM tachometer studs (Figure 10, Item 1) with two new lockwashers (Figure 10, Item 3) and nuts (Figure 10, Item 4). Push and twist light bulb (Figure 10, Item 8) clockwise and install light bulb in light fixture (Figure 10, Item 6). Install retainer clip (Figure 10, Item 7) on light fixture (Figure 10, Item 6). Push light fixture (Figure 10, Item 6) and install light fixture in VPM tachometer.
3 4
6 8 7
M1211SWR

Figure 10. VPM Tachometer and FPM Meter Installation.
0170-9
TM 5-3895-379-23-1
0170
3 2 1
7 6 5
4
M0920SWR
Figure 11. VPM Tachometer and FPM Meter Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Close right-side door assembly. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0170-10
TM 5-3895-379-23-1
0171
FIELD MAINTENANCE HOURMETER PRESSURE SWITCH REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (Volume 2, WP 0289, Table 1, Item 23) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 2, WP 0288, Table 1, Item 12) Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Strap, Tiedown, Electrical (Volume 2, WP 0288, Table 1, Item 67, 68, 69) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 52 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)
0171-1
TM 5-3895-379-23-1
0171
REMOVAL
NOTE
Use drain pan to catch any oil that may drain from system. Dispose of oil IAW local policy and ordinances. Ensure all spills are cleaned up. Cut cable ties as needed. 1. 2. Disconnect hourmeter pressure switch connector (Figure 1, Item 3) from connector (Figure 1, Item 4). Remove hourmeter pressure switch (Figure 1, Item 2) from tee (Figure 1, Item 1). Cap tee.
3 2 1 4
M0921SWR
Figure 1. Hourmeter Pressure Switch Removal. END OF TASK INSTALLATION
NOTE
Install cable ties as needed. 1. 2. Install hourmeter pressure switch (Figure 2, Item 2) on tee (Figure 2, Item 1) and tighten to 15-18 lb-ft (20-25 Nm). Connect hourmeter pressure switch connector (Figure 2, Item 3) to connector (Figure 2, Item 4).
0171-2
TM 5-3895-379-23-1
0171
3 2 1 4
M1109SWR
Figure 2. Hourmeter Pressure Switch Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Start engine and check for leaks. (TM 5-3895-379-10) Close right-side door assembly. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0171-3/4 blank
TM 5-3895-379-23-1
0172
FIELD MAINTENANCE ENGINE OIL PRESSURE SWITCH REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (Volume 2, WP 0289, Table 1, Item 23) Wrench, Torque, 0-300 in-lb (Volume 2, WP 0289, Table 1, Item 41) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 2, WP 0288, Table 1, Item 12) Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Strap, Tiedown, Electrical (Volume 2, WP 0288, Table 1, Item 67, 68, 69) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 50 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)
0172-1
TM 5-3895-379-23-1
0172
REMOVAL
WARNING
NOTE
Use drain pan to catch any oil that may drain from system. Dispose oil IAW local policy and ordinances. Ensure all spills are cleaned up. Cut electrical tiedown straps as needed. 1. 2. Disconnect oil pressure switch connector (Figure 1, Item 3) from connector (Figure 1, Item 4). Remove oil pressure switch (Figure 1, Item 2) from elbow (Figure 1, Item 1). Cap elbow.
4 3
2 1
M0922SWR
Figure 1. Oil Pressure Switch Removal. END OF TASK
0172-2
TM 5-3895-379-23-1
0172
INSTALLATION
NOTE
Install electrical tiedown straps as needed. 1. 2. Install engine oil pressure switch (Figure 2, Item 2) on elbow (Figure 2, Item 1) and tighten to 180-216 lb-in. (20-25 Nm). Connect connector (Figure 2, Item 4) to oil pressure switch connector (Figure 2, Item 3).
4 3
2 1
M1238SWR
Oil Pressure Switch Installation.
0172-3/4 blank
TM 5-3895-379-23-1
0173
FIELD MAINTENANCE LIGHTS CIRCUIT BREAKER REPLACEMENT
1 2 1 2 3 4
5
M0923SWR
Figure 1.
Lights Circuit Breaker Removal.
0173-1
TM 5-3895-379-23-1
0173
REMOVAL - Continued
NOTE
Tag and mark all wires prior to removal. 4. 5. Remove two screws (Figure 2, Item 3), lockwashers (Figure 2, Item 2), and wires (Figure 2, Items 1 and 8) from lights circuit breaker (Figure 2, Item 7). Discard lockwashers. Remove two screws (Figure 2, Item 5), washers (Figure 2, Item 6), and lights circuit breaker (Figure 2, Item 7) from operator station (Figure 2, Item 4).
1 2 3
8 7 6 5
M0924SWR
Figure 2. END OF TASK INSTALLATION
Lights Circuit Breaker Removal.
NOTE
Before installing lights circuit breaker, ensure that lights circuit breaker is positioned so 20 is readable. 1. 2. Install lights circuit breaker (Figure 3, Item 7) in operator station (Figure 3, Item 4) with two washers (Figure 3, Item 6) and screws (Figure 3, Item 5). Install two wires (Figure 3, Items 1 and 8) on lights circuit breaker (Figure 3, Item 7) with two new lockwashers (Figure 3, Item 2) and screws (Figure 3, Item 3).
0173-2
TM 5-3895-379-23-1
0173
1 2 3
8 7 6 5
M1237SWR
Figure 3. 3.
Lights Circuit Breaker Installation.
1 2 1 2 3 4
5
M0925SWR
Lights Circuit Breaker Installation.
0173-3
TM 5-3895-379-23-1
0173
0173-4
TM 5-3895-379-23-1
0174
FIELD MAINTENANCE STARTING AID RESISTOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Locknut (Volume 2, WP 0290, Table 1, Item 123) Qty: 2 Lockwasher (Volume 2, WP 0290, Table 1, Item 127) Qty: 2 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 50 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)
1 2 1 2 3 4
5
M0926SWR
Figure 1.
Starting Aid Resistor Removal.
0174-1
TM 5-3895-379-23-1
0174
REMOVAL - Continued 4. Remove two screws (Figure 2, Item 8), washers (Figure 2, Item 9), and starting aid resistor (Figure 2, Item 7) from panel assembly (Figure 2, Item 1).
NOTE
Tag and mark all wires prior to removal. 5. Remove two locknuts (Figure 2, Item 2), wires (Figure 2, Items 3 and 6), lockwashers (Figure 2, Item 4), and screws (Figure 2, Item 5) from starting aid resistor (Figure 2, Item 7). Discard locknuts and lockwashers.
3 4 9 8 7 6
M0927SWR
Figure 2. Starting Aid Resistor Removal. END OF TASK
0174-2
TM 5-3895-379-23-1
0174
INSTALLATION 1. 2. Install two new lockwashers (Figure 3, Item 4) and wires (Figure 3, Items 3 and 6) on starting aid resistor (Figure 3, Item 7) with two screws (Figure 3, Item 5) and new locknuts (Figure 3, Item 2). Install starting aid resistor (Figure 3, Item 7) on panel assembly (Figure 3, Item 1) with two screws (Figure 3, Item 8) and washers (Figure 3, Item 9).
3 4 9 8 7 6
M1106SWR
Figure 3. 3.
Starting Aid Resistor Installation.
1 2 1 2 3 4
5
M0928SWR
Starting Aid Resistor Installation.
0174-3
TM 5-3895-379-23-1
0174
0174-4
TM 5-3895-379-23-1
0175
FIELD MAINTENANCE FUEL SOLENOID RESISTOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Lockwasher (Volume 2, WP 0290, Table 1, Item 124) Qty: 2 Lockwasher (Volume 2, WP 0290, Table 1, Item 66) Qty: 4 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 50 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)
1 2 1 2 3 4
5
M0929SWR
Figure 1.
Fuel Solenoid Resistor Removal.
0175-1
TM 5-3895-379-23-1
0175
REMOVAL - Continued
NOTE
Tag and mark all wires prior to removal. 4. 5. Remove two nuts (Figure 2, Item 6), lockwashers (Figure 2, Item 7), wires (Figure 2, Items 5 and 9), and washers (Figure 2, Item 4) from fuel solenoid resistor (Figure 2, Item 8). Discard lockwashers. Remove four screws (Figure 2, Item 1), lockwashers (Figure 2, Item 2), and fuel solenoid resistor (Figure 2, Item 8) from panel assembly (Figure 2, Item 3). Discard lockwashers.
2 1
9 4 5
8 7 6
M0930SWR
Fuel Solenoid Resistor Removal.
Install fuel solenoid resistor (Figure 3, Item 8) on panel assembly (Figure 3, Item 3) with four new lockwashers (Figure 3, Item 2) and screws (Figure 3, Item 1). Install two washers (Figure 3, Item 4) and wires (Figure 3, Items 5 and 9) on fuel solenoid resistor (Figure 3, Item 8) with two new lockwashers (Figure 3, Item 7) and nuts (Figure 3, Item 6).
0175-2
TM 5-3895-379-23-1
0175
2 1
9 4 5
8 7 6
M1105SWR
Figure 3. 3.
Fuel Solenoid Resistor Installation.
1 2 1 2 3 4
5
M0931SWR
Fuel Solenoid Resistor Installation.
0175-3
TM 5-3895-379-23-1
0175
0175-4
TM 5-3895-379-23-1
0176
FIELD MAINTENANCE ALTERNATOR LIGHT REPLACEMENT
REMOVAL 1. 2. 3. Turn lens (Figure 1, Item 1) counterclockwise and remove lens from lamp assembly (Figure 1, Item 4). Remove seal (Figure 1, Item 2) from lens (Figure 1, Item 1). Push lamp (Figure 1, Item 3) in and turn counterclockwise and remove lamp from lamp assembly (Figure 1, Item 4).
1 2
M0932SWR
Figure 1.
Alternator Light Removal.
0176-1
TM 5-3895-379-23-1
0176
REMOVAL - Continued 4. 5. 6. Remove two shoulder screws (Figure 2, Item 1), washers (Figure 2, Item 2), and vandal guard (Figure 2, Item 3) from instrument box assembly (Figure 2, Item 7). Remove three screws (Figure 2, Item 6) and washers (Figure 2, Item 5) from operator station (Figure 2, Item 4). Lift and tilt back instrument box assembly (Figure 2, Item 7) to gain access to back of instrument box assembly.
3 2 1
4
M0933SWR
Figure 2. Alternator Light Removal.
0176-2
TM 5-3895-379-23-1
0176
REMOVAL - Continued
NOTE
Tag and mark all wires prior to removal. 7. Remove two screws (Figure 3, Item 2) and wires (Figure 3, Item 3) from lamp assembly (Figure 3, Item 1).
2 2 3
Figure 3. 8. 9. 10.
3
M0934SWR
Remove nut (Figure 4, Item 4) and lockwasher (Figure 4, Item 3) from lamp assembly (Figure 4, Item 1). Discard lockwasher. Remove lamp assembly (Figure 4, Item 1) from instrument box assembly (Figure 4, Item 5). Remove seal (Figure 4, Item 2) from lamp assembly (Figure 4, Item 1).
1
3 5 4
M0935SWR
0176-3
TM 5-3895-379-23-1
0176
INSTALLATION 1. 2. 3. Install seal (Figure 5, Item 2) on lamp assembly (Figure 5, Item 1). Install lamp assembly (Figure 5, Item 1) in instrument box assembly (Figure 5, Item 5). Install new lockwasher (Figure 5, Item 3) and nut (Figure 5, Item 4) on lamp assembly (Figure 5, Item 1).
1
3 5 4
M1102SWR
Figure 5. Alternator Light Installation.
0176-4
TM 5-3895-379-23-1
0176
INSTALLATION - Continued 4. Install two wires (Figure 6, Item 3) on lamp assembly (Figure 6, Item 1) with screws (Figure 6, Item 2).
2 2 3
Figure 6. 5. 6.
3
M1104SWR
Alternator Light Installation.
Install instrument box assembly (Figure 7, Item 7) on operator station (Figure 7, Item 4) with three washers (Figure 7, Item 5) and screws (Figure 7, Item 6). Install vandal guard (Figure 7, Item 3) on instrument box assembly (Figure 7, Item 7) with two washers (Figure 7, Item 2) and shoulder screws (Figure 7, Item 1).
3 2 1
4
M1103SWR
Figure 7.
Alternator Light Installation.
0176-5
TM 5-3895-379-23-1
0176
INSTALLATION - Continued 7. 8. 9. Push lamp (Figure 8, Item 3) and turn clockwise and install lamp in lamp assembly (Figure 8, Item 4). Install seal (Figure 8, Item 2) on lens (Figure 8, Item 1). Turn lens (Figure 8, Item 1) clockwise and install lens on lamp assembly (Figure 8, Item 4).
1 2
M0936SWR
Figure 8. Alternator Light Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Close right-side door assembly. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0176-6
TM 5-3895-379-23-1
0177
FIELD MAINTENANCE FUNCTIONAL INDICATOR LIGHT ASSEMBLY REPLACEMENT
0177-1
TM 5-3895-379-23-1
0177
3 2 1
7 6 5
4
M0937SWR
Figure 1.
Functional Indicator Light Removal.
NOTE
Tag and mark all wires prior to removal. 4. Lift tab and disconnect connector (Figure 2, Item 2) from functional indicator light assembly (Figure 2, Item 1).
0177-2
TM 5-3895-379-23-1
0177
REMOVAL - Continued
1

M0938SWR
Figure 2. 5. 6. 7. 8.
Remove nut (Figure 3, Item 7), lockwasher (Figure 3, Item 6), and bracket (Figure 3, Item 5) from stud (Figure 3, Item 8). Discard lockwasher. Remove functional indicator light assembly (Figure 3, Item 2) from instrument box assembly (Figure 3, Item 1). Turn four lamp assemblies (Figure 3, Item 4) counterclockwise and remove from functional indicator light assembly (Figure 3, Item 2). Remove four lamps (Figure 3, Item 3) from lamp assemblies (Figure 3, Item 4).
1 2
3 8 4 5 6 7
M0939SWR
0177-3
TM 5-3895-379-23-1
0177
INSTALLATION 1. 2. 3. Install four lamps (Figure 4, Item 3) in lamp assemblies (Figure 4, Item 4). Install four lamp assemblies (Figure 4, Item 4) in functional indicator light assembly (Figure 4, Item 2). Position functional indicator light assembly (Figure 4, Item 2) on instrument box assembly (Figure 4, Item 1).
NOTE
Before installing functional indicator light assembly bracket on functional indicator light assembly, ensure functional indicator light assembly is positioned so icons are right-side up when instrument box assembly is installed. 4. Install functional indicator light assembly bracket (Figure 4, Item 5) on stud (Figure 4, Item 8) with new lockwasher (Figure 4, Item 6) and nut (Figure 4, Item 7).
1 2
3 8 4 5 6 7
Figure 4.
M1202SWR
Functional Indicator Light Installation.
0177-4
TM 5-3895-379-23-1
0177
INSTALLATION - Continued 5. Connect connector (Figure 5, Item 2) to functional indicator light assembly (Figure 5, Item 1).
1

M1201SWR
Figure 5.
0177-5
TM 5-3895-379-23-1
0177
3 2 1
7 6 5
4
M0940SWR
0177-6
TM 5-3895-379-23-1
0178
FIELD MAINTENANCE WORK LIGHT ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Strap, Tiedown, Electrical (Volume 2, WP 0288, Table 1, Item 67, 68, 69) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 51 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)
REMOVAL
NOTE
Cut electrical tiedown straps as necessary to allow movement of cables. 1. Remove two screws (Figure 1, Item 1), washers (Figure 1, Item 2), screw (Figure 1, Item 4), washer (Figure 1, Item 2), and support (Figure 1, Item 5) from support (Figure 1, Item 3).
1 2
3 4
2
M0941SWR
Figure 1.
Work Light Removal.
0178-1
TM 5-3895-379-23-1
0178
REMOVAL - Continued 2. Remove nut (Figure 2, Item 4), screw (Figure 2, Item 7), and work light assembly (Figure 2, Item 3) from bracket (Figure 2, Item 5).
NOTE
Tag and mark all wires prior to removal. 3. 4. Loosen two screws (Figure 2, Item 2) and remove wires (Figure 2, Item 1) from work light assembly (Figure 2, Item 3). Remove work light assembly (Figure 2, Item 3) from support (Figure 2, Item 6).
6 5 4 3
M0942SWR
Figure 2. Work Light Removal. 5. Remove nut (Figure 3, Item 1), washer (Figure 3, Item 5), screw (Figure 3, Item 3), and bracket (Figure 3, Item 2) from support (Figure 3, Item 4).
0178-2
TM 5-3895-379-23-1
0178
REMOVAL - Continued
2 3
Figure 3. END OF TASK INSTALLATION 1. Install bracket (Figure 4, Item 2) on support (Figure 4, Item 4) with screw (Figure 4, Item 3), washer (Figure 4, Item 5), and nut (Figure 4, Item 1). Work Light Removal.
M0943SWR
2 3
Figure 4. Work Light Installation.
M1233SWR
0178-3
TM 5-3895-379-23-1
0178
INSTALLATION - Continued 2. 3. 4. Position work light assembly (Figure 5, Item 3) in support (Figure 5, Item 6). Position two wires (Figure 5, Item 1) on work light assembly (Figure 5, Item 3) and tighten screws (Figure 5, Item 2). Install work light assembly (Figure 5, Item 3) in bracket (Figure 5, Item 5) with screw (Figure 5, Item 7) and nut (Figure 5, Item 4).
6 5 4 3
M1234SWR
Figure 5.
Work Light Installation.
NOTE
Use cable ties as necessary to attach cables to vehicle. 5. Install support (Figure 6, Item 5) in support (Figure 6, Item 3) with two washers (Figure 6, Item 2), screws (Figure 6, Item 1), washer (Figure 6, Item 2), and screw (Figure 6, Item 4). Tighten screws.
0178-4
TM 5-3895-379-23-1
0178
1 2
3 4
2
M0944SWR
Figure 6. END OF TASK ADJUSTMENT 1.
Work Light Installation.
Remove two screws (Figure 7, Item 1), washers (Figure 7, Item 2), screws (Figure 7, Item 4), washer (Figure 7, Item 2), and support (Figure 7, Item 5) from support (Figure 7, Item 3).
1 2
3 4
2
M1235SWR
Figure 7.
Work Light Adjustment.
0178-5
TM 5-3895-379-23-1
0178
ADJUSTMENT - Continued 2. To raise or lower beam, loosen nut (Figure 8, Item 4) and reposition work light assembly (Figure 8, Item 3) in bracket (Figure 8, Item 5). Tighten nut.
6 5 4 3
M1236SWR
Figure 8. 3.
Work Light Adjustment.
Install support (Figure 7, Item 5) in support (Figure 7, Item 3) with two washers (Figure 7, Item 2), screws (Figure 7, Item 1), washer (Figure 7, Item 2), and screws (Figure 7, Item 4). Tighten screws.
END OF TASK FOLLOW-ON MAINTENANCE Remove chocks. (TM 5-3895-379-10) END OF TASK END OF WORK PACKAGE
0178-6
TM 5-3895-379-23-1
0179
FIELD MAINTENANCE WORK LIGHT BULB REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 51 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)
REMOVAL 1. Remove four screws (Figure 1, Item 4), bezel (Figure 1, Item 3), and lens assembly (Figure 1, Item 1) from work light body assembly (Figure 1, Item 2).
3 2
M0945SWR
Figure 1.
Work Light Bulb Removal.
0179-1
TM 5-3895-379-23-1
0179
REMOVAL - Continued 2. 3. Pinch lockwires (Figure 2, Item 4) together and remove from notches (Figure 2, Item 6) in lens assembly (Figure 2, Item 5). Remove bulb (Figure 2, Item 1) from lens assembly (Figure 2, Item 5).
NOTE
Tag and mark all wires prior to removal. 4. 5. Disconnect bulb (Figure 2, Item 1) from connector (Figure 2, Item 2). If damaged, disconnect lens assembly (Figure 2, Item 5) from connector (Figure 2, Item 3).
2 1
5 4
M0946SWR
Figure 2. END OF TASK INSTALLATION 1. 2. 3. 4.
Work Light Bulb Removal.
If removed, connect lens assembly (Figure 3, Item 5) to connector (Figure 3, Item 3). Connect bulb (Figure 3, Item 1) to connector (Figure 3, Item 2). Install bulb (Figure 3, Item 1) in lens assembly (Figure 3, Item 5). Position lockwires (Figure 3, Item 4) over bulb (Figure 3, Item 1), pinch together, and position in notches (Figure 3, Item 6) in lens assembly.
0179-2
TM 5-3895-379-23-1
0179
2 1
6 3
5 4
M1204SWR
Figure 3. 5.
Work Light Bulb Installation.
Install lens assembly (Figure 4, Item 1) and bezel (Figure 4, Item 3) in work light body assembly (Figure 4, Item 2) with four screws (Figure 4, Item 4). Tighten screws.
3 2
M0947SWR
Work Light Bulb Installation.
0179-3
TM 5-3895-379-23-1
0179
FOLLOW-ON MAINTENANCE Remove chocks. (TM 5-3895-379-10) END OF TASK END OF WORK PACKAGE
0179-4
TM 5-3895-379-23-1
0180
FIELD MAINTENANCE WARNING LIGHTS ASSEMBLY REPLACEMENT
0180-1
TM 5-3895-379-23-1
0180
3 2 1
7 6 5
4
M0948SWR
Figure 1. Warning Light Removal.
NOTE
Tag and mark all wires prior to removal. 4. Lift tab and disconnect connector (Figure 2, Item 2) from warning lights assembly (Figure 2, Item 1).
0180-2
TM 5-3895-379-23-1
0180
REMOVAL - Continued
1

M0949SWR
Figure 2. 5. 6. 7. 8.
Warning Light Removal.
Remove nut (Figure 3, Item 7), lockwasher (Figure 3, Item 6), and warning lights assembly bracket (Figure 3, Item 5) from stud (Figure 3, Item 8). Discard lockwasher. Remove warning lights assembly (Figure 3, Item 2) from instrument box assembly (Figure 3, Item 1). Turn four lamp assemblies (Figure 3, Item 4) counterclockwise and remove from warning lights assembly (Figure 3, Item 2). Remove four lamps (Figure 3, Item 3) from lamp assemblies (Figure 3, Item 4).
1 2
3 8 4 5 6 7
M0950SWR
Warning Light Removal.
0180-3
TM 5-3895-379-23-1
0180
INSTALLATION 1. 2. 3. Install four lamps (Figure 4, Item 3) lamp assemblies (Figure 4, Item 4). Install four lamp assemblies (Figure 4, Item 4) in warning lights assembly (Figure 4, Item 2). Position warning lights assemblies (Figure 4, Item 2) on instrument box assembly (Figure 4, Item 4).
NOTE
Before installing warning lights assembly bracket on warning lights assembly, ensure warning lights assembly is positioned so icons are right-side up when instrument box assembly is installed. 4. Install warning lights assembly bracket (Figure 4, Item 5) on stud (Figure 4, Item 8) with new lockwasher (Figure 4, Item 6) and nut (Figure 4, Item 7).
1 2
3 8 4 5 6 7
Figure 4.
M1296SWR
Warning Light Installation.
0180-4
TM 5-3895-379-23-1
0180
INSTALLATION - Continued 5. Connect connector (Figure 5, Item 2) to warning lights assembly (Figure 5, Item 1).
1

M1295SWR
Figure 5.
0180-5
TM 5-3895-379-23-1
0180
3 2 1
7 6 5
4
M0951SWR
Close right-side door assembly. (TM 5-3895-379-10) Remove chocks. (TM-5-3895-379-10)
0180-6
TM 5-3895-379-23-1
0181
FIELD MAINTENANCE BACKUP ALARM SENDING UNIT REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Sealing Compound, Loctite 271 (Volume 2, WP 0288, Table 1, Item 62) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Lockwasher (Volume 2, WP 0290, Table 1, Item 124) Qty: 2 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 52 and 53 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)
1 2 1 2 3 4
5
M0952SWR
Figure 1. Backup Alarm Sending Unit Removal.
0181-1
TM 5-3895-379-23-1
0181
REMOVAL - Continued 4. 5. Remove two screws (Figure 2, Item 6), lockwashers (Figure 2, Item 5), and wires (Figure 2, Items 2 and 4) from backup alarm sending unit (Figure 2, Item 3). Discard lockwashers. Remove backup alarm sending unit (Figure 2, Item 3) from adapter (Figure 2, Item 1).
6 5 4
M0953SWR
Figure 2. Backup Alarm Sending Unit Removal. END OF TASK INSTALLATION 1. 2. 3. Apply sealing compound to threads of backup alarm sending unit (Figure 3, Item 3). Install backup alarm sending unit (Figure 3, Item 3) in adapter (Figure 3, Item 1). Install two wires (Figure 3, Item 2 and 4) on backup alarm sending unit (Figure 3, Item 3) with two screws (Figure 3, Item 6) and new lockwashers (Figure 3, Item 5).
6 5 4
M1280SWR
Figure 3. Backup Alarm Sending Unit Installation.
0181-2
TM 5-3895-379-23-1
0181
1 2 1 2 3 4
5
M0954SWR
Figure 4. Backup Alarm Sending Unit Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Close right-side door assembly. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0181-3/4 blank
TM 5-3895-379-23-1
0182
FIELD MAINTENANCE WATER TEMPERATURE SENDING UNIT REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Goggles (Volume 2, WP 0289, Table 1, Item 13) Pan, Drain, 5 Gal Cap. (Volume 2, WP 0289, Table 1, Item 23) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Sealing Compound, Loctite 271 (Volume 2, WP 0288, Table 1, Item 62) Strap, Tiedown, Electrical (Volume 2, WP 0288, Table 1, Item 67, 68, 69) Materials/Parts (cont.) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) O-ring (Volume 2, WP 0290, Table 1, Item 73) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 52 WP 0139 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)
0182-1
TM 5-3895-379-23-1
0182
REMOVAL
WARNING
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 will cause burns. Wear effective eye, glove, and skin protection when handling coolants. Failure to do so may cause injury. 1. Disconnect connector (Figure 1, Item 1) from water temperature sending unit connector (Figure 1, Item 2).
NOTE
Use drain pan to catch any coolant that may drain from water temperature sending unit. Dispose of coolant IAW local policy and ordinances. Ensure all spills are cleaned up. 2. Place drain pan with 1 gal (3.8 Liters) minimum capacity under water temperature sending unit (Figure 1, Item 4) to catch draining coolant.
NOTE
Remove electrical tiedown straps as required. 3. Remove water temperature sending unit (Figure 1, Item 5) and O-ring (Figure 1, Item 4) from water intake manifold (Figure 1, Item 3). Discard O-ring.
4 5
M1203SWR
Water Temperature Sending Unit Removal.
0182-2
TM 5-3895-379-23-1
0182
INSTALLATION 1. 2. 3. Coat threads of water temperature sending unit (Figure 2, Item 5) with sealing compound. Install water temperature sending unit (Figure 2, Item 5) and O-ring (Figure 2, Item 4) in water intake manifold (Figure 2, Item 3). Tighten water temperature sending unit 32-44 lb-ft (44-60 Nm). Connect connector (Figure 2, Item 1) to water temperature sending unit connector (Figure 2, Item 2).
4 5
M0955SWR
Water Temperature Sending Unit Installation.
Fill cooling system to proper level. (WP 0139) Close right-side door assembly. (TM 5-3895-379-10) Start engine and check for coolant leaks. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0182-3/4 blank
TM 5-3895-379-23-1
0183
FIELD MAINTENANCE FUEL LEVEL SENDING UNIT REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (Volume 2, WP 0289, Table 1, Item 23) Materials/Parts Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Gasket (Volume 2, WP 0290, Table 1, Item 113) Qty: 1 Lockwasher (Volume 2, WP 0290, Table 1, Item 112) Qty: 5 Lockwasher (Volume 2, WP 0290, Table 1, Item 125) Qty: 2 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 52 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)
0183-1
TM 5-3895-379-23-1
0183
REMOVAL
WARNING
DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing damage to roller and injury or death.
NOTE
Use drain pan to catch any fuel that may drain from system. Dispose of fuel In Accordance With (IAW) local policy and ordinances. Ensure all spills are cleaned up. Tag and mark all wires prior to removal. 1. 2. Remove two nuts (Figure 1, Item 2), lockwashers (Figure 1, Item 3), washers (Figure 1, Item 4), and wires (Figure 1, Item 5) from fuel level sending unit (Figure 1, Item 8). Discard lockwashers. Remove five screws (Figure 1, Item 1), lockwashers (Figure 1, Item 9), fuel level sending unit (Figure 1, Item 8), and gasket (Figure 1, Item 6) from fuel tank (Figure 1, Item 7). Discard gasket and lockwashers.
1 2 3 4 9
8 7
M0956SWR
Figure 1. Fuel Level Sending Unit Removal. END OF TASK
0183-2
TM 5-3895-379-23-1
0183
INSTALLATION
NOTE
Fuel level sending unit must be installed so that outside electrical stud is on left-side of roller. 1. 2. Install new gasket (Figure 2, Item 6) and fuel level sending unit (Figure 2, Item 8) on fuel tank (Figure 2, Item 7) with five new lockwashers (Figure 2, Item 9) and screws (Figure 2, Item 1). Install two wires (Figure 2, Item 5) on fuel level sending unit (Figure 2, Item 8) with two washers (Figure 2, Item 4), new lockwashers (Figure 2, Item 3), and nuts (Figure 2, Item 2).
1 2 3 4 9
8 7
M1051SWR
Fuel Level Sending Unit Installation.
0183-3/4 blank
TM 5-3895-379-23-1
0184
FIELD MAINTENANCE VIBRATION SENSOR MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (Volume 2, WP 0289, Table 1, Item 23) Wrench, Torque, 90-600 ft-lb (Volume 2, WP 0289, Table 1, Item 44) Materials/Parts Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 52 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) Hydraulic tank drained. (WP 0124)
0184-1
TM 5-3895-379-23-1
0184
REMOVAL
NOTE
Right and left-front vibration sensors are maintained the same way. Right-front sensor is shown. Vibration sensors are located on left-side of rear drum and right-side of front drum. 1. Disconnect connector (Figure 1, Item 2) from vibratory sensor connector (Figure 1, Item 3).
WARNING
NOTE
Use drain pan to catch any hydraulic oil that may drain from hose assembly. Dispose of oil IAW local policy and ordinances. 2. 3. 4. Place drain pan with 2 qt (1.9 Liters) minimum capacity under hose assembly (Figure 1, Item 4). Disconnect hose assembly (Figure 1, Item 4) from elbow (Figure 1, Item 5) and allow hydraulic fluid to drain into drain pan. Loosen nut (Figure 1, Item 6) and remove vibration sensor (Figure 1, Item 7) and spacer (Figure 1, Item 8) from plate (Figure 1, Item 1).
1 2 8 7 6 3
4
M0957SWR
Figure 1. Vibration Sensor Removal. END OF TASK
0184-2
TM 5-3895-379-23-1
0184
INSTALLATION 1. 2. 3. Install spacer (Figure 2, Item 8) and vibration sensor (Figure 2, Item 7) in plate (Figure 2, Item 1). Do not tighten nut (Figure 2, Item 6). Install vibration motor hydraulic line (Figure 2, Item 4) on elbow (Figure 2, Item 5). Connect connector (Figure 2, Item 2) to vibratory sensor connector (Figure 2, Item 3).
1 2 8 7 6 3
5
Figure 2. 4.
4
M1309SWR
Vibration Sensor Installation.
Adjust sensor. Refer to ADJUSTMENT in this work package.
END OF TASK
0184-3
TM 5-3895-379-23-1
0184
ADJUSTMENT 1. 2. Adjust gap between vibration sensor (Figure 3, Item 1) and disc (Figure 3, Item 2) to 0.040-0.020 in. (1.0-0.5 mm). Tighten nut (Figure 3, Item 3) to 32-42 lb-ft (43-57 Nm).
1 0.040 TO 0.020 IN. (1.0 - 0.5 MM)
3
M0958SWR
Vibration Sensor Adjustment.
0184-4
TM 5-3895-379-23-1
0185
FIELD MAINTENANCE HYDRAULIC OIL TEMPERATURE SENSOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (Volume 2, WP 0289, Table 1, Item 23) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Sealing Compound, Loctite 271 (Volume 2, WP 0288, Table 1, Item 62) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 52 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) Hydraulic tank drained. (WP 0124) Left-side door assembly opened. (TM 5-3895-379-10)
0185-1
TM 5-3895-379-23-1
0185
REMOVAL
NOTE
Tag and mark all wires prior to removal. 1. Loosen two screws (Figure 1, Item 3) on hydraulic oil temperature sensor (Figure 1, Item 2) and remove two wires (Figure 1, Item 4).
NOTE
Use drain pan to catch any hydraulic oil that may drain from system. Dispose of oil In Accordance With (IAW) local policy and ordinances. Ensure all spills are cleaned up. 2. Remove hydraulic oil temperature sensor (Figure 1, Item 2) from hydraulic oil tank fitting (Figure 1, Item 1).
1
2 3 4 3 4
M0959SWR
Temperature Sensor Removal.
0185-2
TM 5-3895-379-23-1
0185
INSTALLATION 1. 2. Apply sealing compound to threads of hydraulic oil temperature sensor (Figure 2, Item 2) and install in hydraulic oil tank fitting (Figure 2, Item 1). Tighten sensor to 26-33 lb-ft (35-45 Nm). Position two wires (Figure 2, Item 4) on hydraulic oil temperature sensor (Figure 2, Item 2) and tighten two screws (Figure 2, Item 3).
1
2 3 4 3 4
M1050SWR
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Fill hydraulic tank. (WP 0124)
Temperature Sensor Installation.
Close left-side door assembly. (TM 5-3895-379-10) Start engine and check for leaks. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0185-3/4 blank
TM 5-3895-379-23-1
0186
FIELD MAINTENANCE WARNING HORN ASSEMBLY REPLACEMENT
REMOVAL 1. Remove four shoulder screws (Figure 1, Item 1), washers (Figure 1, Item 2), and cover (Figure 1, Item 4) from operator station (Figure 1, Item 3).
M0960SWR
Figure 1.
Warning Horn Removal.
0186-1
TM 5-3895-379-23-1
0186
REMOVAL - Continued 2. Remove screw (Figure 2, Item 2), washer (Figure 2, Item 3), and horn assembly (Figure 2, Item 4) from operator station (Figure 2, Item 5).
NOTE
Tag and mark all wires prior to removal. 3. Remove two screws (Figure 2, Item 1), washers (Figure 2, Item 8), wires (Figure 2, Items 9 and 11), and lockwashers (Figure 2, Item 10) from horn assembly terminals (Figure 2, Items 6 and 7). Discard lockwashers.
1 2 3 8 11 5 4
10
9 10 1 8
6 7
M0961SWR
Figure 2. Warning Horn Removal. END OF TASK INSTALLATION 1. 2. Install two new lockwashers (Figure 3, Item 10) and wires (Figure 3, Items 9 and 11) on horn assembly terminals (Figure 3, Items 6 and 7) with two new lockwashers (Figure 3, Item 8) and screws (Figure 3, Item 1). Install horn assembly (Figure 3, Item 4) on operator station (Figure 3, Item 5) with washer (Figure 3, Item 3) and screw (Figure 3, Item 2).
0186-2
TM 5-3895-379-23-1
0186
1 2 3 8 11 5 4
10
9 10 1 8
6 7
M1069SWR
Figure 3. 3.
Warning Horn Installation.
Install cover (Figure 4, Item 4) on operator station (Figure 4, Item 3) with four washers (Figure 4, Item 2) and screws (Figure 4, Item 1).
M0962SWR
Warning Horn Installation.
0186-3/4 blank
TM 5-3895-379-23-1
0187
FIELD MAINTENANCE BACKUP ALARM REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 0-300 in-lb (Volume 2, WP 0289, Table 1, Item 41) Materials/Parts Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 53 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Decontamination kit bracket removed. (Volume 2, WP 0230)
0187-1
TM 5-3895-379-23-1
0187
REMOVAL
WARNING
Use caution when handling heavy parts. Provide adequate support and use assistance during procedure. Failure to follow this warning may cause injury.
NOTE
Plate assembly with decontamination kit bracket attached weighs 22 lb (10 kg). 1. Remove four screws (Figure 1, Item 3), washers (Figure 1, Item 4), and cover (Figure 1, Item 1) from rear bumper assembly (Figure 1, Item 2).
1
4 3 2
M0963SWR
Figure 1.
Backup Alarm Removal.
0187-2
TM 5-3895-379-23-1
0187
REMOVAL - Continued 2. 3. Completely loosen two screws (Figure 2, Item 7). Remove backup alarm (Figure 2, Item 5), two screws (Figure 2, Item 7), and washers (Figure 2, Item 8) from rear bumper assembly (Figure 2, Item 6).
NOTE
Tag and mark all wires prior to removal. 4. Remove two nuts (Figure 2, Item 2), washers (Figure 2, Item 3), and wires (Figure 2, Items 1 and 4) from backup alarm (Figure 2, Item 5).
1 2 3 4 5 6 8 7
M0964SWR
Backup Alarm Removal.
0187-3
TM 5-3895-379-23-1
0187
INSTALLATION
NOTE
Plate assembly with decontamination kit bracket attached weighs 22 lb (10 kg). 1. 2. 3. Install wires (Figure 3, Items 1 and 4) on backup alarm (Figure 3, Item 5) with two washers (Figure 3, Item 3) and nuts (Figure 3, Item 2). Install two washers (Figure 3, Item 8) and screws (Figure 3, Item 7) on backup alarm (Figure 3, Item 5). Position backup alarm (Figure 3, Item 5) on bumper assembly (Figure 3, Item 6) and tighten two screws (Figure 3, Item 7) securely.
1 2 3 4 5 6 8 7
M1046SWR
Figure 3.
Backup Alarm Installation.
0187-4
TM 5-3895-379-23-1
0187
INSTALLATION - Continued 4. Install cover (Figure 4, Item 1) on rear bumper assembly (Figure 4, Item 2) with four washers (Figure 4, Item 4) and screws (Figure 4, Item 3). Tighten screws to 177-301 lb-in. (20-34 Nm).
1
4 3 2
M0965SWR
Backup Alarm Installation.
Install decontamination kit bracket. (Volume 2, WP 0230) Remove chocks. (TM 5-3895-379-10)
0187-5/6 blank
TM 5-3895-379-23-1
0188
FIELD MAINTENANCE HORN SWITCH REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Tag, Marker (Volume 2, WP Lockwasher (Volume 2, WP Qty: 1 Lockwasher (Volume 2, WP Qty: 2 Lockwasher (Volume 2, WP Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 53 0288, Table 1, Item 70) 0290, Table 1, Item 66) 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)
0290, Table 1, Item 125)
0290, Table 1, Item 126)
1 2 1 2 3 4
5
M0966SWR
Figure 1.
Horn Switch Removal.
0188-1
TM 5-3895-379-23-1
0188
REMOVAL - Continued
NOTE
Tag and mark all wires prior to removal. 4. 5. 6. Remove two screws (Figure 2, Item 5), lockwashers (Figure 2, Item 6), and wires (Figure 2, Items 7 and 11) from horn switch (Figure 2, Item 8). Discard lockwashers. Remove screw (Figure 2, Item 2), lockwasher (Figure 2, Item 3), and knob (Figure 2, Item 1) from horn switch (Figure 2, Item 8). Discard lockwasher. Remove nut (Figure 2, Item 10), lockwasher (Figure 2, Item 9), and horn switch (Figure 2, Item 8) from panel assembly (Figure 2, Item 4). Discard lockwasher.
1 2 3
10
9 11 8 7 6 5
M0967SWR
Figure 2. Horn Switch Removal. END OF TASK INSTALLATION 1. 2. 3. Install horn switch (Figure 3, Item 8) on panel assembly (Figure 3, Item 4) with new lockwasher (Figure 3, Item 9) and nut (Figure 3, Item 10). Install knob (Figure 3, Item 1) on horn switch (Figure 3, Item 8) with new lockwasher (Figure 3, Item 3) and screw (Figure 3, Item 2). Install two wires (Figure 3, Items 7 and 11) on horn switch (Figure 3, Item 8) with two new lockwashers (Figure 3, Item 6) and screws (Figure 3, Item 5).
0188-2
TM 5-3895-379-23-1
0188
1 2 3
10
9 11 8 7 6 5
M1048SWR
Figure 3. 4.
Horn Switch Installation.
1 2 1 2 3 4
5
M1315SWR
Horn Switch Installation.
0188-3
TM 5-3895-379-23-1
0188
0188-4
TM 5-3895-379-23-1
0189
FIELD MAINTENANCE HORN ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 0-300 in-lb (Volume 2, WP 0289, Table 1, Item 41) Materials/Parts Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Locknut (Volume 2, WP 0290, Table 1, Item 111) Qty: 1 Lockwasher (Volume 2, WP 0290, Table 1, Item 124) Qty: 2 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 53 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)
0189-1
TM 5-3895-379-23-1
0189
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). 1. Remove four screws (Figure 1, Item 3), washers (Figure 1, Item 2), and cover (Figure 1, Item 4) from bumper assembly (Figure 1, Item 1).
4 2 3
M0969SWR
Figure 1.
Horn Removal.
0189-2
TM 5-3895-379-23-1
0189
REMOVAL - Continued 2. Remove locknut (Figure 2, Item 7), washer (Figure 2, Item 8), screw (Figure 2, Item 10), and horn assembly (Figure 2, Item 1) from clip (Figure 2, Item 9). Discard locknut.
NOTE
Tag and mark all wires prior to removal. 3. 4. Remove two screws (Figure 2, Item 3), washers (Figure 2, Item 4), wires (Figure 2, Items 5 and 6), and lockwashers (Figure 2, Item 2) from horn assembly (Figure 2, Item 1). Discard lockwashers. Remove screw (Figure 2, Item 10), washer (Figure 2, Item 8), and clip (Figure 2, Item 9) from bumper assembly (Figure 2, Item 11).
10 8 6 7 8 9 9 10
2 1
3 4 5
11
11
M0970SWR
Horn Removal.
0189-3
TM 5-3895-379-23-1
0189
INSTALLATION 1. 2. 3. Install clip (Figure 3, Item 9) on bumper assembly (Figure 3, Item 11) with washer (Figure 3, Item 8) and screw (Figure 3, Item 10). Tighten screw to 177-304 lb-in. (20-34 Nm). Install two wires (Figure 3, Items 5 and 6) on horn assembly (Figure 3, Item 1) with two new lockwashers (Figure 3, Item 2), washers (Figure 3, Item 4), and screws (Figure 3, Item 3). Install horn assembly (Figure 3, Item 11) on clip (Figure 3, Item 9) with screw (Figure 3, Item 10), washer (Figure 3, Item 8), and new locknut (Figure 3, Item 7). Tighten locknut to 177-300 lb-in. (20-34 Nm).
10 8 6 7 8 9 9 10
2 1
3 4 5
11
11
M1047SWR
Figure 3.
Horn Installation.
0189-4
TM 5-3895-379-23-1
0189
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). 4. Install cover (Figure 4, Item 2) on bumper assembly (Figure 4, Item 1) with four washers (Figure 4, Item 3) and screws (Figure 4, Item 4). Tighten screws to 177-304 lb-ft (20-34 Nm).
2 3 4
M0971SWR
Horn Installation.
0189-5/6 blank
TM 5-3895-379-23-1
0190
FIELD MAINTENANCE BATTERY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Goggles (Volume 2, WP 0289, Table 1, Item 13) Materials/Parts Petrolatum Technical (Volume 2, WP 0288, Table 1, Item 59) Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 54 and 55 TM 9-6140-200-13 Equipment Condition Engine off. (TM 5-3895-379-10) Operator platform assembly raised. (Volume 2, WP 0235) Battery disconnect switch in OFF position. (TM 5-3895-379-10)
0190-1
TM 5-3895-379-23-1
0190
INSPECTION
WARNING
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. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating, damage to equipment, and injury. Sulfuric acid contained in batteries can cause burns. If battery corrosion or electrolyte makes contact with skin, eyes, or clothing, take immediate action to stop the corrosive burning effects. Failure to follow these procedures may cause injury.
CAUTION
Always disconnect the negative (-) battery cable before servicing battery or positive (+) battery cable. Failure to do so can result in damage to electrical system. Do not allow battery cable ends to contact each other or roller. Failure to follow this caution may cause damage to battery or electrical system.
NOTE
Clean top of batteries with a clean rag prior to inspection. 1. 2. Raise terminal covers (Figure 1, Items 6 and 7) and inspect battery terminals (Figure 1, Items 10 and 12) on both batteries (Figure 1, Items 11 and 16) for corrosion and looseness. Raise terminal covers (Figure 1, Item 2) and inspect battery terminals (Figure 1, Items 3 and 17) for corrosion and looseness. a. b. 3. 4. 5. If terminals (Figure 1, Items 3, 10, 12, or 17) are loose, replace battery (Figure 1, Items 1 or 11). Refer to REMOVAL in this work package. If terminals (Figure 1, Items 3, 10, 12, or 17) are corroded, clean terminals and coat with petrolatum.
Install terminal covers (Figure 1, Item 7). Inspect batteries (Figure 1, Items 11 and 16) for cracks or signs of leakage. If damaged, replace batteries, refer to REMOVAL in this work package. Inspect battery brackets (Figure 1, Item 13) for looseness. If brackets are loose, tighten nuts (Figure 1, Item 14).
0190-2
TM 5-3895-379-23-1
0190
INSPECTION - Continued
1 18 17 16
2 3
5 6
10 11 12 15 13 14
13
M0972SWR
Figure 1. 6.
Battery Inspection.
Lower operator platform assembly (Volume 2, WP 0235).
END OF TASK SERVICE/TEST Service batteries IAW TM 9-6140-200-14. END OF TASK
0190-3
TM 5-3895-379-23-1
0190
REMOVAL
NOTE
Tag and mark all wires prior to removal. 1. 2. 3. Loosen nut (Figure 2, Item 5) and remove cable (Figure 2, Item 8) from negative (-) terminal (Figure 2, Item 10) on battery (Figure 2, Item 11). Loosen nut (Figure 2, Item 4) and remove cable (Figure 2, Item 9) from positive (+) terminal (Figure 2, Item 12) on battery (Figure 2, Item 16). Loosen nuts (Figure 2, Items 1 and 18) and remove cable (Figure 2, Item 15) from negative (-) terminal (Figure 2, Item 17) on battery (Figure 2, Item 16) and positive (+) terminal (Figure 2, Item 3) on battery (Figure 2, Item 11).
1 18 17 16 2 3 9 4 5 6 7 8
10 11 12 15 13 14
13
M1271SWR
Figure 2. 4.
Battery Removal.
Remove four nuts (Figure 3, Item 5), washers (Figure 3, Item 4), screws (Figure 3, Item 1), washers (Figure 3, Item 2), and two holder assemblies (Figure 3, Item 7) from frame assembly (Figure 3, Item 6).
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. 5. With assistance, remove two batteries (Figure 3, Items 3 and 8) from frame assembly (Figure 3, Item 6).
0190-4
TM 5-3895-379-23-1
0190
REMOVAL - Continued
1
2 8
4 5
M0973SWR
Battery Removal.
0190-5
TM 5-3895-379-23-1
0190
INSTALLATION
WARNING
CAUTION
Install battery and/or positive (+) battery cable completely before connecting the negative (-) battery cable. Failure to do so can result in damage to electrical system. 1. With assistance, position two batteries (Figure 4, Items 3 and 8) in frame assembly (Figure 4, Item 6).
CAUTION
Do not overtighten screw and nut. Damage to battery may result. 2. 3. Position two holder assemblies (Figure 4, Item 7) on batteries (Figure 4, Items 3 and 8). Install holder assemblies (Figure 4, Item 7) on frame assembly (Figure 4, Item 6) with two washers (Figure 4, Item 2), screws (Figure 4, Item 1), washers (Figure 4, Item 4), and nuts (Figure 4, Item 5).
1
2 8
4 5
M1272SWR
Figure 4.
Battery Installation.
0190-6
TM 5-3895-379-23-1
0190
INSTALLATION - Continued 4. 5. 6. Install cable (Figure 5, Item 15) on positive (+) terminal (Figure 5, Item 3) of battery (Figure 5, Item 11) and negative (-) terminal (Figure 5, Item 17) of battery (Figure 5, Item 16) with nuts (Figure 5, Items 1 and 18). Install cable (Figure 5, Item 9) on positive (+) terminal (Figure 5, Item 12) of battery (Figure 5, Item 16) with nut (Figure 5, Item 4). Tighten nut securely. Install cable (Figure 5, Item 8) on negative (-) terminal (Figure 5, Item 10) of battery (Figure 5, Item 11) with nut (Figure 5, Item 5). Tighten nut securely.
1 18 17 16
2 3
5 6
10 11 12 15 13 14
13
M1053SWR
Battery Installation.
0190-7/8 blank
TM 5-3895-379-23-1
0191
FIELD MAINTENANCE BATTERY DISCONNECT SWITCH REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Lockwasher (Volume 2, WP 0290, Table 1, Item 126) Qty: 2 Lockwasher (Volume 2, WP 0290, Table 1, Item 115) Qty: 2 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 55 Equipment Condition Operator platform assembly raised. (Volume 2, WP 0235) Battery disconnect switch in OFF position. (TM 5-3895-379-10)
0191-1
TM 5-3895-379-23-1
0191
REMOVAL
CAUTION
Always disconnect the negative (-) battery cable before servicing the battery or positive (+) battery cable. Failure to do so can result in damage to electrical system. Do not allow battery cable ends to contact each other or roller. Failure to follow this caution may cause damage to battery or electrical system.
NOTE
Tag and mark all wires prior to removal. 1. Loosen nut (Figure 1, Item 3) and remove cable (Figure 1, Item 4) from negative (-) terminal (Figure 1, Item 2) on battery (Figure 1, Item 1).
M0974SWR
Figure 1. Battery Disconnect Switch Removal.
0191-2
TM 5-3895-379-23-1
0191
REMOVAL - Continued 2. 3. 4. Slide boot (Figure 2, Item 6) off of cable (Figure 2, Item 7). Remove two nuts (Figure 2, Item 5), lockwashers (Figure 2, Item 4), and cables (Figure 2, Item 7) from battery disconnect switch (Figure 2, Item 3). Discard lockwashers. Remove key (Figure 2, Item 10), nut (Figure 2, Item 9), lockwasher (Figure 2, Item 1), and plate (Figure 2, Item 8) from battery disconnect switch (Figure 2, Item 3). Remove battery disconnect switch (Figure 2, Item 3) from frame assembly (Figure 2, Item 2). Remove lockwasher (Figure 2, Item 1) from battery disconnect switch (Figure 2, Item 3). Discard lockwashers.
3 4
1 7 1
8 9 10
M0975SWR
Battery Disconnect Switch Removal.
0191-3
TM 5-3895-379-23-1
0191
INSTALLATION
NOTE
Use alignment pin on battery disconnect switch to ensure proper placement of switch and plate. 1. Install battery disconnect switch (Figure 3, Item 3) and new lockwasher (Figure 3, Item 1) on frame assembly (Figure 3, Item 2). Install plate (Figure 3, Item 8), lockwasher (Figure 3, Item 1), and nut (Figure 3, Item 9) on battery disconnect switch (Figure 3, Item 3). Install key (Figure 3, Item 10). Install two cables (Figure 3, Item 6) on battery disconnect switch (Figure 3, Item 3) with two new lockwashers (Figure 3, Item 1) and nuts (Figure 3, Item 4). Position boot (Figure 3, Item 5) over cable (Figure 3, Item 6).
3 4
2. 3.
1 7 1
8 9 10
M1200SWR
Figure 3.
Battery Disconnect Switch Installation
0191-4
TM 5-3895-379-23-1
0191
INSTALLATION - Continued 4. Install cable (Figure 4, Item 4) on negative (-) terminal (Figure 4, Item 2) of battery (Figure 4, Item 1) with nut (Figure 4, Item 3).
M1199SWR
Figure 4. Battery Disconnect Switch Installation. END OF TASK FOLLOW-ON MAINTENANCE Lower operator platform assembly. (Volume 2, WP 0235) END OF TASK END OF WORK PACKAGE
0191-5/6 blank
TM 5-3895-379-23-1
0192
FIELD MAINTENANCE BATTERY CABLE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 54 and 55 Equipment Condition Operator platform assembly raised. (Volume 2, WP 0235) Battery disconnect switch in OFF position. (TM 5-3895-379-10) Right-side door assembly opened. (TM 5-3895-379-10)
0192-1
TM 5-3895-379-23-1
0192
REMOVAL
WARNING
CAUTION
Always disconnect negative (-) battery cable before servicing battery or positive (+) battery cable. Failure to do so can result in damage to electrical system. Do not allow battery cable ends to contact each other or roller. Failure to follow this caution may cause damage to battery or electrical system.
NOTE
Tag and mark all cables prior to removal. 1. 2. 3. Loosen nut (Figure 1, Item 6) and remove cable (Figure 1, Item 7) from negative (-) terminal (Figure 1, Item 8) on battery (Figure 1, Item 4). Loosen nut (Figure 1, Item 5) and remove cable (Figure 1, Item 9) from positive (+) terminal (Figure 1, Item 10) on battery (Figure 1, Item 12). Loosen nuts (Figure 1, Items 1 and 3) and remove cable (Figure 1, Item 2) from negative (-) terminal (Figure 1, Item 12) on battery (Figure 1, Item 13) and positive (+) terminal (Figure 1, Item 11) on battery (Figure 1, Item 4).
0192-2
TM 5-3895-379-23-1
0192
REMOVAL - Continued
13
12
11
10
M0976SWR
Figure 1. 4.
Battery Cable Removal.
Remove two screws (Figure 2, Item 1), washers (Figure 2, Item 2), and clips (Figure 2, Item 3) from frame assembly (Figure 2, Item 4).
1 2 3
2
M0977SWR
Figure 2.
0192-3
TM 5-3895-379-23-1
0192
REMOVAL - Continued 5. 6. 7. 8. Slide boot (Figure 3, Item 5) away from battery cable connector. Remove two nuts (Figure 3, Item 4), washers (Figure 3, Item 3), and cables (Figure 3, Items 6 and 10) from switch (Figure 3, Item 2). Remove cable (Figure 3, Item 1) by pulling from battery side of frame assembly (Figure 3, Item 9) through grommet. Remove nut (Figure 3, Item 7), washer (Figure 3, Item 8), and cable (Figure 3, Item 6) from frame assembly (Figure 3, Item 9).
10 9
8 7 4 6 5 3
M0978SWR
Figure 3. Battery Cable Removal.
0192-4
TM 5-3895-379-23-1
0192
REMOVAL - Continued 9. Remove two screws (Figure 4, Item 5), washers (Figure 4, Item 4), and cables (Figure 4, Items 1, 2, and 6) from North Atlantic Treaty Organization (NATO) connector (Figure 4, Item 3).
2 3
4 5 4 6 5
M0979SWR
Figure 4.
0192-5
TM 5-3895-379-23-1
0192
REMOVAL - Continued 10. 11. 12. Remove screw (Figure 5, Item 2), washer (Figure 5, Item 3), and cable (Figure 5, Item 4) from frame assembly (Figure 5, Item 1). Remove four screws (Figure 5, Item 5), washers (Figure 5, Item 6), and clips (Figure 5, Item 7) from frame assembly (Figure 5, Item 1). Slide four clips (Figure 5, Item 7) off battery cable (Figure 5, Item 4).
7 6 5
M0980SWR
Figure 5. Battery Cable Removal.
0192-6
TM 5-3895-379-23-1
0192
REMOVAL - Continued 13. Remove nut (Figure 6, Item 1), washer (Figure 6, Item 2), wire (Figure 6, Item 4), and cable (Figure 6, Item 3) from starter (Figure 6, Item 5).
4 3 1 2 5
M0981SWR
0192-7
TM 5-3895-379-23-1
0192
INSTALLATION
CAUTION
Install positive (+) battery cable completely before connecting negative (-) battery cable. 1. Install cable (Figure 7, Item 3) on positive (+) terminal (Figure 7, Item 4) of battery (Figure 7, Item 1) with nut (Figure 7, Item 2). Feed cable through grommet.
2 1
M0982SWR
Figure 7. Battery Cable Installation. 2. Install one clip (Figure 8, Item 3) on frame assembly (Figure 8, Item 4) with washer (Figure 8, Item 2) and screw (Figure 8, Item 1).
1 2 3
2
M0983SWR
Figure 8. Battery Cable Installation.
0192-8
TM 5-3895-379-23-1
0192
INSTALLATION - Continued 3. 4. 5. Position four clips (Figure 9, Item 7) on battery cable (Figure 9, Item 4). Install four clips (Figure 9, Item 7) on frame assembly (Figure 9, Item 1) with washers (Figure 9, Item 6) and screws (Figure 9, Item 5). Install cable (Figure 9, Item 4) on frame assembly (Figure 9, Item 1) with washer (Figure 9, Item 3) and screw (Figure 9, Item 2).
7 6 5
M0984SWR
Figure 9.
Battery Cable Installation.
0192-9
TM 5-3895-379-23-1
0192
INSTALLATION - Continued 6. Install cable (Figure 10, Item 3) and wire (Figure 10, Item 4) on starter (Figure 10, Item 5) with washer (Figure 10, Item 2) and nut (Figure 10, Item 1).
4 3 1 2 5
M0985SWR
Figure 10.
0192-10
TM 5-3895-379-23-1
0192
INSTALLATION - Continued 7. Install cables (Figure 11, Items 1, 2, and 6) on NATO connector (Figure 11, Item 3) with two washers (Figure 11, Item 4) and screws (Figure 11, Item 5).
2 3
4 5 4 6 5
M0986SWR
Figure 11.
0192-11
TM 5-3895-379-23-1
0192
NOTE
Cable must be fed through grommet from battery side of frame assembly prior to closing rightside door assembly. 8. 9. 10. Install cable (Figure 12, Item 6) on frame assembly (Figure 12, Item 9) with washer (Figure 12, Item 8) and nut (Figure 12, Item 7). Install cables (Figure 12, Items 6 and 10) on switch (Figure 12, Item 2) with two washers (Figure 12, Item 3) and nuts (Figure 12, Item 4). Position boot (Figure 12, Item 5) over battery cable connector.
10 9
8 7 4 6 5 3
M0987SWR
Figure 12.
0192-12
TM 5-3895-379-23-1
0192
INSTALLATION - Continued 11. 12. 13. Install cable (Figure 13, Item 2) on positive (+) terminal (Figure 13, Item 13) of battery (Figure 13, Item 4) with nut (Figure 13, Item 3). Install cable (Figure 13, Item 2) on negative (-) terminal (Figure 13, Item 11) of battery (Figure 13, Item 12) with nut (Figure 13, Item 1). Install cable (Figure 13, Item 7) on negative (-) terminal (Figure 13, Item 8) of battery (Figure 13, Item 4) with nut (Figure 13, Item 6).
13
12
11
10
M0988SWR
Figure 13. 14.
Install other clip (Figure 14, Item 3) on frame assembly (Figure 14, Item 4) with washer (Figure 14, Item 2) and screw (Figure 14, Item 1).
1 2 3
2
M0989SWR
0192-13
TM 5-3895-379-23-1
0192
FOLLOW-ON MAINTENANCE 1. 2. Lower operator platform assembly. (Volume 2, WP 0235) Close right-side door assembly. (TM 5-3895-379-10)
0192-14
TM 5-3895-379-23-1
0193
FIELD MAINTENANCE NATO CONNECTOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Goggles (Volume 2, WP 0289, Table 1, Item 13) Materials/Parts Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Locknut (Volume 2, WP 0290, Table 1, Item 42) Qty: 4 Gasket (Volume 2, WP 0290, Table 1, Item 121) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 3895-379-23P, Figure 54 Equipment Condition Operator platform assembly raised. (Volume 2, WP 0235) Battery disconnect switch in OFF position. (TM 5-3895-379-10)
0193-1
TM 5-3895-379-23-1
0193
REMOVAL
WARNING
CAUTION
Always disconnect negative (-) battery cable before servicing battery or positive (+) battery cable. Failure to do so can result in damage to electrical system. Do not allow battery cable ends to contact each other or roller. Failure to follow this caution may cause damage to battery or electrical system.
NOTE
Tag and mark all cables prior to removal. 1. 2. Slide battery cable cover (Figure 1, Item 3) back and away from negative (-) terminal (Figure 1, Item 5). Loosen nut (Figure 1, Item 2) and remove cable (Figure 1, Item 4) from negative (-) terminal (Figure 1, Item 5) on battery (Figure 1, Item 1).
0193-2
TM 5-3895-379-23-1
0193
REMOVAL - Continued
3 2 1 4 5
M0990SWR
Figure 1.
NATO Connector Removal.
0193-3
TM 5-3895-379-23-1
0193
REMOVAL - Continued 3. 4. 5. 6. Remove cap (Figure 2, Item 5) from North Atlantic Treaty Organization (NATO) connector (Figure 2, Item 4). Remove two screws (Figure 2, Item 1), washers (Figure 2, Item 2), and three cables (Figure 2, Item 3) from NATO connector (Figure 2, Item 4). Remove four locknuts (Figure 2, Item 12), washers (Figure 2, Item 11), screws (Figure 2, Item 6), and rope clamp (Figure 2, Item 7) from NATO connector (Figure 2, Item 4). Discard locknuts. Remove NATO connector (Figure 2, Item 4), gasket (Figure 2, Item 8), and insulator (Figure 2, Item 10) from frame assembly (Figure 2, Item 9). Discard gasket.
3 2 1
4 12 11 5
7 10 9 8 6
M0991SWR
Figure 2. NATO Connector Removal. END OF TASK
0193-4
TM 5-3895-379-23-1
0193
INSTALLATION 1. 2. 3. 4. Position new gasket (Figure 3, Item 8), NATO connector (Figure 3, Item 4), and insulator (Figure 3, Item 10) on frame assembly (Figure 3, Item 9). Install rope clamp (Figure 3, Item 7), four screws (Figure 3, Item 6), washers (Figure 3, Item 11), and new locknuts (Figure 3, Item 12) to NATO connector (Figure 3, Item 4). Install three cables (Figure 3, Item 3) on NATO connector (Figure 3, Item 4) with two washers (Figure 3, Item 2) and screws (Figure 3, Item 1). Install cap (Figure 3, Item 5) on connector (Figure 3, Item 4).
2 3 2 1
4 12 11 5
7 10 9 8 6
M1264SWR
Figure 3.
NATO Connector Installation.
0193-5
TM 5-3895-379-23-1
0193
INSTALLATION - Continued 5. 6. Install cable (Figure 4, Item 4) on negative (-) terminal (Figure 4, Item 5) of battery (Figure 4, Item 1) with nut (Figure 4, Item 2). Position battery cable cover (Figure 4, Item 3) over negative (-) terminal (Figure 4, Item 5) of battery (Figure 4, Item 1).
3 2 1 4 5
M1263SWR
NATO Connector Installation.
0193-6
TM 5-3895-379-23-1
0194
FIELD MAINTENANCE GROUND CABLE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 55 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)
0194-1
TM 5-3895-379-23-1
0194
REMOVAL
NOTE
Tag and mark all cables prior to removal. 1. 2. 3. 4. 5. Remove screw (Figure 1, Item 14), washer (Figure 1, Item 13), ground cable (Figure 1, Item 5), and ground strap (Figure 1, Item 12) from frame assembly (Figure 1, Item 11). Remove screw (Figure 1, Item 2), washer (Figure 1, Item 1), and ground strap (Figure 1, Item 12) from flywheel housing (Figure 1, Item 15). Remove screw (Figure 1, Item 7), washer (Figure 1, Item 8), and clamp (Figure 1, Item 9) from bracket (Figure 1, Item 10). Remove clamp (Figure 1, Item 9) from ground cable (Figure 1, Item 5). Remove screw (Figure 1, Item 3), washer (Figure 1, Item 4), and cable (Figure 1, Item 5) from engine block (Figure 1, Item 6).
1 2 3 4 5 6 7
8 14 13 9 15
12 5 10
11
M0992SWR
Ground Cable Removal.
0194-2
TM 5-3895-379-23-1
0194
INSPECTION 1. 2. 3. 4. Check cable ends for corrosion. Clean as necessary. Check for torn or frayed wires on ground strap (Figure 2, Item 12) and ground cable (Figure 2, Item 5). Check continuity by attaching positive and negative lead of multimeter to opposite ends of cable. Reading of infinite ohms means there is good continuity. Discard cable if reading shows less than infinite ohms. Check contact of frame assembly (Figure 2, Item 11) and flywheel housing (Figure 2, Item 15) for corrosion. Clean as necessary.
END OF TASK REPLACEMENT Replace all damaged parts. END OF TASK
0194-3
TM 5-3895-379-23-1
0194
INSTALLATION 1. 2. 3. 4. 5. Install ground cable (Figure 2, Item 5) on engine block (Figure 2, Item 6) with screw (Figure 2, Item 3) and washer (Figure 2, Item 4). Tighten screw to 28-42 lb-ft (38-57 Nm). Install clamp (Figure 2, Item 9) on ground cable (Figure 2, Item 5). Install clamp (Figure 2, Item 9) on bracket (Figure 2, Item 10) with washer (Figure 2, Item 8) and screw (Figure 2, Item 7). Tighten screw to 60-90 lb-ft (81-122 Nm). Install ground strap (Figure 2, Item 12) on flywheel housing (Figure 2, Item 15) with washer (Figure 2, Item 1) and screw (Figure 2, Item 2). Tighten screw to 60-90 lb-ft (81-122 Nm). Install ground cable (Figure 2, Item 5) and ground strap (Figure 2, Item 12) on frame assembly (Figure 2, Item 11) with washer (Figure 2, Item 13) and screw (Figure 2, Item 14). Tighten screw to 28-42 lb-ft (38-57 Nm).
1 2 3 4 5 6 7
8 14 13 9 15
12 5 10
11
M0993SWR
Ground Cable Installation.
0194-4
TM 5-3895-379-23-1
0195
FIELD MAINTENANCE GENERAL WIRING REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Tool Kit, Electrical Contact (Volume 2, WP 0289, Table 1, Item 40) Materials/Parts Solder Tin Alloy (WI) (Volume 2, WP 0288, Table 1, Item 66) Personnel Required Construction Equipment Repairer 91L 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)
0195-1
TM 5-3895-379-23-1
0195
SOLDERLESS TERMINAL REPLACEMENT
CAUTION
Terminals come in different styles and sizes. To prevent equipment damage, be sure to use only exact replacements. Do not attempt to modify terminal to fit. 1. Remove old terminal (Figure 1, Item 1) and trim end of wire (Figure 1, Item 2) as required.
NOTE
If trimming causes wire to become too short, refer to WIRE SPLICING USING BUTT CONNECTORS or WIRE SPLICING USING SOLDER METHOD in this work package. 2. Remove insulation (Figure 1, Item 3) from wire (Figure 1, Item 2) and equal to dimension A.
NOTE
Be sure all strands of wire are inside terminal when installing terminal to wire. 3. 4. Install terminal (Figure 1, Item 1) over bare end of wire (Figure 1, Item 2). Crimp terminal (Figure 1, Item 1) firmly in place.
A 1 2
M0994SWR
Figure 1. Solderless Terminal Replacement. END OF TASK
0195-2
TM 5-3895-379-23-1
0195
WIRE SPLICING USING BUTT CONNECTORS
NOTE
Whenever possible, use solder method of wire splicing. Refer to WIRE SPLICING USING SOLDER METHOD in this work package. If repairing a broken wire, perform Steps (1) through (4) only. If a section of wire is being replaced, perform Steps (5) through (11). 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Remove damaged wire (Figure 2, Item 3) section. Remove insulation (Figure 2, Item 1) from both ends of wire (Figure 2, Item 3) equal to dimension A. Install butt connector (Figure 2, Item 2) over bare ends of wire (Figure 2, Item 3) and crimp securely over both ends. Inspect splice and be sure no bare wire is visible. Install two butt connectors (Figure 2, Item 2) securely in place over wire (Figure 2, Item 3). Crimp one end of both butt connectors (Figure 2, Item 2) securely in place over wire (Figure 2, Item 3). Measure distance between two open ends of butt connectors (Figure 2, Item 2). Cut section of new wire (Figure 2, Item 5) 1 in. (2.54 cm) longer than distance measured in Step (7). Remove insulation (Figure 2, Item 4) from both ends of new wire (Figure 2, Item 5) equal to dimension A. Install bare ends of new wire (Figure 2, Item 5) into butt connectors (Figure 2, Item 2) and crimp securely into place. Inspect splice and be sure that no bare wire (Figure 2, Item 3) is visible.
1 2 A 3
3 1
2 4
5 4
2 1
3
M0995SWR
Figure 2. Wire Splicing Using Butt Connectors. END OF TASK
0195-3
TM 5-3895-379-23-1
0195
WIRE SPLICING USING SOLDER METHOD
WARNING
Never use an open flame to apply heat to heat shrink tubing. Failure to follow this warning may cause injury. Allow heat shrink tubing to cool before handling. Failure to follow this warning may cause injury. Allow solder to cool before handling wire. Failure to follow this warning may cause injury.
NOTE
This method produces a stronger and more permanent repair. Use this method whenever possible. If repairing a broken wire perform Steps (1) through (6) only. If a section of wire is being replaced, perform Steps (7) through (13). 1. 2. 3. 4. Remove broken section of wire (Figure 3, Item 2). Remove 0.75 in. (1.9 cm) of insulation (Figure 3, Item 1) from both ends of wire (Figure 3, Item 2). Slide 3 in. (7.62 cm) piece of proper size heat shrink tubing (Figure 3, Item 3) over one end of wire (Figure 3, Item 2). Twist the two ends of wire (Figure 3, Item 2) together and solder. Be sure solder flows evenly onto both ends of wire.
WARNING
Allow solder to cool before handling wire. Failure to follow this warning may cause injury. 5. Slide heat shrink tubing (Figure 3, Item 3) over solder joint.
0195-4
TM 5-3895-379-23-1
0195
WIRE SPLICING USING SOLDER METHOD - Continued

1 2 APPLY SOLDER 2 3 2 1 2 3 2
M0996SWR
2 3
Figure 3.
Wire Splicing Using Solder Method.
0195-5
TM 5-3895-379-23-1
0195
WIRE SPLICING USING SOLDER METHOD - Continued
NOTE
Be sure solder joint is centered in heat shrink tubing. 6. 7. 8. 9. 10. 11. 12. Apply heat and allow heat shrink tubing (Figure 4, Item 1) to shrink until tight on solder joint and insulation of wire (Figure 4, Item 2). If replacing a section of wire, measure distance between ends of wire. Cut a section of new wire (Figure 4, Item 3) 2 in. (5.08 cm) longer than the distance measured in Step (7). Remove 3/4 in. (1.9 cm) of insulation (Figure 4, Item 4) from both ends of new wire (Figure 4, Item 3). Slide two 3 in. (7.62 cm) pieces of heat shrink tubing (Figure 4, Item 1) over ends of wire (Figure 4, Item 2). Twist bare ends of wires (Figure 4, Item 2) and new wire (Figure 4, Item 3) together and solder. Ensure solder flows evenly onto wires of each joint. Slide heat shrink tubing (Figure 4, Item 1) over solder joint.
NOTE
Be sure solder joint is centered in heat shrink tubing. 13. Apply heat and allow heat shrink tubing (Figure 4, Item 1) to shrink until tight on solder joint and insulation of wire (Figure 4, Item 2).
1 3 1 2 4 2 4 1 2
M0997SWR
2 APPLY SOLDER 4 3 4 2 1 2 3 1 2
Figure 4. Wire Splicing Using Solder Method. END OF TASK
0195-6
TM 5-3895-379-23-1
0195
MALE CABLE CONNECTOR REPLACEMENT 1. 2. 3. 4. Slide outer shell (Figure 5, Item 1) back from wire (Figure 5, Item 5). Remove C-washer (Figure 5, Item 2) from wire (Figure 5, Item 5). Remove contact (Figure 5, Item 3) from wire (Figure 5, Item 5). Trim end of wire (Figure 5, Item 5) as needed to make an undamaged end.
NOTE
If trimming causes wire to become too short, refer to WIRE SPLICING USING BUTT CONNECTORS or WIRE SPLICING USING SOLDER METHOD in this work package. 5. 6. 7. 8. 9. 10. Remove 3/8 in. (1.0 cm) of insulation (Figure 5, Item 4) from end of wire (Figure 5, Item 5). Install contact (Figure 5, Item 3) over bare end of wire (Figure 5, Item 5). Crimp contact (Figure 5, Item 3) securely in place. Install C-washer (Figure 5, Item 2) to wire (Figure 5, Item 5). Slide outer shell (Figure 5, Item 1) over C-washer (Figure 5, Item 2) and contact (Figure 5, Item 3). Be sure no bare wire (Figure 5, Item 5) is visible outside of outer shell (Figure 5, Item 1).
1
2 5 3
4
M0998SWR
Male Cable Connector Replacement.
0195-7
TM 5-3895-379-23-1
0195
FEMALE CABLE CONNECTOR REPLACEMENT 1. 2. 3. Slide outer shell (Figure 6, Item 2) and sleeve (Figure 6, Item 1) back on wire (Figure 6, Item 3). Remove contact (Figure 6, Item 5) from wire (Figure 6, Item 3). Trim end of wire (Figure 6, Item 3) as needed to make an undamaged end.
NOTE
If trimming causes wire to become too short, refer to WIRE SPLICING USING BUTT CONNECTORS or WIRE SPLICING USING SOLDER METHOD in this work package. 4. 5. 6. 7. 8. 9. Remove 1/4 in. (6.4 mm) of insulation (Figure 6, Item 4) from end of wire (Figure 6, Item 3). Install sleeve (Figure 6, Item 1) over end of wire (Figure 6, Item 3). Install contact (Figure 6, Item 5) securely into place. Crimp contact (Figure 6, Item 5) securely into place. Slide outer shell (Figure 6, Item 2) over sleeve (Figure 6, Item 1) and contact (Figure 6, Item 5). Be sure no bare wire (Figure 6, Item 3) shows outside of outer shell (Figure 6, Item 2).
4 5 3
M0999SWR
Female Cable Connector Replacement.
0195-8
TM 5-3895-379-23-1
0195
GROUP I TERMINAL DISASSEMBLY
WARNING
Use caution when using removal tool. Tip of tool is very sharp. Failure to follow this warning may cause injury.
NOTE
Locking tab on the terminal mates with molded tab in plastic connector to retain cable assembly. All Group I connectors are repaired the same way. Number of wires in connection may vary. 1. 2. 3. Insert tip of removal tool (Figure 7, Item 2) between locking tab (Figure 7, Item 3) of terminal (Figure 7, Item 1) and wall of connector (Figure 7, Item 4). Release locking tab (Figure 7, Item 3) from connector (Figure 7, Item 4). Push terminal (Figure 7, Item 1) through front of connector (Figure 7, Item 4).
1 3 4
M1000SWR
Figure 7.
Wiring Repair.
0195-9
TM 5-3895-379-23-1
0195
GROUP I TERMINAL DISASSEMBLY - Continued
NOTE
Perform Step only if old terminal is still attached to wire. Make cut directly behind damaged terminal. 4. 5. Cut and remove terminal (Figure 8, Item 1) from wire (Figure 8, Item 2). Discard terminal. Remove wire (Figure 8, Item 2) and seal (Figure 8, Item 4) from connector (Figure 8, Item 3).
1 2
3
M1001SWR
Figure 8. END OF TASK GROUP I TERMINAL ASSEMBLY 1.
Wiring Repair.
Push wire (Figure 9, Item 1) through seal (Figure 9, Item 3) and cavity of connector (Figure 9, Item 2).
1 2
3
M1002SWR
Figure 9.
Wiring Repair.
0195-10
TM 5-3895-379-23-1
0195
GROUP I TERMINAL ASSEMBLY - Continued
CAUTION
Strip wire after placing it through seal and connector body to prevent damage to individual strands. 2. Strip end of wire (Figure 10, Item 1) using crimp tool (Figure 10, Item 3) leaving 1/4 in. (0.64 cm) of bare wire.
NOTE
When installing terminal be sure terminal wings point to the upper jaw of crimping tool. 3. Push terminal holder open and insert terminal (Figure 10, Item 2) until attaching portion of terminal rests on anvil.
M1003SWR
Figure 10.
Wiring Repair.
0195-11
TM 5-3895-379-23-1
0195
GROUP I TERMINAL ASSEMBLY - Continued
NOTE
Wire should be positioned so larger wings of terminal will crimp around insulation and smaller wings will crimp around exposed bare wire. 4. 5. Position wire (Figure 11, Item 2) on terminal (Figure 11, Item 1). Press handle(s) of crimp tool together until ratchet releases and crimp is complete.
NOTE
Locking tab should be positioned toward notch in connector cavity when properly installed. 6. 7. Pull wire (Figure 11, Item 2) and terminal (Figure 11, Item 1) back through connector (Figure 11, Item 4) until seated. Seat seal (Figure 11, Item 3) into connector (Figure 11, Item 4).
1 1
2 2
3
M1004SWR
Figure 11. END OF TASK GROUP II TERMINAL DISASSEMBLY
Wiring Repair.
NOTE
Connector is removed by gently prying up on clip and pulling on connector or pushing in on clip on connector. All Group II connectors are repaired the same way. Number of wires in connector may vary. The general shape of Group II connectors may vary. Both halves of connectors are repaired the same way. 1. 2. Disconnect connector (Figure 12, Item 1). Unlatch and open two secondary locks (Figure 12, Item 2) on connector (Figure 12, Item 1).
0195-12
TM 5-3895-379-23-1
0195
GROUP II TERMINAL DISASSEMBLY - Continued
2
M1005SWR
Figure 12.
Wiring Repair.
WARNING
Tip of removal tool is very sharp. Use caution when using tool. Failure to comply may cause injury to personnel. 3. 4. Insert removal tool (Figure 13, Item 2) into cavity (Figure 13, Item 3) on connector (Figure 13, Item 1) until seated. Pull wire (Figure 13, Item 6) back through connector (Figure 13, Item 1) and remove tool.
NOTE
Perform Step (5) only if old terminal is still attached to wire. Make cut directly behind damaged terminal. 5. Cut terminal (Figure 13, Item 4) and wire seal (Figure 13, Item 5) from wire (Figure 13, Item 6). Discard terminal and seal.
2 1
4 5
Figure 13. Wiring Repair.
M1006SWR
0195-13
TM 5-3895-379-23-1
0195
GROUP II TERMINAL DISASSEMBLY - Continued 6. Insert 1 in. (2.5 cm) of wire (Figure 14, Item 2) through new wire seal (Figure 14, Item 1).
CAUTION
Strip wire after placing it through seal to prevent damage to individual wire strands. 7. Strip end of wire (Figure 14, Item 2) leaving 1/4 in. (0.64 cm) of bare wire.
2 1
M1007SWR
Figure 14. END OF TASK GROUP II TERMINAL ASSEMBLY 1. 2.
Wiring Repair.
Insert new terminal (Figure 15, Item 3) in locating hole of crimp tool (Figure 15, Item 5) using proper hole according to gauge of wire (Figure 15, Item 2). Slide seal (Figure 15, Item 5) down to end of insulation (Figure 15, Item 1).
1 2 3
4
M1008SWR
Figure 15.
Wiring Repair.
0195-14
TM 5-3895-379-23-1
0195
GROUP II TERMINAL ASSEMBLY - Continued
NOTE
Wire and seal should be positioned so larger wings of terminal will crimp around seal and smaller wings will crimp around exposed bare wire. 3. 4. 5. Position wire (Figure 16, Item 3) on terminal (Figure 16, Item 2). Press handles of crimp tool together until ratchet releases and crimp is complete. Push new terminal (Figure 16, Item 2) and wire (Figure 16, Item 3) through connector (Figure 16, Item 1) until seated.
3
M1009SWR
Figure 16. 6. 7.
Wiring Repair.
Close two secondary locks (Figure 17, Item 2) on connector (Figure 17, Item 1). Connect connector (Figure 17, Item 1).
2
M1010SWR
Wiring Repair.
0195-15
TM 5-3895-379-23-1
0195
0195-16
TM 5-3895-379-23-1
0196
FIELD MAINTENANCE ENGINE WIRING HARNESS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 0-300 in-lb (Volume 2, WP 0289, Table 1, Item 41) Materials/Parts Strap, Tiedown, Electrical (Volume 2, WP 0288, Table 1, Item 67, 68, 69) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Lockwasher (Volume 2, WP 0290, Table 1, Item 23) Qty: 2 Lockwasher (Volume 2, WP 0290, Table 1, Item 125) Qty: 2 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 56 and 57 WP 0195 Volume 2, WP 0280 Equipment Condition Operator platform assembly raised. (Volume 2, WP 0235) Battery cables disconnected. (WP 0192)
0196-1
TM 5-3895-379-23-1
0196
INSPECTION AND TESTING Wiring and electrical inspection and repair is presented in General Wiring Repair (WP 0195). Electrical testing is presented in Electrical General Maintenance Instructions (Volume 2, WP 0280). END OF TASK REMOVAL
NOTE
Tag and mark all wires prior to removal. Cut electrical tiedown straps as needed for removal. 1. 2. 3. 4. Disconnect engine wiring harness connector (Figure 1, Item 3) from connector (Figure 1, Item 7). If damaged, remove nut (Figure 1, Item 1), bracket (Figure 1, Item 4), washer (Figure 1, Item 5), and screw (Figure 1, Item 6) from frame assembly (Figure 1, Item 8). Loosen screw (Figure 1, Item 9) in connector (Figure 1, Item 10) and disconnect connector from engine wiring harness connector (Figure 1, Item 2). Remove three screws (Figure 1, Item 11), lockwashers (Figure 1, Item 12), and engine wiring harness connector (Figure 1, Item 2) from frame assembly (Figure 1, Item 8). Discard lockwashers.
0196-2
TM 5-3895-379-23-1
0196
REMOVAL - Continued
1 12 11 10
3 4 5 8 9 7 6
M1011SWR
Figure 1.
Engine Wiring Harness Removal.
0196-3
TM 5-3895-379-23-1
0196
REMOVAL - Continued 5. Disconnect engine wiring harness connector (Figure 2, Item 1) from low charge pressure switch connector (Figure 2, Item 2).
M1012SWR
Figure 2. Engine Wiring Harness Removal. 6. 7. 8. Remove nut (Figure 3, Item 8), washer (Figure 3, Item 7), and two wires (Figure 3, Item 6) from frame assembly (Figure 3, Item 5). Disconnect engine wiring harness connector (Figure 3, Item 4) from rear wiring harness connector (Figure 3, Item 3). Disconnect engine wiring harness connector (Figure 3, Item 1) from front wiring harness connector (Figure 3, Item 2).
3 4 8 7 6 5

M1013SWR
Figure 3. Engine Wiring Harness Removal.
0196-4
TM 5-3895-379-23-1
0196
REMOVAL - Continued 9. Loosen two nuts (Figure 4, Item 2) and remove two wires (Figure 4, Item 1) from fuel solenoid (Figure 4, Item 3).
M1014SWR
Figure 4. 10.
Disconnect engine wiring harness connector (Figure 5, Item 1) from water temperature sensor connector (Figure 5, Item 2).
1 2
M1015SWR
Figure 5.
0196-5
TM 5-3895-379-23-1
0196
REMOVAL - Continued 11. 12. Remove nut (Figure 6, Item 1), washer (Figure 6, Item 2), and wire (Figure 6, Item 3) from D+ terminal (Figure 6, Item 4) of alternator (Figure 6, Item 5). Remove nut (Figure 6, Item 9), washer (Figure 6, Item 8), and wire (Figure 6, Item 7) from B+ terminal (Figure 6, Item 6) of alternator (Figure 6, Item 5).
4 1 2 3
6 9 8 7
M1016SWR
Figure 6. Engine Wiring Harness Removal. 13. Disconnect engine wiring harness connector (Figure 7, Item 2) from hourmeter connector (Figure 7, Item 1).
M1017SWR
0196-6
TM 5-3895-379-23-1
0196
REMOVAL - Continued 14. Disconnect engine wiring harness connector (Figure 8, Item 2) from engine oil pressure switch connector (Figure 8, Item 1).
2 1
M1018SWR
Figure 8. 15.
Position two cable boots (Figure 9, Item 4) to expose ends of cables (Figure 9, Item 1) and remove two screws (Figure 9, Item 3), lockwashers (Figure 9, Item 2), and two cables from alternator reset (Figure 9, Item 5). Discard lockwashers.
2 3
5 4 2 3
M1019SWR
Figure 9.
0196-7
TM 5-3895-379-23-1
0196
REMOVAL - Continued 16. 17. Disconnect engine wiring harness connector (Figure 10, Item 4) from two-speed valve connector (Figure 10, Item 3). Disconnect engine wiring harness connector (Figure 10, Item 1) from brake valve connector (Figure 10, Item 2).
1 4 3
M1020SWR
Figure 10. Engine Wiring Harness Removal. 18. 19. Loosen two screws (Figure 11, Item 2) and disconnect two engine wiring harness connectors (Figure 11, Item 3) from two vibratory pump connectors (Figure 11, Item 1). Disconnect two engine wiring harness connectors (Figure 11, Item 4) from two vibratory control valve connectors (Figure 11, Item 5).
5 2 1 3 4
M1021SWR
0196-8
TM 5-3895-379-23-1
0196
REMOVAL - Continued 20. Disconnect engine wiring harness connector (Figure 12, Item 1) from starter relay connector (Figure 12, Item 2).
1 2
M1022SWR
Figure 12. 21.
Position boot (Figure 13, Item 4) so that end of cable (Figure 13, Item 2) can be seen and remove two nuts (Figure 13, Item 6), washers (Figure 13, Item 5), and two cables (Figure 13, Items 1 and 2) from starter relay switch assembly (Figure 13, Item 3).
3 1 2
5 6
5 6
Figure 13.
4
M1023SWR
0196-9
TM 5-3895-379-23-1
0196
REMOVAL - Continued 22. Loosen two screws (Figure 14, Item 2) and remove two wires (Figure 14, Item 3) from hydraulic temperature sensor (Figure 14, Item 1).
1 2 3
2 3
M1024SWR
Figure 14. Engine Wiring Harness Removal. 23. Remove two nuts (Figure 15, Item 1), lockwashers (Figure 15, Item 2), washers (Figure 15, Item 3), and wires (Figure 15, Item 4) from fuel level sending unit (Figure 15, Item 5). Discard lockwashers.
1 2 3 4
1 2 3 4 5
M1025SWR
0196-10
TM 5-3895-379-23-1
0196
REMOVAL - Continued 24. Disconnect engine wiring harness clip (Figure 16, Item 1) from starting aid (Figure 16, Item 2).
M1026SWR
Figure 16. 25.
Position boot (Figure 17, Item 6) to expose cable (Figure 17, Item 7) end and remove nut (Figure 17, Item 8), lockwasher (Figure 17, Item 9), and cable (Figure 17, Item 7) from starter (Figure 17, Item 4). Discard lockwasher. Open cover (Figure 17, Item 5) on starter (Figure 17, Item 4) and remove screw (Figure 17, Item 1), lockwasher (Figure 17, Item 2), and cable (Figure 17, Item 3) from starter (Figure 17, Item 4). Discard lockwasher.
26.
8 9
7 6
3 4
M1027SWR
Figure 17. 27.
Note position of engine wiring harness. Carefully remove wiring harness from roller.
END OF TASK
0196-11
TM 5-3895-379-23-1
0196
INSTALLATION
NOTE
Install electrical tiedown straps as required. 1. 2. 3. Position loose wiring harness in general installation position. Install cable (Figure 18, Item 3) on starter (Figure 18, Item 4) with new lockwasher (Figure 18, Item 2) and screw (Figure 18, Item 1). Close cover (Figure 18, Item 5). Install cable (Figure 18, Item 7) on starter (Figure 18, Item 4) with new lockwasher (Figure 18, Item 9) and nut (Figure 18, Item 8). Position boot (Figure 18, Item 6) to cover cable end.
8 9
7 6
3 4
M1028SWR
Figure 18. Engine Wiring Harness Installation. 4. Connect engine wiring harness clip (Figure 19, Item 1) to starting aid (Figure 19, Item 2).
M1029SWR
Figure 19. Engine Wiring Harness Installation. 5. Install two wires (Figure 20, Item 4) on fuel level sending unit (Figure 20, Item 5) with two washers (Figure 20, Item 3), new lockwashers (Figure 20, Item 2), and nuts (Figure 20, Item 1).
0196-12
TM 5-3895-379-23-1
0196
1 2 3 4
1 2 3 4 5
M1030SWR
Figure 20. 6.
Engine Wiring Harness Installation.
Position two wires (Figure 21, Item 3) on hydraulic temperature sensor (Figure 21, Item 1) and tighten two screws (Figure 21, Item 2).
1 2 3
2 3
M1031SWR
Figure 21. 7.
Install two cables (Figure 22, Items 1 and 2) on starter relay switch assembly (Figure 22, Item 3) with two washers (Figure 22, Item 5) and nuts (Figure 22, Item 6). Position boot (Figure 22, Item 4) to cover cable (Figure 22, Item 2).
3 1 2
5 6
5 6
Figure 22.
4
M1032SWR
0196-13
TM 5-3895-379-23-1
0196
INSTALLATION - Continued 8. Connect engine wiring harness connector (Figure 23, Item 1) to starter relay connector (Figure 23, Item 2).
1 2
M1033SWR
Figure 23. Engine Wiring Harness Installation. 9. 10. Connect two engine wiring harness connectors (Figure 24, Item 4) to vibratory control valve connectors (Figure 24, Item 5). Position two engine wiring harness connectors (Figure 24, Item 3) on vibratory pump connectors (Figure 24, Item 1) and tighten screws (Figure 24, Item 2).
5 2 1 3 4
M1034SWR
Figure 24. Engine Wiring Harness Installation.
0196-14
TM 5-3895-379-23-1
0196
INSTALLATION - Continued 11. 12. Connect engine wiring harness connector (Figure 25, Item 1) to brake valve connector (Figure 25, Item 2). Connect engine wiring harness connector (Figure 25, Item 4) to two-speed valve connector (Figure 25, Item 3).
1 4 3
M1035SWR
Figure 25. 13.
Install two cables (Figure 26, Item 1) on alternator reset (Figure 26, Item 5) with two new lockwashers (Figure 26, Item 2) and screws (Figure 26, Item 3). Position two boots (Figure 26, Item 4) to cover cable ends.
2 3
5 4 2 3
M1036SWR
Figure 26.
0196-15
TM 5-3895-379-23-1
0196
INSTALLATION - Continued 14. Connect engine wiring harness connector (Figure 27, Item 2) to engine oil pressure switch connector (Figure 27, Item 1).
2 1
M1037SWR
Figure 27. Engine Wiring Harness Installation. 15. Connect engine wiring harness connector (Figure 28, Item 2) to hourmeter connector (Figure 28, Item 1).
1
M1038SWR
0196-16
TM 5-3895-379-23-1
0196
INSTALLATION - Continued 16. 17. Install wire (Figure 29, Item 7) on B+ terminal (Figure 29, Item 6) of alternator (Figure 29, Item 5) with washer (Figure 29, Item 8) and nut (Figure 29, Item 9). Tighten nut to 60-72 lb-in. (7-8 Nm). Install wire (Figure 29, Item 3) on D+ terminal (Figure 29, Item 4) of alternator (Figure 29, Item 5) with washer (Figure 29, Item 2) and nut (Figure 29, Item 1). Tighten nut to 12-16.8 lb-in. (1.35-1.9 Nm).
4 1 2 3
6 9 8 7
M1039SWR
Figure 29. 18.
Connect engine wiring harness connector (Figure 30, Item 1) to water temperature sensor connector (Figure 30, Item 2).
M1040SWR
Figure 30.
0196-17
TM 5-3895-379-23-1
0196
INSTALLATION - Continued 19. Position two wires (Figure 31, Item 1) on fuel solenoid (Figure 31, Item 3) and tighten two nuts (Figure 31, Item 2).
M1041SWR
Figure 31. Engine Wiring Harness Installation. 20. 21. 22. Connect engine wiring harness connector (Figure 32, Item 1) to front wiring harness connector (Figure 32, Item 2). Connect engine wiring harness connector (Figure 32, Item 4) to rear wiring harness connector (Figure 32, Item 3). Install two wires (Figure 32, Item 6) to frame assembly (Figure 32, Item 5) with washer (Figure 32, Item 7) and nut (Figure 32, Item 8).
3 4 8 7 6 5

M1042SWR
0196-18
TM 5-3895-379-23-1
0196
INSTALLATION - Continued 23. Connect engine wiring harness connector (Figure 33, Item 1) to low charge pressure switch connector (Figure 33, Item 2).
M1043SWR
Figure 33.
0196-19
TM 5-3895-379-23-1
0196
INSTALLATION - Continued 24. 25. 26. 27. Install engine wiring harness connector (Figure 34, Item 2) to frame assembly (Figure 34, Item 8) with three new lockwashers (Figure 34, Item 12) and screws (Figure 34, Item 11). Connect engine wiring harness connector (Figure 34, Item 2) to connector (Figure 34, Item 10) and tighten screw (Figure 34, Item 9). If removed, install bracket (Figure 34, Item 4) to frame assembly (Figure 34, Item 8) with screw (Figure 34, Item 6), washer (Figure 34, Item 5), and nut (Figure 34, Item 1). Connect engine wiring harness connector (Figure 34, Item 3) to connector (Figure 34, Item 7).
1 12 11 10
3 4 5 8 9 7 6
M1044SWR
Figure 34. Engine Wiring Harness Installation. END OF TASK
0196-20
TM 5-3895-379-23-1
0196
FOLLOW-ON MAINTENANCE 1. 2. Connect battery cables. (WP 0192) Lower operator platform assembly. (Volume 2, WP 0235)
0196-21/22 blank
TM 5-3895-379-23-1
0197
FIELD MAINTENANCE FRONT WIRING HARNESS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Strap, Tiedown, Electrical (Volume 2, WP 0288, Table 1, Item 67, 68, 69) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Lockwasher (Volume 2, WP 0290, Table 1, Item 124) Qty: 2 Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figures 58 and 59 References (cont.) WP 0195 Volume 2, WP 0280 Equipment Condition Front water tank removed. (Volume 2, WP 0269) Battery cables disconnected. (WP 0192) Right-side door assembly opened. (TM 5-3895-379-10)
0197-1
TM 5-3895-379-23-1
0197
NOTE
Remove electrical tiedown straps as required. Tag and mark all wires prior to REMOVAL. Tag and mark general position of wiring harness in chassis as components are removed. Harness will need to be repositioned at start of installation. 1. 2. Remove nut (Figure 1, Item 6), washer (Figure 1, Item 5), and two wires (Figure 1, Item 4) from frame assembly (Figure 1, Item 3). Disconnect front wire harness connector (Figure 1, Item 2) from connector (Figure 1, Item 1).
1 2
5 4 3
M0284SWR
Figure 1. 3. 4.
Front Wiring Harness Removal.
Loosen eight nuts (Figure 2, Item 3) on four brackets (Figure 2, Item 1). Remove bottom nuts (Figure 2, Item 3) and screws (Figure 2, Item 4) and pull front wiring harness (Figure 2, Item 2) through brackets (Figure 2, Item 1).
0197-2
TM 5-3895-379-23-1
0197
REMOVAL - Continued
1 2
LOOSEN 4
REMOVE
M0285SWR
Figure 2. 5.
Remove screw (Figure 3, Item 3), washer (Figure 3, Item 2), and bracket (Figure 3, Item 1) from frame assembly (Figure 3, Item 4).
3 2 1 4
M0286SWR
Figure 3.
0197-3
TM 5-3895-379-23-1
0197
REMOVAL - Continued 6. 7. Remove screw (Figure 4, Item 5), washer (Figure 4, Item 4), clip (Figure 4, Item 3), and washer (Figure 4, Item 4) from welded nut (Figure 4, Item 2) on clip assembly (Figure 4, Item 1). Remove clip (Figure 4, Item 1) from front wiring harness (Figure 4, Item 6).
1
2 4 3
4 5
M0287SWR
Figure 4. 8.
Disconnect front wiring harness connector (Figure 5, Item 2) from front vibratory sensor connector (Figure 5, Item 1).
M0288SWR
Figure 5. 9.
Remove two screws (Figure 6, Item 3), washers (Figure 6, Item 2), screw (Figure 6, Item 5), washer (Figure 6, Item 2), and support (Figure 6, Item 4) from support (Figure 6, Item 1).
0197-4
TM 5-3895-379-23-1
0197
REMOVAL - Continued
1 2 3
2 4
M0289SWR
Figure 6. 10. 11.
Remove nut (Figure 7, Item 5), screw (Figure 7, Item 3), and right-front work light assembly (Figure 7, Item 6) from bracket (Figure 7, Item 4). Loosen two screws (Figure 7, Item 1) and remove two wires (Figure 7, Item 2) from right-front work light assembly (Figure 7, Item 6).
1 3
4 5
M0290WR
Figure 7.
0197-5
TM 5-3895-379-23-1
0197
REMOVAL - Continued 12. Disconnect front wiring harness connector (Figure 8, Item 2) from water spray pump connector (Figure 8, Item 1).
M0291SWR
Figure 8. 13.
Loosen two screws (Figure 9, Item 1), washers (Figure 9, Item 6), wires (Figure 9, Items 2 and 5), and lockwashers (Figure 9, Item 3) from horn assembly (Figure 9, Item 4). Discard lockwashers.
1 6 5 3 2
M0292SWR
Figure 9.
0197-6
TM 5-3895-379-23-1
0197
REMOVAL - Continued 14. Remove two screws (Figure 10, Item 1), washers (Figure 10, Item 2), screw (Figure 10, Item 4), washer (Figure 10, Item 2), and support (Figure 10, Item 5) from support (Figure 10, Item 3).
2 3
2 4
M0293SWR
Figure 10.
0197-7
TM 5-3895-379-23-1
0197
REMOVAL - Continued 15. 16. 17. Remove nut (Figure 11, Item 5), screw (Figure 11, Item 7), and left-front work light assembly (Figure 11, Item 4) from bracket (Figure 11, Item 6). Loosen two screws (Figure 11, Item 3) and remove two wires (Figure 11, Item 2) from left-front work light assembly (Figure 11, Item 4). Remove front chassis wiring harness (Figure 11, Item 1) from front support assembly, frame assembly, and yoke assembly.
2 1 3
6 5
M0294SWR
Figure 11. Front Wiring Harness Removal. END OF TASK INSTALLATION
NOTE
Install electrical tiedown straps as required. 1. 2. 3. Position front chassis wiring harness (Figure 12, Item 1) in frame assembly, yoke assembly, and front support assembly. Install two wires (Figure 12, Item 2) on left-front work light assembly (Figure 12, Item 4) and tighten two screws (Figure 12, Item 3). Install left-front work light assembly (Figure 12, Item 4) on bracket (Figure 12, Item 6) with screw (Figure 12, Item 7) and nut (Figure 12, Item 5).
0197-8
TM 5-3895-379-23-1
0197
2 1 3
6 5
M0295SWR
Figure 12. 4.
Front Wiring Harness Installation.
Install support (Figure 13, Item 6), washer (Figure 13, Item 5), screw (Figure 13, Item 4), two washers (Figure 13, Item 2), and screws (Figure 13, Item 1) on support (Figure 13, Item 3).
2 3
5 6
M0296SWR
Figure 13.
0197-9
TM 5-3895-379-23-1
0197
INSTALLATION - Continued 5. Install two new lockwashers (Figure 14, Item 3), wires (Figure 14, Items 2 and 5), washers (Figure 14, Item 6), and screws (Figure 14, Item 1) on horn assembly (Figure 14, Item 4).
1 6 5 3 2
4
M0297SWR
Figure 14. Front Wiring Harness Installation. 6. Connect water spray pump connector (Figure 15, Item 1) to front wiring harness connector (Figure 15, Item 2).
M0298SWR
Figure 15. Front Wiring Harness Installation. 7. 8. Install two wires (Figure 16, Item 1) on right-front work light assembly (Figure 16, Item 5) and tighten two screws (Figure 16, Item 6). Install right-front work light assembly (Figure 16, Item 5) on bracket (Figure 16, Item 3) with screw (Figure 16, Item 2) and nut (Figure 16, Item 4).
0197-10
TM 5-3895-379-23-1
0197
6 2 5
3 4
M0299SWR
Figure 16. 9.
1 2 3
5 4
M0300SWR
Figure 17.
0197-11
TM 5-3895-379-23-1
0197
INSTALLATION - Continued 10. Connect front vibratory sensor connector (Figure 18, Item 1) to front wiring harness connector (Figure 18, Item 2).
M0301SWR
Figure 18. Front Wiring Harness Installation. 11. 12. Install clip (Figure 19, Item 1) on front wiring harness (Figure 19, Item 6). Install washer (Figure 19, Item 4), clip (Figure 19, Item 3), washer (Figure 19, Item 4), and screw (Figure 19, Item 5) to welded nut (Figure 19, Item 2) on clip assembly (Figure 19, Item 1).
1
2 4 3
4 5
M0302SWR
Figure 19. Front Wiring Harness Installation. 13. Install bracket (Figure 20, Item 1) to frame assembly (Figure 20, Item 4) with washer (Figure 20, Item 2) and screw (Figure 20, Item 3).
0197-12
TM 5-3895-379-23-1
0197
3 2 1 4
M0303SWR
Figure 20. 14. 15.
Feed front wiring harness (Figure 21, Item 2) through four brackets (Figure 21, Item 1) and install bottom nuts (Figure 20, Item 3) and screw (Figure 20, Item 4). Tighten remaining nuts (Figure 21, Item 3) on brackets (Figure 21, Item 1).
1 2
LOOSEN 4
REMOVE
M0304SWR
Figure 21.
0197-13
TM 5-3895-379-23-1
0197
INSTALLATION - Continued 16. 17. Connect front wiring harness connector (Figure 22, Item 2) to connector (Figure 22, Item 1). Install two wires (Figure 22, Item 4) on frame assembly (Figure 22, Item 3) with washer (Figure 22, Item 5) and nut (Figure 22, Item 6).
1 2
5 4 3
M0305SWR
Figure 22. Front Wiring Harness Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Close right-side door assembly. (TM 5-3895-379-10) Install front water tank. (Volume 2, WP 0269) Connect battery cables. (WP 0192)
0197-14
TM 5-3895-379-23-1
0198
FIELD MAINTENANCE REAR WIRING HARNESS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Strap, Tiedown, Electrical (Volume 2, WP 0288, Table 1, Item 67, 68, 69) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figures 58 and 60 References (cont.) WP 0195 Volume 2, WP 0280 Equipment Condition Right and left-side door assembly opened. (TM 5-3895-379-10) Rear water tank removed. (Volume 2, WP 0269) Battery cables disconnected. (WP 0192)
0198-1
TM 5-3895-379-23-1
0198
NOTE
Remove cable ties as required. Tag and mark all wires prior to removal. Tag and mark general position of wiring harness in chassis as components are removed. Harness will need to be repositioned at start of installation. 1. 2. Remove nut (Figure 1, Item 6), washer (Figure 1, Item 5), and two wires (Figure 1, Item 4) from frame assembly (Figure 1, Item 3). Disconnect rear wire harness connector (Figure 1, Item 2) from connector (Figure 1, Item 1).
1 2
5 4 3
M0306SWR
Figure 1. Rear Wiring Harness Removal. 3. 4. Remove nut (Figure 2, Item 7), washer (Figure 2, Item 6), clip (Figure 2, Item 5), washer (Figure 2, Item 3), and screw (Figure 2, Item 2) from clip assembly (Figure 2, Item 1). Remove clip (Figure 2, Item 5) from rear wiring harness (Figure 2, Item 4).
0198-2
TM 5-3895-379-23-1
0198
REMOVAL - Continued
2
M0307SWR
Figure 2. 5.
Rear Wiring Harness Removal.
Remove screw (Figure 3, Item 1), washer (Figure 3, Item 2), and bracket (Figure 3, Item 4) from frame assembly (Figure 3, Item 3).
1 2 3
M0308SWR
Figure 3.
0198-3
TM 5-3895-379-23-1
0198
REMOVAL - Continued 6. 7. Remove screw (Figure 4, Item 5), washer (Figure 4, Item 4), clip (Figure 4, Item 6), and washer (Figure 4, Item 4) from welded nut (Figure 4, Item 2) on clip assembly (Figure 4, Item 3). Remove clip (Figure 4, Item 6) from rear wiring harness (Figure 4, Item 1).
2 1
3
M0309SWR
Figure 4. Rear Wiring Harness Removal. 8. Disconnect rear wiring harness connector (Figure 5, Item 1) from rear vibratory sensor connector (Figure 5, Item 2).
1
M0310SWR
Figure 5. Rear Wiring Harness Removal.
0198-4
TM 5-3895-379-23-1
0198
1 2 3
2 4
M0311SWR
Figure 6.
0198-5
TM 5-3895-379-23-1
0198
REMOVAL - Continued 10. 11. Remove nut (Figure 7, Item 4), screw (Figure 7, Item 2), and left-rear work light assembly (Figure 7, Item 5) from bracket (Figure 7, Item 3). Loosen two screws (Figure 7, Item 6) and remove two wires (Figure 7, Item 1) from left-rear work light assembly (Figure 7, Item 5).
6 2
3 4
M0312SWR
0198-6
TM 5-3895-379-23-1
0198
REMOVAL - Continued 12. Disconnect rear wiring harness connector (Figure 8, Item 2) from water spray pump connector (Figure 8, Item 1).
M0313SWR
Figure 8. 13. 14. 15. Loosen two screws (Figure 9, Item 5).
Remove backup alarm (Figure 9, Item 7), two screws (Figure 9, Item 5), and washers (Figure 9, Item 6) from rear bumper assembly (Figure 9, Item 8). Remove two nuts (Figure 9, Item 2), washer (Figure 9, Item 3), and wires (Figure 9, Items 1 and 4) from backup alarm (Figure 9, Item 7).
1 2 3 4 5 6
M0314SWR
Figure 9.
0198-7
TM 5-3895-379-23-1
0198
1 2
5 6
M0315SWR
0198-8
TM 5-3895-379-23-1
0198
REMOVAL - Continued 17. 18. 19. Remove nut (Figure 11, Item 4), screw (Figure 11, Item 6), and right-rear work light assembly (Figure 11, Item 3) from bracket (Figure 11, Item 5). Loosen two screws (Figure 11, Item 2) and remove two wires (Figure 11, Item 1) from right-rear work light assembly (Figure 11, Item 3). Remove wiring harness from roller.
1
5 4
M0316SWR
0198-9
TM 5-3895-379-23-1
0198
INSTALLATION
NOTE
Install electrical tiedown straps as required. 1. 2. 3. Position wiring harness in frame assembly and yoke assembly. Install two wires (Figure 12, Item 1) on right-rear work light assembly (Figure 12, Item 3) and tighten two screws (Figure 12, Item 2). Install right-rear work light assembly (Figure 12, Item 3), screw (Figure 12, Item 6), and nut (Figure 12, Item 4) on bracket (Figure 12, Item 5).
1
5 4
M1269SWR
Figure 12. 4.
Rear Wiring Harness Installation.
0198-10
TM 5-3895-379-23-1
0198
1 2
5 6
M0317SWR
Figure 13. 5. 6. 7.
Install two wires (Figure 14, Items 1 and 4), washers (Figure 14, Item 3), and nuts (Figure 14, Item 2) on backup alarm (Figure 14, Item 7). Insert two washers (Figure 14, Item 6) and screws (Figure 14, Item 5) on backup alarm (Figure 14, Item 7) and position on rear bumper assembly (Figure 14, Item 8). Tighten two screws (Figure 14, Item 5).
1 2 3 4 5 6
M0318SWR
Figure 14.
0198-11
TM 5-3895-379-23-1
0198
INSTALLATION - Continued 8. Connect water spray pump connector (Figure 15, Item 1) to rear wiring harness connector (Figure 15, Item 2).
M0319SWR
Figure 15. 9. 10.
Install two wires (Figure 16, Item 1) on left-rear work light assembly (Figure 16, Item 5) and tighten two screws (Figure 16, Item 6). Install left-rear work light assembly (Figure 16, Item 5) on bracket (Figure 16, Item 3) with screw (Figure 16, Item 2) and nut (Figure 16, Item 4).
0198-12
TM 5-3895-379-23-1
0198
6 2
3 4
M0320SWR
Figure 16. 11.
1 2 3
2 4
M0321SWR
Figure 17. 12.
Connect rear vibratory sensor connector (Figure 18, Item 2) to rear wiring harness connector (Figure 18, Item 1).
0198-13
TM 5-3895-379-23-1
0198
1
M0322SWR
Figure 18. 13. 14.
Install clip (Figure 19, Item 6) on rear wiring harness (Figure 19, Item 1). Install washer (Figure 19, Item 4), clip (Figure 19, Item 6), washer (Figure 19, Item 4), and screw (Figure 19, Item 5) on welded nut (Figure 19, Item 2) on clip assembly (Figure 19, Item 3).
2 1
3
M0323SWR
Figure 19.
0198-14
TM 5-3895-379-23-1
0198
INSTALLATION - Continued 15. Install bracket (Figure 20, Item 4) to frame assembly (Figure 20, Item 3) with washer (Figure 20, Item 2) and screw (Figure 20, Item 1).
1 2 3
M0324SWR
Figure 20. 16. 17.
Install clip (Figure 21, Item 5) on rear wiring harness (Figure 21, Item 4). Install screw (Figure 21, Item 2), washer (Figure 21, Item 3), clip (Figure 21, Item 5), washer (Figure 21, Item 3), and nut (Figure 21, Item 6) on clip assembly (Figure 21, Item 1).
2
M0325SWR
Figure 21.
0198-15
TM 5-3895-379-23-1
0198
INSTALLATION - Continued 18. 19. Connect rear wiring harness connector (Figure 22, Item 2) to connector (Figure 22, Item 1). Install two wires (Figure 22, Item 4) on frame assembly (Figure 22, Item 3) with washer (Figure 22, Item 5) and nut (Figure 22, Item 6).
1 2
5 4 3
M0326SWR
Check left- and right-side door assemblies. (TM 5-3895-379-10) Install rear water tank. (Volume 2, WP 0269) Connect battery cables. (WP 0192)
0198-16
TM 5-3895-379-23-1
0199
FIELD MAINTENANCE INSTRUMENT WIRING HARNESS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Soldering Gun (Volume 2, WP 0289, Table 1, Item 33) Materials/Parts Solder Tin Alloy (WI) (Volume 2, WP 0288, Table 1, Item 66) Strap, Tiedown, Electrical (Volume 2, WP 0288, Table 1, Item 67, 68, 69) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Locknut (Volume 2, WP 0290, Table 1, Item 74) Qty: 1 Lockwasher (Volume 2, WP 0290, Table 1, Item 75) Qty: 6 Lockwasher Materials/Parts (cont.) (Volume 2, WP 0290, Table 1, Item 9) Qty: 2 Lockwasher (Volume 2, WP 0290, Table 1, Item 124) Qty: 3 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 43, 62, and 102 Volume 2, WP 0280 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Right-side door assembly opened. (TM 5-3895-379-10) Battery cables disconnected. (WP 0192)
0199-1
TM 5-3895-379-23-1
0199
INSPECTION AND TESTING Wiring and electrical inspection and repair is presented in General Wiring Repair (WP 0195). Electrical testing is presented in Electrical General Maintenance Instructions (Volume 2, WP 0280).
END OF TASK REMOVAL
NOTE
The instrument wiring harness for the CB534B and CB534C Rollers are replaced the same way. CB534B Roller is shown. The CB534C Roller is equipped with additional wiring. 1. 2. 3. 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). Remove three screws (Figure 1, Item 5) and washers (Figure 1, Item 6) from operator station (Figure 1, Item 7). Lift and tilt back instrument box assembly (Figure 1, Item 4) to gain access to back of instrument box assembly.
1 2 3
7 6 5
4
M0327SWR
Figure 1. Instrument Wiring Harness Removal.
0199-2
TM 5-3895-379-23-1
0199
REMOVAL - Continued 4. Remove four screws (Figure 2, Item 1), washers (Figure 2, Item 2), and cover (Figure 2, Item 3) from operator station (Figure 2, Item 4).
3 2 1
M0328SWR
Figure 2.
Instrument Wiring Harness Removal.
0199-3
TM 5-3895-379-23-1
0199
REMOVAL - Continued 5. Remove locknut (Figure 3, Item 8), washer (Figure 3, Item 7), and clamp (Figure 3, Item 5) from operator station stud (Figure 3, Item 3). Discard locknut.
NOTE
Tag and mark all wires prior to removal. Remove cable ties as required for removal of wiring harness assembly. 6. 7. 8. 9. 10. 11. 12. Remove clamp (Figure 3, Item 5) from instrument wiring harness assembly (Figure 3, Item 4). Disconnect connector (Figure 3, Item 9) from connector (Figure 3, Item 10). Disconnect connector (Figure 3, Item 13) from connector (Figure 3, Item 12). Disconnect connector (Figure 3, Item 17) from connector (Figure 3, Item 16). Disconnect connector (Figure 3, Item 2) from connector (Figure 3, Item 13). Disconnect connector (Figure 3, Item 1) from connector (Figure 3, Item 14). Carefully lift instrument box assembly (Figure 3, Item 6) and instrument wiring harness assembly (Figure 3, Item 4) from operator station (Figure 3, Item 11) and place on work bench.
2 3
5 6 7 8 15 16 9 17 10
14
13 12 11
M0329SWR
Figure 3. Instrument Wiring Harness Removal. 13. 14. Remove lamp assembly (Figure 4, Item 6) from Vibrations Per Minute (VPM) tachometer (Figure 4, Item 7). Remove three nuts (Figure 4, Item 1), wires (Figure 4, Items 4, 5, and 10), and lockwashers (Figure 4, Item 3) from VPM tachometer terminals (Figure 4, Items 2, 8, and 9). Discard lockwashers.
0199-4
TM 5-3895-379-23-1
0199
REMOVAL - Continued
1 2 3 10 3 9 8 1 4 1 5 3
6 7
M0330SWR
Figure 4. 15.
Lift tab (Figure 5, Item 2) and remove instrument wiring harness connector (Figure 5, Item 1) from functional light assembly (Figure 5, Item 3).
M0331SWR
Figure 5.
0199-5
TM 5-3895-379-23-1
0199
REMOVAL - Continued 16. Cut and remove wires (Figure 6, Items 1 and 5) from two terminals (Figure 6, Items 2 and 4) of seven fuse holders (Figure 6, Item 3).
2 1 4 3
M0332SWR
Figure 6. Instrument Wiring Harness Removal. 17. Lift tab and remove instrument wiring harness connector (Figure 7, Item 1) from warning light assembly (Figure 7, Item 2).
M0333SWR
0199-6
TM 5-3895-379-23-1
0199
REMOVAL - Continued 18. Remove two screws (Figure 8, Item 5) and wires (Figure 8, Items 1 and 4) from alternator light assembly terminals (Figure 8, Items 2 and 3).
1 2 3 4 5
M0334SWR
Figure 8. 19.
Remove two screws (Figure 9, Item 1), wires (Figure 9, Items 2 and 6), and lockwashers (Figure 9, Item 3) from starting aid switch terminals (Figure 9, Items 4 and 5). Discard lockwashers.
1
2 3 6 4
M0335SWR
Figure 9.
0199-7
TM 5-3895-379-23-1
0199
REMOVAL - Continued 20. 21. 22. Remove instrument wiring harness connector (Figure 10, Item 1) from hourmeter (Figure 10, Item 6). Remove thumb nut (Figure 10, Item 2) and clamp (Figure 10, Item 4) from hourmeter stud (Figure 10, Item 5). Remove clamp (Figure 10, Item 4) from instrument wiring harness assembly (Figure 10, Item 3).
6 3 4 5
M0336SWR
Figure 10. Instrument Wiring Harness Removal. 23. 24. Remove lamp assembly (Figure 11, Item 8) from fuel level indicator (Figure 11, Item 7). Remove three nuts (Figure 11, Item 1), wires (Figure 11, Items 2, 3, and 5), and lockwashers (Figure 11, Item 4) from fuel level indicator terminals (Figure 11, Items 6, 9, and 10). Discard lockwashers.
3 4 1
4 9
10
5 4 6 8 7
M0337SWR
0199-8
TM 5-3895-379-23-1
0199
REMOVAL - Continued 25. Remove three screws (Figure 12, Item 1), wires (Figure 12, Items 2, 5, and 8), and lockwashers (Figure 12, Item 3) from starter switch assembly terminals (Figure 12, Items 4, 6, and 9). Discard lockwashers.
1 2 3 4 9 1
8 3 7 6 3 5 1
M0338SWR
Figure 12.
0199-9
TM 5-3895-379-23-1
0199
REMOVAL - Continued
NOTE
Perform Steps (26) through (30) for the CB534C Roller. 26. 27. 28. 29. 30. 31. Remove lamp assembly (Figure 13, Item 11) from Feet Per Minute (FPM) meter (Figure 13, Item 12). Remove nut (Figure 13, Item 1), instrument wiring harness connector (Figure 13, Item 15), and washer (Figure 13, Item 16) from FPM meter (Figure 13, Item 12). Remove nut (Figure 13, Item 3), instrument wiring harness connector (Figure 13, Item 2), and washer (Figure 13, Item 4) from FPM meter (Figure 13, Item 12). Remove nut (Figure 13, Item 6), instrument wiring harness connector (Figure 13, Item 5), and washer (Figure 13, Item 7) from FPM meter (Figure 13, Item 12). Remove nut (Figure 13, Item 9), instrument wiring harness connector (Figure 13, Item 8), and washer (Figure 13, Item 10) from FPM meter (Figure 13, Item 12). Remove instrument wiring harness assembly (Figure 13, Item 14) from instrument box assembly (Figure 13, Item 13).
5 6 7
15 16
8 9 10 11
12 14 13
M0339SWR
Figure 13. Instrument Wiring Harness Removal. END OF TASK
0199-10
TM 5-3895-379-23-1
0199
INSTALLATION
NOTE
Install cable ties as required for installation of wiring harness assembly. 1. 2. Place instrument box assembly (Figure 14, Item 13) on clean surface. Position instrument wiring harness assembly (Figure 14, Item 14) in instrument box assembly (Figure 14, Item 13).
NOTE
Perform Steps (3) through (7) for CB534C Roller. 3. 4. 5. 6. 7. Install washer (Figure 14, Item 10), instrument wiring harness connector (Figure 14, Item 8), and nut (Figure 14, Item 9) to FPM meter (Figure 14, Item 12). Install washer (Figure 14, Item 7), instrument wiring harness connector (Figure 14, Item 5), and nut (Figure 14, Item 6) to FPM meter (Figure 14, Item 12). Install washer (Figure 14, Item 4), instrument wiring harness connector (Figure 14, Item 2), and nut (Figure 14, Item 3) to FPM meter (Figure 14, Item 12). Install washer (Figure 14, Item 16), instrument wiring harness connector (Figure 14, Item 15), and nut (Figure 14, Item 1) to FPM meter (Figure 14, Item 12). Install lamp assembly (Figure 14, Item 11) to FPM meter (Figure 14, Item 12).
5 6 7
15 16
8 9 10 11
12 14 13
M1292SWR
Figure 14.
Instrument Wiring Harness Installation.
0199-11
TM 5-3895-379-23-1
0199
INSTALLATION - Continued 8. Install three new lockwashers (Figure 15, Item 3), wires (Figure 15, Items 2, 5, and 8), and screws (Figure 15, Item 1) on starter switch assembly terminals (Figure 15, Items 4, 6, and 9).
1 2 3 4 9 1
8 3 7 6 3 5 1
M1291SWR
Figure 15. Instrument Wiring Harness Installation. 9. 10. Install three new lockwashers (Figure 16, Item 4), wires (Figure 16, Items 2, 3, and 5), and nuts (Figure 16, Item 1) on fuel level indicator terminals (Figure 16, Items 6, 9, and 10). Install lamp assembly (Figure 16, Item 8) on fuel level indicator (Figure 16, Item 7).
3 4 1
4 9
10
5 4 6 8 7
M0340SWR
Figure 16. Instrument Wiring Harness Installation.
0199-12
TM 5-3895-379-23-1
0199
INSTALLATION - Continued 11. 12. 13. Position clamp (Figure 17, Item 4) on instrument wiring harness assembly (Figure 17, Item 3). Install clamp (Figure 17, Item 4) on hourmeter stud (Figure 17, Item 5) with thumb nut (Figure 17, Item 2). Connect instrument wiring harness connector (Figure 17, Item 1) to hourmeter (Figure 17, Item 6).
6 3 4 5
M0341SWR
Figure 17. 14.
Install two new lockwashers (Figure 18, Item 3), wires (Figure 18, Items 2 and 6), and screws (Figure 18, Item 1) on starting aid switch terminals (Figure 18, Items 4 and 5).
1 2 3 6 4
M0342SWR
Figure 18.
0199-13
TM 5-3895-379-23-1
0199
INSTALLATION - Continued 15. Install two wires (Figure 19, Items 1 and 4) on alternator light assembly terminals (Figure 19, Items 2 and 3) with screws (Figure 19, Item 5).
1 2 3 4 5
M0343SWR
Figure 19. Instrument Wiring Harness Installation. 16. Connect instrument wiring harness connector (Figure 20, Item 1) to warning light assembly (Figure 20, Item 2).
M0344SWR
Figure 20. Instrument Wiring Harness Installation.
0199-14
TM 5-3895-379-23-1
0199
INSTALLATION - Continued 17. Using a soldering gun, install two wires (Figure 21, Items 1 and 5) on two terminals (Figure 21, Items 2 and 4) of seven fuse holders (Figure 21, Item 3).
2 1 4 3
M0345SWR
Figure 21. 18.
Connect instrument wiring harness connector (Figure 22, Item 1) on functional light assembly (Figure 22, Item 2).
M0346SWR
Figure 22.
0199-15
TM 5-3895-379-23-1
0199
INSTALLATION - Continued 19. 20. Install three new lockwashers (Figure 23, Item 3), wires (Figure 23, Items 4, 5, and 10), and nuts (Figure 23, Item 1) on VPM tachometer terminals (Figure 23, Items 2, 8, and 9). Install lamp assembly (Figure 23, Item 6) in VPM tachometer (Figure 23, Item 7).
1 2 3 10 3 9 8 1 4 1 5 3
6 7
M0347SWR
Figure 23. Instrument Wiring Harness Installation. 21. 22. 23. 24. 25. 26. 27. 28. Carefully position instrument box assembly (Figure 24, Item 6) and instrument wiring harness assembly (Figure 24, Item 4) on operator station (Figure 24, Item 11). Connect connector (Figure 24, Item 1) to connector (Figure 24, Item 14). Connect connector (Figure 24, Item 2) to connector (Figure 24, Item 13). Connect connector (Figure 24, Item 15) to connector (Figure 24, Item 16). Connect connector (Figure 24, Item 13) to connector (Figure 24, Item 12). Connect connector (Figure 24, Item 9) to connector (Figure 24, Item 10). Position clamp (Figure 24, Item 5) on instrument wiring harness assembly (Figure 24, Item 4). Install clamp (Figure 24, Item 5) on operator station stud (Figure 24, Item 3) with washer (Figure 24, Item 7) and new locknut (Figure 24, Item 8).
0199-16
TM 5-3895-379-23-1
0199
2 3
5 6 7 8 15 16 9 17 10
14
13 12 11
M0348SWR
Figure 24. 29.
Install cover (Figure 25, Item 3) on operator station (Figure 25, Item 4) with four washers (Figure 25, Item 2) and screws (Figure 25, Item 1).
3 2 1
M0349SWR
Figure 25.
0199-17
TM 5-3895-379-23-1
0199
INSTALLATION - Continued 30. 31. Install box assembly (Figure 26, Item 4) on cover (Figure 26, Item 7) with three washers (Figure 26, Item 6) and screws (Figure 26, Item 5). Install vandal guard (Figure 26, Item 3) on instrument box assembly (Figure 26, Item 4) with two washers (Figure 26, Item 2) and shoulder screws (Figure 26, Item 1).
1 2 3
7 6 5
4
M0350SWR
Figure 26. Instrument Wiring Harness Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Close right-side door assembly. (TM 5-3895-379-10) Connect battery cables. (WP 0192)
0199-18
TM 5-3895-379-23-1
0200
FIELD MAINTENANCE MAIN WIRING HARNESS REPLACEMENT (CB534B)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Strap, Tiedown, Electrical (Volume 2, WP 0288, Table 1, Item 67, 68, 69) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 63 WP 0131 WP 0154 WP 0156 WP 0157 WP 0159 WP 0160 WP 0161 References (cont.) WP 0162 WP 0163 WP 0165 WP 0172 WP 0173 WP 0175 WP 0177 WP 0180 WP 0181 WP 0182 WP 0185 WP 0188 WP 0196 WP 0199 WP 0206 Volume 2, WP 0280 Equipment Condition Engine off. (TM 5-3895-379-10) Operator platform assembly raised. (Volume 2, WP 0235) Battery disconnect switch in OFF position. (TM 5-3895-379-10)
0200-1
TM 5-3895-379-23-1
0200
REMOVAL
NOTE
Refer to Repair Parts and Special Tools Lists (TM 5-3895-379-23P) for identification. Main wiring harness can be repaired without being removed from roller. Refer to (Volume 2, WP 0280) for repair instructions as needed. Tag and mark all wires prior to removal to aid in installation. Cut electrical tiedown straps as needed for removal. Discard electrical tiedown straps. Note position and routing of main wiring harness as it is disconnected and removed to aid in installation. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. Disconnect main harness wire terminals from throttle control timer connector (WP 0131). Disconnect main harness connector from main relay connector (WP 0154). Disconnect main harness connector from light circuit breaker connector (WP 0173). Disconnect main harness connector from intermittent spray timer connector (WP 0163). Disconnect main harness connector from rear intermittent relay connector (TM 5-3895-379-23P, Figure 63, Item G). Disconnect main harness connector from front intermittent relay connector (TM 5-3895-379-23P, Figure 63, Item H). Disconnect main harness connector from brake #1 relay connector (TM 5-3895-379-23P, Figure 63, Item J). Disconnect main harness connector from brake #2 relay connector (TM 5-3895-379-23P, Figure 63, Item K). Disconnect main harness connector from neutral start relay #1 connector (TM 5-3895-379-23P, Figure 63, Item M). Disconnect main harness connector from neutral start relay #2 connector (TM 5-3895-379-23P, Figure 63, Item L). Disconnect main harness connector from starting aid resistor connector (WP 0165). Disconnect main harness connector from hydraulic charge oil pressure relay connector (TM 5-3895-379-23P, Figure 63, Item Q). Disconnect main harness connector from propel control lever connector (WP 0206). Disconnect main harness connector from horn switch connector (WP 0188). Disconnect main harness connector from propel speed range switch connector (WP 0161). Disconnect main harness connector from parking brake switch connector (WP 0156). Disconnect main harness connector from backup alarm pressure switch connector (WP 0181). Disconnect main harness connector from water spray switch connector (WP 0157). Disconnect main harness connector from work light control switch connector (WP 0162). Disconnect main harness connector from drum offset switch connector (TM 5-3895-379-23P, Figure 63, Item Z). Disconnect main harness wire terminals from drum select switch connector (TM 5-3895-379-23P, Figure 63, Item AB). Disconnect main harness wire terminals from amplitude select switch connector (WP 0160). Disconnect main harness wire terminals from vibration control switch connector (WP 0159).
0200-2
TM 5-3895-379-23-1
0200
REMOVAL - Continued 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. Disconnect main harness wire terminals from fuel solenoid resistor connector (WP 0175). Disconnect main harness wire terminals from turn signal switch connector (TM 5-3895-379-23P, Figure 63, Item AF). Disconnect main harness connector from engine oil pressure relay connector (WP 0172). Disconnect main harness connector from water temperature sending unit connector (WP 0182). Disconnect main harness connector from warning light relay connector (WP 0180). Disconnect main harness connector from hydraulic oil temperature relay connector (WP 0185). Disconnect main harness connector from functional indicator light relay connector (WP 0177). Disconnect main harness connector from instrument wiring harness connector (WP 0199). Disconnect main harness wire terminals from diagnostic warning diode assembly connector (TM 5-3895-379-23P, Figure 63, Item AP). Disconnect main harness connector from engine wiring harness connector (WP 0196). Carefully remove main wiring harness from roller.
END OF TASK INSTALLATION
NOTE
Install new electrical tiedown straps as necessary. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Position loose wiring harness in general installation position. Connect main harness connector to engine wiring harness connector (WP 0196). Connect main harness connector to diagnostic warning diode assembly connector (TM 5-3895-379-23P, Figure 63, Item AP). Connect main harness connector to instrument wiring harness connector (WP 0199). Connect main harness connector to functional indicator light relay connector (WP 0177). Connect main harness connector to hydraulic oil temperature relay connector (WP 0185). Connect main harness connector to warning light relay connector (WP 0180). Connect main harness connector to water temperature sending unit relay connector (WP 0182). Connect main harness connector to engine oil pressure relay connector (WP 0172). Connect main harness wire terminals to turn signal switch connector (TM 5-3895-379-23P, Figure 63, Item AF). Connect main harness wire terminals to fuel solenoid resistor connector (WP 0175). Connect main harness wire terminals to vibration control switch connector (WP 0159). Connect main harness wire terminals to amplitude select switch connector (WP 0160). Connect main harness wire terminals to drum select switch connector (TM 5-3895-379-23P, Figure 63, Item AB). Connect main harness connector to drum offset switch connector (TM 5-3895-379-23P, Figure 63, Item Z). Connect main harness connector to work light control switch connector (WP 0162).
0200-3
TM 5-3895-379-23-1
0200
INSTALLATION - Continued 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. Connect main harness connector to water spray switch connector (WP 0157). Connect main harness connector to parking brake switch connector (WP 0156). Connect main harness connector to backup alarm pressure switch connector (WP 0181). Connect main harness connector to parking brake switch connector (WP 0156). Connect main harness connector to propel speed range switch connector (WP 0161). Connect main harness connector to horn switch connector (WP 0188). Connect main harness connector to propel control lever connector (WP 0206). Connect main harness connector to hydraulic charge oil pressure relay connector (TM 5-3895-379-23P, Figure 63, Item Q). Connect main harness connector to starting aid resistor connector (WP 0165). Connect main harness connector to neutral start relay #2 connector (TM 5-3895-379-23P, Figure 63, Item L). Connect main harness connector to neutral start relay #1 connector (TM 5-3895-379-23P, Figure 63, Item M). Connect main harness connector to brake #2 relay connector (TM 5-3895-379-23P, Figure 63, Item K). Connect main harness connector to brake #1 relay connector (TM 5-3895-379-23P, Figure 63, Item J). Connect main harness connector to front intermittent relay connector (TM 5-3895-379-23P, Figure 63, Item H). Connect main harness connector to rear intermittent relay connector (TM 5-3895-379-23P, Figure 63, Item G). Connect main harness connector to intermittent spray timer connector (WP 0163). Connect main harness connector to light circuit breaker connector (WP 0173). Connect main harness connector to main relay connector (WP 0154). Connect main harness connector to throttle control timer connector (WP 0131).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Turn battery disconnect switch to ON position. (TM 5-3895-379-10) Lower operator platform assembly. (Volume 2, WP 0235) Start engine and check for proper operation. (TM 5-3895-379-10)
0200-4
TM 5-3895-379-23-1
0201
FIELD MAINTENANCE MAIN WIRING HARNESS REPLACEMENT (CB534C)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Strap, Tiedown, Electrical (Volume 2, WP 0288, Table 1, Item 67, 68, 69) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 62 and 63 WP 0133 WP 0154 WP 0156 WP 0157 WP 0161 WP 0162 References (cont.) WP 0163 WP 0165 WP 0172 WP 0173 WP 0175 WP 0180 WP 0181 WP 0182 WP 0185 WP 0188 WP 0196 WP 0199 WP 0206 Volume 2, WP 0280 Equipment Condition Engine off. (TM 5-3895-379-10) Operator platform assembly raised. (Volume 2, WP 0235) Battery disconnect switch in OFF position. (TM 5-3895-379-10)
0201-1
TM 5-3895-379-23-1
0201
REMOVAL
NOTE
Refer to Repair Parts and Special Tools Lists (TM 5-3895-379-23P) for identification. Main wiring harness can be repaired without being removed from roller. Refer to (Volume 2, WP 0280) for repair instructions as needed. Tag and mark all wires prior to removal to aid in installation. Cut electrical tiedown straps as needed for removal. Discard electrical tiedown straps. Note position and routing of main wiring harness as it is disconnected and removed to aid in installation. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Disconnect main harness wire terminals from drum offset switch connector (TM 5-3895-379-23P, Figure 63, Item A). Disconnect main harness wire terminals from cutter switch connector (TM 5-3895-379-23P, Figure 63, Item B). Disconnect main harness wire terminals from drum select switch connector (TM 5-3895-379-23P, Figure 63, Item C). Disconnect main harness wire terminals from dual amp switch connector (TM 5-3895-379-23P, Figure 63, Item D). Disconnect main harness connector from work light control switch connector (WP 0162). Disconnect main harness wire terminals from water spray switch connector (WP 0157). Disconnect main harness connector from auto man switch connector (TM 5-3895-379-23P, Figure 63, Item G). Disconnect main harness connector from front/rear pump switch connector (TM 5-3895-379-23P, Figure 63, Item J). Disconnect main harness connector from fuel solenoid resistor connector (WP 0175). Disconnect main harness connector from turn signal switch connector (TM 5-3895-379-23P, Figure 63, Item L). Disconnect main harness connector from engine oil pressure switch connector (WP 0172). Disconnect main harness connector from water temperature sending unit relay connector (WP 0182). Disconnect main harness connector from warning light relay connector (WP 0180). Disconnect main harness connector from hydraulic oil temperature relay connector (WP 0185). Disconnect main harness connector from light circuit breaker connector (WP 0173). Disconnect main harness connector from instrument wiring harness connector (WP 0199). Disconnect main harness connector from functional light relay connector (WP 0199). Disconnect main harness connector from recording module connector (TM 5-3895-379-23P, Figure 63, Item T). Disconnect main harness connector from diagnostic warning diode assembly connector (TM 5-3895-379-23P, Figure 63, Item U). Disconnect main harness connector from engine wiring harness connector (WP 0196). Disconnect main harness connector from backup alarm pressure switch connector (WP 0181).
0201-2
TM 5-3895-379-23-1
0201
REMOVAL - Continued 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. Disconnect main harness connector from parking brake switch connector (WP 0156). Disconnect main harness connector from propel control lever connector (WP 0206). Disconnect main harness connector from hydraulic charge oil pressure connector (TM 5-3895-379-23P, Figure 63, Item Z). Disconnect main harness connector from starting aid resistor connector (WP 0165). Disconnect main harness connector from throttle control relay connector (WP 0133). Disconnect main harness connector from propel speed range switch connector (WP 0161). Disconnect main harness connector from horn switch connector (WP 0188). Disconnect main harness connector from neutral start relay #1 connector (TM 5-3895-379-23P, Figure 63, Item AE). Disconnect main harness connector from neutral start relay #2 connector (TM 5-3895-379-23P, Figure 63, Item AF). Disconnect main harness connector from brake #1 relay connector (TM 5-3895-379-23P, Figure 63, Item AH). Disconnect main harness connector from brake #2 relay connector (TM 5-3895-379-23P, Figure 63, Item AG). Disconnect main harness connector from warning light relay connector (TM 5-3895-379-23P, Figure 63, Item AJ). Disconnect main harness wire terminals from intermittent water spray timer connector (WP 0163). Disconnect main harness wire terminals from flasher connector (TM 5-3895-379-23P, Figure 63, Item AL). Disconnect main harness wire terminals from main relay connector (WP 0154). Disconnect main harness connector from throttle control timer connector (WP 0133). Carefully remove main wiring harness from roller.
END OF TASK INSTALLATION
NOTE
Install new electrical tiedown straps as necessary. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Position loose wiring harness in general installation position. Connect main harness wire terminals to throttle control timer connector (WP 0133). Connect main harness connector to main relay connector (WP 0154). Connect main harness wire terminals to light circuit breaker connector (WP 0173). Connect main harness connector to flasher connector (TM 5-3895-379-23P, Figure 63, Item AL). Connect main harness wire terminals to intermittent water spray timer connector (WP 0163). Connect main harness connector to warning light relay connector (TM 5-3895-379-23P, Figure 63, Item AJ). Connect main harness connector to brake #2 relay connector (TM 5-3895-379-23P, Figure 63, Item AG). Connect main harness connector to brake #1 relay connector (TM 5-3895-379-23P, Figure 63, Item AH). Connect main harness connector to neutral start relay #2 connector (TM 5-3895-379-23P, Figure 63, Item AF). Connect main harness connector to neutral start relay #1 connector (TM 5-3895-379-23P, Figure 63, Item AE).
0201-3
TM 5-3895-379-23-1
0201
INSTALLATION - Continued 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. Connect main harness connector to throttle control relay connector (WP 0133). Connect main harness connector to horn switch connector (WP 0189). Connect main harness connector to propel speed range switch connector (WP 0161). Connect main harness connector to starting aid resistor connector (WP 0165). Connect main harness connector to throttle control relay connector (WP 0133). Connect main harness connector to hydraulic charge oil pressure connector (TM 5-3895-379-23P, Figure 63, Item Z). Connect main harness connector to propel control lever connector (WP 0206). Connect main harness connector to parking brake switch connector (WP 0156). Connect main harness connector to backup alarm pressure switch connector (WP 0181). Connect main harness connector to engine wiring harness connector (WP 0196). Connect main harness connector to diagnostic warning diode assembly connector (TM 5-3895-379-23P, Figure 63, Item U). Connect main harness connector to recording module connector (TM 5-3895-379-23P, Item T). Connect main harness connector to instrument wiring harness connector (WP 0199). Connect main harness connector to functional light relay connector (WP 0177). Connect main harness connector to hydraulic oil temperature relay connector (WP 0185). Connect main harness connector to warning light relay connector (WP 0180). Connect main harness connector to water temperature sending unit relay connector (WP 0182). Connect main harness connector to engine oil pressure switch connector (WP 0172). Connect main harness connector to turn signal switch connector (TM 5-3895-379-23P, Figure 63, Item L). Connect main harness connector to resistor fuel solenoid resistor connector (WP 0175). Connect main harness connector to front/rear pump switch connector (TM 5-3895-379-23, Figure 63, Item J). Connect main harness connector to auto man switch connector (TM 5-3895-379-23P, Figure 63, Item G). Connect main harness wire terminals to water spray switch connector (WP 0157). Connect main harness connector to work light control switch connector (WP 0162). Connect main harness wire terminals to dual amp switch connector (TM 5-3895-379-23P, Figure 63, Item D). Connect main harness wire terminals to drum select switch connector (TM 5-3895-379-23P, Figure 63, Item C). Connect main harness wire terminals to cutter switch connector (TM 5-3895-379-23P, Figure 63, Item B). Connect main harness wire terminals to drum offset switch connector (TM 5-3895-379-23P, Figure 63, Item A).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Turn battery disconnect switch ON. (TM 5-3895-379-10) Lower operator platform assembly. (Volume 2, WP 0235)
0201-4
TM 5-3895-379-23-1
0201
FOLLOW-ON MAINTENANCE - Continued 3. Start engine and check for proper operation. (TM 5-3895-379-10)
0201-5/6 blank
TM 5-3895-379-23-1
0202
FIELD MAINTENANCE SEPARATE AND CONNECT VIBRATORY AND PROPEL PUMPS
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 2, WP 0288, Table 1, Item 12) O-ring (Volume 2, WP 0290, Table 1, Item 122) Qty: 4 Wooden Block Qty: 2 Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figures 122 and 123 Equipment Condition Vibratory and propel pumps removed. (WP 0203)
0202-1
TM 5-3895-379-23-1
0202
SEPARATE
WARNING
CAUTION
Be sure work area is clean when working with hydraulic components. Contaminants entering the system may damage components.
NOTE
Place vibratory and propel pump assemblies on wooden blocks for ease of access. 1. 2. 3. 4. Disconnect two hose assemblies (Figure 1, Item 1) from vibratory control valve (Figure 1, Item 4). Remove six bolts (Figure 1, Item 3) from vibratory control valve (Figure 1, Item 4) and vibratory pump (Figure 1, Item 2). Remove vibratory control valve (Figure 1, Item 4) and spacer (Figure 1, Item 5) from vibratory pump (Figure 1, Item 2). Remove four O-rings (Figure 2, Item 3) from spacer (Figure 1, Item 5) and vibratory control valve (Figure 1, Item 4). Discard O-rings.
1
5 2 4 3 2
1
M0351SWR
Figure 1. 5.
Vibratory and Propel Pumps Separate.
Remove two bolts (Figure 2, Item 2) and separate vibratory pump (Figure 1, Item 2) from propel pump (Figure 2, Item 1).
0202-2
TM 5-3895-379-23-1
0202
SEPARATE - Continued
1
M0352SWR
Figure 2. END OF TASK CONNECT 1. 2.
Vibratory and Propel Pumps Separate.
Connect propel pump (Figure 3, Item 1) to vibratory pump (Figure 4, Item 2) with two bolts (Figure 3, Item 2). Install four new O-rings (Figure 3, Item 3) on spacer (Figure 4, Item 5) and vibratory control valve (Figure 4, Item 4).
1
M1226SWR
Figure 3.
Vibratory and Propel Pumps Connect.
0202-3
TM 5-3895-379-23-1
0202
CONNECT - Continued 3. 4. 5. Install vibratory control valve (Figure 4, Item 4) and spacer (Figure 4, Item 5) on vibratory pump (Figure 4, Item 2). Install six bolts (Figure 4, Item 3) on vibratory control valve (Figure 4, Item 4) and vibratory pump (Figure 4, Item 2). Connect two hose assemblies (Figure 4, Item 1) to vibratory control valve (Figure 4, Item 4).
1
5 2 4 3 2
1
M1225SWR
Vibratory and Propel Pumps Connect.
Install vibratory and propel pumps. (WP 0203) END OF TASK END OF WORK PACKAGE
0202-4
TM 5-3895-379-23-1
0203
FIELD MAINTENANCE VIBRATORY AND PROPEL PUMPS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Lifting Device, Minimum Capacity 198 lb (90 kg) Link (Volume 2, WP 0289, Table 1, Item 22) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 2, WP 0288, Table 1, Item 12) Strap, Tiedown, Electrical (Volume 2, WP 0288, Table 1, Item 67, 68, 69) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 70 and 71 Equipment Condition Hydraulic tank drained. (WP 0124) Operator platform assembly raised. (Volume 2, WP 0235) Left-side door assembly opened. (TM 5-3895-379-10)
0203-1
TM 5-3895-379-23-1
0203
REMOVAL
CAUTION
Cap and plug all lines and fittings immediately to prevent any contaminants from entering the system.
NOTE
Weight of vibratory and propel pumps as a unit is 198 lb (90 kg). Tag and mark all hydraulic lines and electrical wires as they are removed or disconnected. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Disconnect four hose assemblies (Figure 1, Item 5) and hose assembly (Figure 1, Item 16) from vibratory control valve (Figure 1, Item 9). Disconnect hose assemblies (Figure 1, Items 3 and 4) from propel pump (Figure 1, Item 2). Disconnect two electrical connector wires (Figure 1, Item 6). Remove two screws (Figure 1, Item 12) that fasten electrical connectors (Figure 1, Item 13) to vibratory pump (Figure 1, Item 11). Remove electrical connectors (Figure 1, Item 13) from vibratory pump (Figure 1, Item 11). Remove two screws (Figure 1, Item 7) that fasten two electrical connectors (Figure 1, Item 8) to vibratory control valve (Figure 1, Item 9). Remove electrical connectors (Figure 1, Item 8) from vibratory control valve (Figure 1, Item 9). Remove electrical tiedown straps and move wiring harness (Figure 1, Item 10) aside from vibratory control valve (Figure 1, Item 9). Disconnect two hose assemblies (Figure 1, Item 14) from vibratory pump (Figure 1, Item 11) and three hose assemblies (Figure 1, Item 1) from propel pump (Figure 1, Item 2). Remove nut (Figure 1, Item 17) and bolt (Figure 1, Item 18) that fasten clip (Figure 1, Item 19) to hose assemblies (Figure 1, Items 1 and 16). Remove valve (Figure 1, Item 15) from propel pump (Figure 1, Item 2). Attach a lifting device to vibratory and propel pump as a unit. Remove two bolts (Figure 1, Item 20) and remove vibratory and propel pumps as a unit from roller.
0203-2
TM 5-3895-379-23-1
0203
REMOVAL - Continued
5 1 6 5 20 7, 8 1 19 10 11 16 17, 18 16 VIEW FROM UNDER ROLLER

Figure 1. END OF TASK Vibratory and Propel Pumps Removal.
15
14 12, 13
M0353SWR
0203-3
TM 5-3895-379-23-1
0203
INSTALLATION
NOTE
Use lifting device to position vibratory and propel pumps. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Install with two bolts (Figure 2, Item 20) to roller. Install valve (Figure 2, Item 15) to propel pump (Figure 2, Item 2). Install nut (Figure 2, Item 17) and bolt (Figure 1, Item 18) that fasten clip (Figure 2, Item 19) to hose assemblies (Figure 2, Items 1 and 16). Connect two hose assemblies (Figure 2, Item 14) to vibratory pump (Figure 2, Item 11). Connect three hose assemblies (Figure 2, Item 1) to propel pump (Figure 1, Item 2). Install electrical tiedown straps and move wiring harness (Figure 2, Item 10) aside from vibratory control valve (Figure 2, Item 9). Install two electrical connectors (Figure 2, Item 8) and two screws (Figure 2, Item 7) to vibratory control valve (Figure 2, Item 9). Install two electrical connectors (Figure 2, Item 13) and two screws (Figure 2, Item 12) to vibratory pump (Figure 2, Item 11). Connect two electrical connector wires (Figure 2, Item 6). Connect hose assemblies (Figure 2, Items 3 and 4) to propel pump (Figure 2, Item 2). Connect four hose assemblies (Figure 2, Item 5) and hose assembly (Figure 2, Item 16) to vibratory control valve (Figure 2, Item 9).
0203-4
TM 5-3895-379-23-1
0203
5 1 6 5 20 7, 8 1 19 10 11 16 17, 18 16 VIEW FROM UNDER ROLLER

Figure 2. Vibratory and Propel Pumps Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Lower operator platform assembly. (Volume 2, WP 0235) Fill hydraulic oil tank with oil to correct level. (WP 0071) Close left-side door assembly. (TM 5-3895-379-10)
15
14 12, 13
M1198SWR
0203-5/6 blank
TM 5-3895-379-23-1
0204
FIELD MAINTENANCE REAR PROPEL MOTOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (Volume 2, WP 0289, Table 1, Item 23) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 2, WP 0288, Table 1, Item 12) Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figure 68 Equipment Condition Hydraulic system drained. (WP 0124)
0204-1
TM 5-3895-379-23-1
0204
REMOVAL
WARNING
CAUTION
Wipe area clean around all hydraulic connections to be opened during removal. Cap oil lines and plug opening after removing lines. Contamination of hydraulic system could result in premature failure.
NOTE
Use drain pan to catch any residual hydraulic oil that may drain from system. Dispose of oil IAW local policy and ordinances. Ensure all spills are cleaned up. 1. Disconnect five hose assemblies (Figure 1, Item 1) from rear propel motor (Figure 1, Item 2).
WARNING
Use caution when handling heavy parts. Provide adequate support and use assistance during procedure. Failure to follow this warning may cause injury. 2. Disconnect propel motor sensor (Figure 1, Item 5).
NOTE
Weight of rear propel motor is 40 lb (18 kg). 3. Remove two bolts (Figure 1, Item 4), washers (Figure 1, Item 3), and remove rear propel motor (Figure 1, Item 2). Discard washers.
0204-2
TM 5-3895-379-23-1
0204
REMOVAL - Continued
3, 4 1 5
M0354SWR
3, 4
Rear Propel Motor Removal.
0204-3
TM 5-3895-379-23-1
0204
INSTALLATION
NOTE
Weight of rear propel motor is 40 lb (18 kg). 1. 2. 3. 4. Position rear propel motor (Figure 2, Item 2) on roller. Install two washers (Figure 2, Item 3) and bolts (Figure 2, Item 4). Connect propel motor sensor (Figure 2, Item 5). Connect five hydraulic hose assemblies (Figure 2, Item 1) to rear propel motor (Figure 2 Item 2).
3, 4 1 5
M1197SWR
3, 4
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Refill hydraulic system. (WP 0071)
Rear Propel Motor Installation.
Operate roller and check for proper operation and leaks. (TM 5-3895-379-10)
0204-4
TM 5-3895-379-23-1
0205
FIELD MAINTENANCE PROPEL MOTOR AND TORQUE HUB REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Lifting Device, Minimum Capacity 500 lb (227 kg) Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figures 68, 79, and 133 Equipment Condition Drum assembly removed. (Volume 2, WP 0265)
0205-1
TM 5-3895-379-23-1
0205
REMOVAL 1. Position drum assembly (Figure 1, Item 2) as shown and use wooden blocks to prevent drum assembly from moving.
WARNING
NOTE
Weight of support is 170 lb (77 kg). 2. 3. Attach lifting device to support (Figure 1, Item 1). Remove 17 nuts (Figure 1, Item 4), bolts (Figure 1, Item 3), and support (Figure 1, Item 1) from propel motor and torque hub (Figure 2, Item 2).
1 2
3, 4
M0355SWR
Figure 1. Propel Motor and Torque Hub Removal.
0205-2
TM 5-3895-379-23-1
0205
REMOVAL - Continued
WARNING
NOTE
Weight of drive plate, propel motor and torque hub as a unit is 500 lb (227 kg). 4. 5. 6. 7. Attach lifting device to drive plate (Figure 2, Item 1). Remove 24 bolts (Figure 2, Item 4), washers (Figure 2, Item 3), drive plate (Figure 2, Item 1), and propel motor and torque hub (Figure 2, Item 2) as a unit, from mounts. Position propel motor and torque hub on wooden blocks. Attach lifting device to drive plate (Figure 2, Item 1).
1
2 3, 4
M0356SWR
Figure 2. Propel Motor and Torque Hub Removal.
0205-3
TM 5-3895-379-23-1
0205
REMOVAL - Continued
WARNING
NOTE
Weight of drive plate is 230 lb (104 kg). 8. Remove 10 nuts (Figure 3, Item 3) and drive plate (Figure 3, Item 1) from propel motor and torque hub (Figure 3, Item 2).
M0357SWR
Figure 3. Propel Motor and Torque Hub Removal. END OF TASK
0205-4
TM 5-3895-379-23-1
0205
INSTALLATION
WARNING
NOTE
Weight of drive plate is 230 lb (104 kg). 1. 2. Attach lifting straps and lifting device to drive plate (Figure 4, Item 1). Position drive plate (Figure 4, Item 1) on propel motor and torque hub (Figure 4, Item 2) and install 10 nuts (Figure 4, Item 3).
M1275SWR
Figure 4. Propel Motor and Torque Hub Installation.
0205-5
TM 5-3895-379-23-1
0205
WARNING
NOTE
Weight of support is 170 lb (77 kg). 3. 4. Attach lifting device to support (Figure 5, Item 1). Position support (Figure 5, Item 1) on motor and torque hub (Figure 4, Item 2) and install 17 bolts (Figure 5, Item 3) and nuts (Figure 5, Item 4).
1 2
3, 4
M0358SWR
Figure 5. Propel Motor and Torque Hub Installation.
0205-6
TM 5-3895-379-23-1
0205
WARNING
NOTE
Weight of drive plate, propel motor and torque hub as a unit is 500 lb (227 kg). 5. Install drive plate (Figure 6, Item 1) and propel motor and torque hub (Figure 6, Item 2), as a unit, on mounts with 24 washers (Figure 6, Item 3) and bolts (Figure 6, Item 4).
1
2 3, 4
M0359SWR
Figure 6. Propel Motor and Torque Hub Installation. END OF TASK FOLLOW-ON MAINTENANCE Install drum assembly. (Volume 2, WP 0265) END OF TASK END OF WORK PACKAGE
0205-7/8 blank
TM 5-3895-379-23-1
0206
FIELD MAINTENANCE PROPEL CONTROL LEVER ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (Volume 2, WP 0289, Table 1, Item 23) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 2, WP 0288, Table 1, Item 12) Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Gasket (Volume 2, WP 0290, Table 1, Item 5) Qty: 2 Packing, Preformed (Volume 2, WP 0290, Table 1, Item 93) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 78 Equipment Condition 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)
0206-1
TM 5-3895-379-23-1
0206
REMOVAL
WARNING
At operating temperature oil is hot. Allow oil to cool before disconnecting any hydraulics. Failure to do so could result in injury. Oil is very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury. 1. 2. Remove nine bolts (Figure 1, Item 1), two washers (Figure 1, Item 5), and seven washers (Figure 1, Item 2) from operator station (Figure 1, Item 4). Lift plate assembly (Figure 1, Item 3) and pull away from operator station (Figure 1, Item 4).
5
M0360SWR
Figure 1.
Propel Control Lever Removal.
0206-2
TM 5-3895-379-23-1
0206
REMOVAL - Continued 3. Loosen hydraulic oil tank fill cap (Figure 2, Item 1) to release hydraulic pressure.
NOTE
Tag and mark all lines and wires to ensure correct installation. Cap and plug all lines and fittings to prevent any contaminants from entering the system. Use drain pan to catch any oil that may drain from system. Dispose of oil IAW local policy and ordinances. Ensure all spills are cleaned up. 4. 5. 6. 7. 8. Remove four hose assemblies (Figure 2, Item 10) from propel control valve (Figure 2, Item 5). Disconnect electrical connector (Figure 2, Item 8). Remove two wires (Figure 2, Item 7) from backup alarm switch (Figure 2, Item 9). Remove four bolts (Figure 2, Item 2) and nuts (Figure 2, Item 3) from plate assembly (Figure 2, Item 6). Remove propel control valve (Figure 2, Item 5) and lever assembly (Figure 2, Item 4) as a unit from plate assembly (Figure 2, Item 6).
2, 3
10
M0361SWR
Propel Control Lever Removal.
0206-3
TM 5-3895-379-23-1
0206
DISASSEMBLY 1. Remove retainer ring (Figure 3, Item 3) and boot (Figure 3, Item 4) from handle (Figure 3, Item 1).
CAUTION
Do not turn handle more than one full turn. Handle cannot be removed by unscrewing and should not be forced or turned more than needed to allow access to screws and nuts. Forcing the handle to turn further will damage the handle. 2. Loosen handle (Figure 3, Item 1) on handle pipe (Figure 3, Item 9) by turning handle counterclockwise not more than one full turn.
NOTE
Use care to not lose nuts during removal. Nuts are small and may stay with handle. 3. 4. 5. 6. Remove two screws (Figure 3, Item 29), four screws (Figure 3, Item 30), and six nuts (Figure 3, Item 6) from two handles (Figure 3, Item 1). Remove two handles (Figure 3, Item 1) from handle pipe (Figure 3, Item 9). Remove two gaskets (Figure 3, Item 2) from handles (Figure 3, Item 1). Discard gaskets. Remove nut (Figure 3, Item 7) and preformed packing (Figure 3, Item 8) from handle pipe (Figure 3, Item 9). Discard preformed packing.
NOTE
Note that cams are different lengths. 7. 8. 9. 10. 11. Raise boot (Figure 3, Item 13) and remove two screws (Figure 3, Item 14) and cam (Figure 3, Item 17). Remove two retaining rings (Figure 3, Item 15), pivot pin (Figure 3, Item 25), and two cams (Figure 3, Item 16). Remove two screws (Figure 3, Item 28) and wires (Figure 3, Item 27) from vibration push switch (Figure 3, Item 5). Loosen nut (Figure 3, Item 10) and remove handle pipe (Figure 3, Item 9). Remove nut (Figure 3, Item 10), adjuster (Figure 3, Item 11), boot (Figure 3, Item 13), and boot sleeve (Figure 3, Item 12).
NOTE
Note position of washers to aid in installation. Count number of turns necessary to remove pivot plate from pivot bolt. 12. 13. 14. Remove outer bracket (Figure 3, Item 26), three washers (Figure 3, Item 18), two wires (Figure 3, Item 27), and bronze wear shoe (Figure 3, Item 19) from pivot bolt (Figure 3, Item 21). Remove pivot plate (Figure 3, Item 20) from pivot bolt (Figure 3, Item 21). Remove three screws (Figure 3, Item 24) and switch (Figure 3, Item 23) from pivot bracket (Figure 3, Item 22).
0206-4
TM 5-3895-379-23-1
0206
DISASSEMBLY - Continued
4 3 1 2
7 30 8 29 28 27 9
10 11 12 13 14 26 14 15 14
15
25
16 17 18 19 20 21
22
24
23
M0372SWR
Propel Control Lever Disassembly.
0206-5
TM 5-3895-379-23-1
0206
ASSEMBLY 1. 2. Install switch (Figure 4, Item 23) and three screws (Figure 4, Item 24) on pivot bracket (Figure 4, Item 22). Install pivot bolt (Figure 4, Item 21) on pivot plate (Figure 4, Item 20) using same number of turns noted during removal.
NOTE
Install washers as noted in removal. 3. 4. 5. 6. 7. 8. 9. 10. 11. Install outer bracket (Figure 4, Item 26), three washers (Figure 4, Item 18), two wires (Figure 4, Item 27), and bronze wear shoe (Figure 4, Item 19) to pivot bolt (Figure 4, Item 21). Install adjuster (Figure 4, Item 11), boot (Figure 4, Item 13), and boot sleeve (Figure 4, Item 12). Install, but do not tighten nut (Figure 4, Item 10). Install handle pipe (Figure 4, Item 9) and tighten nut. Install two screws (Figure 4, Item 28) and wires (Figure 4, Item 27) on vibration push switch (Figure 4, Item 5). Install two retaining rings (Figure 4, Item 15), pivot pin (Figure 4, Item 25), and two cams (Figure 4, Item 16). Lower boot (Figure 4, Item 13) and install two screws (Figure 4, Item 14) and cam (Figure 4, Item 17). Install nut (Figure 4, Item 7) and new preformed packing (Figure 4, Item 8) to handle pipe (Figure 4, Item 9). Install two new gaskets (Figure 4, Item 2) to handles (Figure 4, Item 1). Install two handles (Figure 4, Item 1) to handle pipe (Figure 4, Item 9).
NOTE
Grip housings will not fit together if any threads of handle pipe are showing on top side of nut while nut is installed. Mate flat sides of nut with cavity on grip housing. Use care not to lose any nuts during installation. Nuts are small and easily lost. 12. Install two screws (Figure 4, Item 29), four screws (Figure 4, Item 30), and six nuts (Figure 4, Item 6) to two handles (Figure 4, Item 1).
CAUTION
Do not turn handle more than one full turn. Handle should not be forced or turned more than needed to tighten. Forcing the handle to turn further will damage the handle. 13. 14. Tighten handle (Figure 4, Item 1) on handle pipe (Figure 4, Item 9) by turning grip housings clockwise not more than one full turn. Install retainer ring (Figure 4, Item 3) and boot (Figure 4, Item 4) to handle (Figure 4, Item 1).
0206-6
TM 5-3895-379-23-1
0206
ASSEMBLY - Continued
4 3 1 2
7 30 8 29 28 27 9
10 11 12 13 14 26 14 15 14
15
25
16 17 18 19 20 21
22
24
23
M0373SWR
Propel Control Lever Assembly.
0206-7
TM 5-3895-379-23-1
0206
INSTALLATION 1. 2. 3. 4. 5. 6. 7. Install propel control valve and lever assembly (Figure 5, Items 4 and 5), as a unit, to plate assembly (Figure 5, Item 6). Install four bolts (Figure 5, Item 2) and nuts (Figure 5, Item 3) to plate assembly (Figure 5, Item 6). Install two wires (Figure 5, Item 7) to back-up alarm switch (Figure 5, Item 9). Connect electrical connector (Figure 5, Item 8). Install four hose assemblies (Figure 5, Item 10) to propel control valve (Figure 5, Item 5) and lever assembly (Figure 5, Item 4). Check fill level of hydraulic tank (WP 0071). Tighten hydraulic oil tank fill cap (Figure 5, Item 1).
2, 3
10
M0374SWR
Figure 5.
Propel Control Lever Installation.
0206-8
TM 5-3895-379-23-1
0206
INSTALLATION - Continued 8. 9. Install plate assembly (Figure 6, Item 3) to operator station (Figure 6, Item 4). Install nine bolts (Figure 6, Item 1), two washers (Figure 6, Item 5), and seven washers (Figure 6, Item 2) to operator station (Figure 6, Item 4).
5
M0375SWR
Propel Control Lever Installation.
0206-9/10 blank
TM 5-3895-379-23-1
0207
FIELD MAINTENANCE PROPEL CONTROL LEVER VIBRATORY SYSTEM ENGAGEMENT STOPS ADJUSTMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-10 TM 5-3895-379-23P, Figure 78 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0207-1
TM 5-3895-379-23-1
0207
ADJUSTMENT
NOTE
The vibratory system can be activated at various speeds ranging from 10% to 100% of the propel control lever stroke. This activation will occur when the vibratory control switch is in the AUTO position and the vibratory on/off switch is in the ON position. Separate adjustments can be made for both forward and reverse activation of vibratory system. 1. 2. Lift boot (Figure 1, Item 1) to expose cams (Figure 1, Item 3). Start engine (TM 5-3895-379-10).
NOTE
Cam toward front of roller controls vibratory system when roller is traveling in reverse direction. Cam toward rear of roller controls vibratory system when roller is traveling in forward direction. 3. 4. Loosen cam adjustment screws (Figure 1, Item 2) and adjust cams (Figure 1, Item 3) until the vibratory system is activated at desired travel speed (usually 40 to 70% of full speed). Tighten cam adjustment screws (Figure 1, Item 2).
ADJUSTS REVERSE VIBRATION
ADJUSTS FORWARD VIBRATION
M0376SWR
Figure 1. Engagement Stops Adjustment. 5. Turn engine off (TM 5-3895-379-10).
NOTE
If cams cannot be adjusted to automatically start vibration, engagement switches may need adjustment. If you have adjusted cams and vibration startup is OK, skip Steps (6) through (13). 6. 7. Remove two screws (Figure 2, Item 1) and washers (Figure 2, Item 11) from operator station (Figure 2, Item 4). Remove seven screws (Figure 2, Item 1) and washers (Figure 2, Item 2) from operator station (Figure 2, Item 4).
0207-2
TM 5-3895-379-23-1
0207
ADJUSTMENT - Continued 8. 9. 10. 11. 12. Lift panel assembly (Figure 2, Item 3) and pull away from operator station (Figure 2, Item 4). Remove four screws (Figure 2, Item 5), washers (Figure 2, Item 6), and propulsion control valve assembly (Figure 2, Item 9) from panel assembly (Figure 2, Item 3). Loosen two screws (Figure 2, Item 8) and move two engagement switches (Figure 2, Item 7) up until cams (Figure 2, Item 10) engage switches (Figure 2, Item 8). Tighten screws. Install propulsion control valve assembly (Figure 2, Item 9) on panel assembly (Figure 2, Item 3) with four washers (Figure 2, Item 6) and screws (Figure 2, Item 5). Install panel assembly (Figure 2, Item 3) on operator station (Figure 2, Item 4) with two washers (Figure 2, Item 11), seven washers (Figure 2, Item 2), and nine screws (Figure 2, Item 1).
3 5 6 1 2
10 7 9 7 1 11
Figure 2. 13. Repeat Steps (2) through (5). Engagement Stops Adjustment.
M0377SWR
0207-3
TM 5-3895-379-23-1
0207
ADJUSTMENT - Continued 14. Return boot (Figure 3, Item 1) to original position.
M1060SWR
Figure 3. Engagement Stops Adjustment. END OF TASK FOLLOW-ON MAINTENANCE Remove chocks. (TM 5-3895-379-10) END OF TASK END OF WORK PACKAGE
0207-4
TM 5-3895-379-23-1
0208
FIELD MAINTENANCE PROPEL CONTROL LEVER TENSION ADJUSTMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Grease, Molybdenum Disulfide (Volume 2, WP 0288, Table 1, Item 28) Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 78 Equipment Condition Engine off. (TM 5-3895-379-10)
ADJUSTMENT
NOTE
There should be enough friction on propel control lever to hold lever in position while vibratory system is operating. 1. 2. 3. 4. Turn adjuster (Figure 1, Item 2) to obtain desired propel control lever tension. Turning adjuster counterclockwise decreases tension, turning adjuster clockwise increases tension. Lift boot (Figure 1, Item 1) to expose pivot bracket (Figure 1, Item 3). Wipe pivot bracket (Figure 1, Item 3) with rags and apply grease to increase smoothness of propel control lever. Return boot (Figure 1, Item 1) to original position.
1 2 1 DECREASE
INCREASE 1 3
M0378SWR
Figure 1. Propel Control Lever Tension Adjustment.
0208-1
TM 5-3895-379-23-1
0208
ADJUSTMENT - Continued 5. 6. Start engine, move roller and operate vibratory system (TM 5-3895-379-10). If there is not enough friction on propel control lever to hold lever in position while vibratory system is operating, turn off vibratory system, stop roller, turn engine off (TM 5-3895-379-10), and repeat Step (1) until adequate friction is obtained.
0208-2
TM 5-3895-379-23-1
0209
FIELD MAINTENANCE PROPEL AND VIBRATORY VALVE TESTS AND ADJUSTMENTS
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gage, Differential, Dial Indicating (Volume 2, WP 0289, Table 1, Item 9) Gage, Differential, Dial Indicating (Volume 2, WP 0289, Table 1, Item 10) Pin, Straight, Threaded (Volume 2, WP 0289, Table 1, Item 24) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 71, 75, and 76 Volume 2, WP 0265 Equipment Condition Drums chocked. (TM 5-3895-379-10) Parking brake engaged. (TM 5-3895-379-10)
CHARGE PUMP SYSTEM PRESSURE TEST
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. Hydraulic system pressure can be over 2,500 psi (17 237 kPa), even with engine and pump OFF. To relieve pressure, shut down engine, then 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. At operating temperature hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulics. Failure to do so may cause injury. Oil is very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury.
NOTE
Perform charge pump system pressure test first, before main (high pressure) relief valve tests. The CB534B and CB534C Roller propel pumps are tested the same, except as noted. 1. Place propel control lever in NEUTRAL (TM 5-3895-379-10).
0209-1
TM 5-3895-379-23-1
0209
CHARGE PUMP SYSTEM PRESSURE TEST - Continued
NOTE
Pressure tap is labeled "CP." 2. Connect pressure gauge to pressure tap (Figure 1, Item 3) to vibratory control valve (Figure 1, Item 6).
NOTE
The charge relief pressure setting should be 360 + 20 psi (2,482 + 138 kPa). 3. 4. Start and run engine at HIGH idle, 2,325 + 25 rpm. Record pressure gauge reading. If needed, adjust as follows: a. b. c. d. 5. 6. Loosen locknut (Figure 1, Item 4). Turn adjustment screw (Figure 1, Item 5) clockwise to increase pressure, counterclockwise to decrease pressure. After adjustment, tighten locknut (Figure 1, Item 4). Lower rpm to LOW idle and recheck pressure. Pressure should be greater than 300 psi (2,068 kPa).
Shut engine off. Remove pressure gauge from tap (Figure 1, Item 3).
3 4, 5 8 7 6
1, 2
M0379SWR
Figure 1. Valve Tests and Adjustments. END OF TASK
0209-2
TM 5-3895-379-23-1
0209
REVERSE MAIN RELIEF VALVE PRESSURE TEST 1. 2. 3. Place propel control lever in NEUTRAL (TM 5-3895-379-10). Loosen setscrew (Figure 2, Item 1) and turn needle valve thumbscrew (Figure 2, Item 2) fully clockwise to close valve. Connect pressure gauges to two pressure taps (Figure 2, Items 7 and 8).
3 4, 5 8 7 6
1, 2
M1189SWR
Figure 2.
Valve Tests and Adjustments.
0209-3
TM 5-3895-379-23-1
0209
REVERSE MAIN RELIEF VALVE PRESSURE TEST - Continued 4. 5. 6. Loosen adjuster locknut (Figure 3, Item 3) on Pressure Override Relief (POR) valve (Figure 3, Item 2). Turn adjuster (Figure 3, Item 4) clockwise one-half turn. Tighten locknut (Figure 3, Item 3). Start and run engine at HIGH idle.
NOTE
Maximum pressure should be 6,525 200 psi (45,000 1 380 kPa). 7. 8. Move propel control lever to the full reverse position (TM 5-3895-379-10). If needed, adjust as follows: a. b. c. d. Stop engine (TM 5-3895-379-10) and remove valve cap (Figure 3, Item 7). Remove cartridge (Figure 3, Item 6) and reinstall cap (Figure 3, Item 7) to prevent oil from spilling. Clamp cartridge (Figure 3, Item 6) in a soft-jawed vice. Loosen locking setscrew (Figure 3, Item 8).
NOTE
One full turn equals 638 psi (4,400 kPa). e. f. g. h. 9. 10. 11. Turn spindle (Figure 3, Item 5) to adjust pressure: clockwise to increase pressure, counterclockwise to decrease pressure. Tighten locking setscrew (Figure 3, Item 8). Remove cartridge (Figure 3, Item 6) from soft-jawed vice and install on propel pump (Figure 3, Item 1). Install cap (Figure 3, Item 7).
Start engine (TM 5-3895-379-10) and check pressure at tap (Figure 2, Item 8). Stop engine (TM 5-3895-379-10). Readjust POR valve (Figure 3, Item 2) by turning adjuster (Figure 3, Item 4) clockwise one-half turn.
0209-4
TM 5-3895-379-23-1
0209
REVERSE MAIN RELIEF VALVE PRESSURE TEST - Continued

1 8 7 6 5 2 3 4
M0380SWR
Figure 3.
0209-5
TM 5-3895-379-23-1
0209
REVERSE MAIN RELIEF VALVE PRESSURE TEST - Continued 12. Tighten setscrew (Figure 2, Item 1) on needle valve thumbscrew (Figure 2, Item 2).
NOTE
Minimum low pressure is 6,327 psi (43,623 kPa). 13. If minimum low pressure is not obtainable, there is too much leakage in the internal circuit.
END OF TASK FORWARD MAIN RELIEF VALVE PRESSURE TEST 1. 2. 3. Place propel control lever in NEUTRAL (TM 5-3895-379-10). Loosen setscrew (Figure 4, Item 1) and turn needle valve thumbscrew (Figure 4, Item 2) fully clockwise to close the valve. Check pressure at pressure tap (Figure 4, Item 7).
3 4, 5 8 7 6
1, 2
M1190SWR
Figure 4. Valve Tests and Adjustments.
0209-6
TM 5-3895-379-23-1
0209
FORWARD MAIN RELIEF VALVE PRESSURE TEST - Continued 4. 5. 6. Loosen adjuster locknut (Figure 5, Item 3) on Pressure Override Relief (POR) valve (Figure 5, Item 2). Turn adjuster locknut (Figure 5, Item 3) clockwise one-half turn. Tighten adjuster locknut (Figure 5, Item 3).
1 8 7 6 5 2 3 4
M1192SWR
Figure 5.
0209-7
TM 5-3895-379-23-1
0209
FORWARD MAIN RELIEF VALVE PRESSURE TEST - Continued 7. Start and run engine at high idle (TM 5-3895-379-10).
NOTE
Maximum pressure should be 6,525 200 psi (45,000 1,380 kPa). 8. 9. Move propel control lever to full forward position (TM 5-3895-379-10). If needed, adjust as follows: a. b. c. d. Stop engine (TM 5-3895-379-10) and remove valve cap (Figure 6, Item 7). Remove cartridge (Figure 6, Item 6) and reinstall cap (Figure 6, Item 7) to prevent oil from spilling. Clamp cartridge (Figure 6, Item 6) in a soft-jawed vice. Loosen locking setscrew (Figure 6, Item 5).
NOTE
One full turn equals 638 psi (4,400 kPa). e. f. g. h. 10. 11. 12. Turn spindle (Figure 6, Item 8) to adjust pressure: clockwise to increase pressure, counterclockwise to decrease pressure. Tighten locking setscrew (Figure 6, Item 5). Remove cartridge (Figure 6, Item 6) from soft-jawed vice and install. Install cap (Figure 6, Item 7) and tighten to specification.
Start engine (TM 5-3895-379-10) and check pressure at tap (Figure 7, Item 7). Stop engine (TM 5-3895-379-10). Readjust POR valve (Figure 6, Item 2) by turning adjuster (Figure 6, Item 4) clockwise one-half turn.
1 2 3 4
8 7 6 5
M0381SWR
0209-8
TM 5-3895-379-23-1
0209
FORWARD MAIN RELIEF VALVE PRESSURE TEST - Continued 13. Tighten setscrew (Figure 7, Item 1) on needle valve thumbscrew (Figure 7, Item 2).
3 4, 5 8 7 6
1, 2
M0382SWR
Figure 7.
0209-9
TM 5-3895-379-23-1
0209
FORWARD MAIN RELIEF VALVE PRESSURE TEST - Continued
NOTE
Minimum low pressure is 6,327 psi (43,623 kPa). 14. If minimum low pressure is not obtainable, there is too much leakage in the internal circuit and pump must be replaced.
END OF TASK HYDRAULIC SERVO NEUTRAL (MECHANICAL CENTER) ADJUSTMENT
NOTE
Charge Pump System Pressure Test must be completed before performing Hydraulic Servo Neutral (Mechanical Center) Adjustment. 1. Place propel control lever in NEUTRAL (TM 5-3895-379-10).
NOTE
The following step equalizes oil pressure on each side of servo piston. 2. Remove two plugs (Figure 8, Item 1) from ports (Figure 8, Item 2) and connect jumper hose between two ports.
1, 2
M0383SWR
0209-10
TM 5-3895-379-23-1
0209
HYDRAULIC SERVO NEUTRAL (MECHANICAL CENTER) ADJUSTMENT - Continued 3. Connect two 9,000 psi (60,000 kPa) pressure gauges to pressure taps (Figure 9, Items 7 and 8).
3 4, 5 8 7 6
1, 2
M1194SWR
Figure 9.
0209-11
TM 5-3895-379-23-1
0209
HYDRAULIC SERVO NEUTRAL (MECHANICAL CENTER) ADJUSTMENT - Continued 4. 5. Move propel control lever to LOW SPEED range (TM 5-3895-379-10). Start and run the engine at 1,500 rpm (TM 5-3895-379-10).
NOTE
Pressure gauge readings should be the same. 6. If readings are not the same, adjust neutral position (mechanical center) of the piston (Figure 10, Item 3) as follows:
5
M1196SWR
Figure 10. Valve Tests and Adjustments. a. b. c. 7. 8. 9. 10. Loosen locknut (Figure 11, Item 2) on piston rod adjustment screw (Figure 11, Item 1). Turn piston rod adjustment screw (Figure 11, Item 1) clockwise or counterclockwise depending on spool movement requirement. Adjust piston rod adjustment screw (Figure 11, Item 1) until pressure readings are same.
Stop engine (TM 5-3895-379-10). Remove two 9,000 psi (60,000 kPa) gauges and install two 600 psi (4,000 kPa) gauges on ports (Figure 8, Item 2). Repeat Steps (5) through (7). Tighten locknut (Figure 11, Item 2).
M0384SWR
0209-12
TM 5-3895-379-23-1
0209
HYDRAULIC SERVO NEUTRAL (MECHANICAL CENTER) ADJUSTMENT - Continued 11. 12. 13. Remove pressure gauges from pressure taps (Figure 9, Items 7 and 8). Remove jumper hose from two ports (Figure 8, Item 2). Install plugs (Figure 8, Item 1) on ports (Figure 8, Item 2).
1 2 3 4
8 7 6 5
M1193SWR
0209-13
TM 5-3895-379-23-1
0209
STABILIZED CONTROL VALVE SPOOL NEUTRAL ADJUSTMENT
NOTE
Prior to controlling the hydraulic servo, oil from the charge pump must control the spool of the stabilized control valve. 1. Perform the following test to verify valve spool neutral setting is correct.
NOTE
Hydraulic Servo Neutral Adjustment must be completed before performing this Stabilized Control Valve Spool Neutral Adjustment. This is done to ensure that neutral (mechanical center) position of servo piston and swash plate is correct. 2. Remove two stabilized control valve end covers (Figure 13, Item 5).
NOTE
Leave springs and shim out for adjustment purposes. 3. 4. 5. Remove two pistons (Figure 13, Item 3) with springs (Figure 13, Item 2) and shim (Figure 13, Item 1) from end covers (Figure 13, Item 5). Install pistons (Figure 13, Item 3) back into stabilized control valve end covers (Figure 13, Item 5). Install two stabilized control valve end covers (Figure 13, Item 5) on the control valve body (Figure 13, Item 4).
5
M0385SWR
0209-14
TM 5-3895-379-23-1
0209
STABILIZED CONTROL VALVE SPOOL NEUTRAL ADJUSTMENT - Continued 6. Remove two fittings (Figure 14, Item 2) and plug ports (Figure 14, Item 1).
1, 2
M0386SWR
Figure 14.
0209-15
TM 5-3895-379-23-1
0209
STABILIZED CONTROL VALVE SPOOL NEUTRAL ADJUSTMENT - Continued 7. Remove plugs (Figure 15, Item 1) and install connectors for pressure gauges at ports (Figure 14, Item 1).
1, 2
M1195SWR
Figure 15. Valve Tests and Adjustments. 8. Install two 600 psi (4,000 kPa) pressure gauges to pressure taps (Figure 16, Items 7 and 8).
3 4, 5 8 7 6
1, 2
M1191SWR
0209-16
TM 5-3895-379-23-1
0209
STABILIZED CONTROL VALVE SPOOL NEUTRAL ADJUSTMENT - Continued 9. Set the propel control lever to HIGH SPEED position (TM 5-3895-379-10).
NOTE
Both test gauges should show identical readings. If the readings are not equal, the valve must be adjusted. 10. Start and run the engine at 1,500 rpm (TM 5-3895-379-10).
NOTE
One-half revolution of adjustment screw gives all adjustment possible. Small movement of screw makes a large difference in pressure. 11. To adjust: a. b. Loosen locknut (Figure 17, Item 2) and turn adjustment screw (Figure 17, Item 1) clockwise or counterclockwise to get equal pressures at the gauges. Tighten locknut (Figure 17, Item 2) on adjustment screw (Figure 17, Item 1).
M0387SWR
Figure 17. 12. 13. 14. 15.
Remove two stabilized control valve end covers (Figure 13, Item 5). Remove two pistons (Figure 13, Item 3) from two stabilized control valve end covers (Figure 13, Item 5). Install springs (Figure 13, Item 2) and shims (Figure 13, Item 1) back into original locations. Assemble two stabilized control valve end covers (Figure 13, Item 5) and install on control valve body (Figure 13, Item 4).
END OF TASK
0209-17
TM 5-3895-379-23-1
0209
DAMPED CONTROL HEAD ADJUSTMENT 1. Disconnect and plug the brake line to the front drum at the torque hub (Volume 2, WP 0233).
WARNING
NOTE
Raise drum 2-3 in. (50-76 mm) off the floor. 2. Raise REAR of roller (Volume 2, WP 0265) and support it on stands.
NOTE
Make sure the drum can turn freely. 3. 4. 5. Mark edge of the drum for use in counting drum revolutions. Remove two 600 psi (4 000 kPa) pressure gauges. Install two 300 psi (2 000 kPa) pressure gauges at ports (Figure 18, Item 1).
1, 2
M1074SWR
0209-18
TM 5-3895-379-23-1
0209
DAMPED CONTROL HEAD ADJUSTMENT - Continued 6. 7. 8. Loosen locknut (Figure 19, Item 2) approximately one-half turn. While holding locknut (Figure 19, Item 2), turn damped adjustment screw (Figure 19, Item 1) until approximately seven threads are exposed beyond locknut (Figure 19, Item 2). Tighten locknut (Figure 19, Item 2). Start roller and set propel control lever to LOW range (TM 5-3895-379-10).
NOTE
Time rear drum for 10 revolutions in forward direction. 9. Move propel control lever forward (TM 5-3895-379-10) until pressure is at 175 psi (1 200 kPa).
NOTE
Time rear drum for 10 revolutions in reverse direction. 10. Move propel control lever rearward (TM 5-3895-379-10) until pressure is at 175 psi (1 200 kPa).
NOTE
If times vary more than 10 percent, more adjustment is necessary. 11. Compare times recorded in Steps (9) and (10).
NOTE
To decrease the reverse drum speed in relation to forward drum speed, screw dampen adjuster clockwise. To increase the reverse drum speed in relation to forward drum speed, turn dampen adjuster (Figure 19, Item 1) counterclockwise. 12. Adjust damped adjustment screw (Figure 19, Item 1) as necessary until the speed variation between forward and reverse is less than 10 percent.
2
M0388SWR
Figure 19. END OF TASK END OF WORK PACKAGE
0209-19/20 blank
TM 5-3895-379-23-1
0210
FIELD MAINTENANCE PRESSURE OVERRIDE RELIEF (POR) VALVE PRESSURE TEST (CB534C)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gage Differential, Dial Indicating (Volume 2, WP 0289, Table 1, Item 10) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 7, 75, and 83 WP 0218 Equipment Condition Drums chocked. (TM 5-3895-379-10) Engine on. (TM 5-3895-379-10)
PRESSURE OVERRIDE RELIEF VALVE PRESSURE TEST 1. 2. 3. 4. Disconnect front and rear propel motor brake lines (WP 0218). Place propel control lever in NEUTRAL position (TM 5-3895-379-10). Connect pressure gauge to tap (Figure 1, Item 1). Loosen Pressure Override Relief valve (POR) setscrew (Figure 1, Item 2) and turn needle valve thumbscrew (Figure 1, Item 3) fully clockwise to close POR valve (Figure 1, Item 4).
1 2, 3 4
M0389SWR
Figure 1.
Pressure Override Relief Valve Pressure Test.
0210-1
TM 5-3895-379-23-1
0210
PRESSURE OVERRIDE RELIEF VALVE PRESSURE TEST - Continued 5. Set speed range switch to HIGH SPEED position (TM 5-3895-379-10).
NOTE
The pressure should read 6,090 +/ 200 psi (42,000 +/ 1 380 kPa). 6. If measurement is not within range noted above, perform the following steps: a. b. c. d. e. Move propel control lever forward or reverse (TM 5-3895-379-10). Record pressure at tap (Figure 2, Item 1). Loosen setscrew (Figure 2, Item 2) on POR valve (Figure 2, Item 4). Turn needle valve thumbscrew (Figure 2, Item 3) clockwise to increase pressure or counterclockwise to decrease pressure. Recheck pressure at tap (Figure 2, Item 1).
1 2, 3 4
M0390SWR
Pressure Override Relief Valve Pressure Test.
Turn engine OFF. (TM 5-3895-379-10) Install propel motor brake lines. (WP 0218) Remove chocks. (TM 5-3895-379-10)
0210-2
TM 5-3895-379-23-1
0211
FIELD MAINTENANCE PROPEL AND SPEED CONTROL VALVE REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Materials/Parts Backup Ring (Volume 2, WP 0290, Table 1, Item 84) Qty: 2 Gasket (Volume 2, WP 0290, Table 1, Item 86) Qty: 1 O-ring (Volume 2, WP 0290, Table 1, Item 83) Qty: 2 Packing, Preformed (Volume 2, WP 0290, Table 1, Item 77) Qty: 3 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 78 Equipment Condition Propel control lever valve removed. (WP 0206)
0211-1
TM 5-3895-379-23-1
0211
DISASSEMBLY 1. 2. 3. 4. Remove three screws (Figure 1, Item 4) and boot clamp (Figure 1, Item 5) from valve body (Figure 1, Item 9). Remove three screws (Figure 1, Item 2), pivot bracket (Figure 1, Item 3), plate (Figure 1, Item 15), and gasket (Figure 1, Item 14) from valve body (Figure 1, Item 9). Discard gasket. Remove two screws (Figure 1, Item 8) and switches (Figure 1, Item 7) from pivot bracket (Figure 1, Item 3). Remove two metering fittings (Figure 1, Item 13), preformed packing (Figure 1, Item 10), O-ring (Figure 1, Item 11), and backup ring (Figure 1, Item 12) from valve body (Figure 1, Item 9). Discard preformed packing, backup ring, and O-ring. Remove two plungers (Figure 1, Item 1) and preformed packings (Figure 1, Item 6) from valve body (Figure 1, Item 9). Discard preformed packings.
5.
3 1 2 6 4 5 1 6 7 8
15 14 7
9 10 11 12
13
M0391SWR
Figure 1. END OF TASK ASSEMBLY 1.
Propel and Speed Control Valve Disassembly.
Install two new preformed packings (Figure 2, Item 6) and plungers (Figure 2, Item 1) on valve body (Figure 2, Item 9).
0211-2
TM 5-3895-379-23-1
0211
ASSEMBLY - Continued 2. 3. 4. 5. Install new backup ring (Figure 2, Item 12), new O-ring (Figure 2, Item 11), new preformed packing (Figure 2, Item 10), and two metering fittings (Figure 2, Item 13) on valve body (Figure 2, Item 9). Install two switches (Figure 2, Item 7) on pivot bracket (Figure 2, Item 3) with screws (Figure 2, Item 8). Install new gasket (Figure 2, Item 14), plate (Figure 2, Item 15), and pivot bracket (Figure 2, Item 3) on valve body (Figure 2, Item 9). Install three screws (Figure 2, Item 4) and boot clamp (Figure 2, Item 5) to valve body (Figure 2, Item 9).
3 1 2 6 4 5 1 6 7 8
15 14 7
9 10 11 12
13
M1153SWR
Propel and Speed Control Valve Assembly.
Install propel control lever. (WP 0206) END OF TASK END OF WORK PACKAGE
0211-3/4 blank
TM 5-3895-379-23-1
0212
FIELD MAINTENANCE HYDRAULIC PUMP DRIVE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 64 Equipment Condition Left-side door assembly opened. (TM 5-3895-379-10) Equipment Condition (cont.) Vibratory and propel pumps removed. (WP 0203) Air cleaner elements and air cleaner assembly removed. (WP 0118)
0212-1
TM 5-3895-379-23-1
0212
REMOVAL 1. 2. Remove 12 capscrews (Figure 1, Item 5), washers (Figure 1, Item 4), and adapter (Figure 1, Item 3) from roller. Remove eight bolts (Figure 1, Item 2) and connector (Figure 1, Item 1) from roller.
1 2 3 4
M0392SWR
Figure 1. Hydraulic Pump Drive Removal. END OF TASK INSTALLATION 1. 2. Install eight bolts (Figure 2, Item 2) and connector (Figure 2, Item 1) to roller. Install 12 capscrews (Figure 2, Item 5), washers (Figure 2, Item 4), and adapter (Figure 2, Item 3) to roller.
0212-2
TM 5-3895-379-23-1
0212
1 2 3 4
M1287SWR
Hydraulic Pump Drive Installation.
Install air cleaner elements and air cleaner assembly. (WP 0118) Install vibratory and propel pumps. (WP 0203) Close left-side door assembly. (TM 5-3895-379-10)
0212-3/4 blank
TM 5-3895-379-23-1
0213
FIELD MAINTENANCE FRONT AND REAR PROPEL GEARBOX SERVICE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (Volume 2, WP 0289, Table 1, Item 23) Materials/Parts Lubricating Oil, Gear, 80W-90 Grade (Volume 2, WP 0288, Table 1, Item 37, 38, 39) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 79 and 80 Equipment Condition Engine on. (TM 5-3895-379-10) Park roller on level ground. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0213-1
TM 5-3895-379-23-1
0213
DRAIN
NOTE
Front and rear propel gearboxes are serviced the same way. Front propel gearbox is shown. 1. 2. 3. 4. 5. 6. Move roller (Figure 1, Item 1) until level check plug (Figure 1, Item 2) is located at 12 o'clock position and fill plug (Figure 1, Item 4) is located at 3 o'clock position. Turn engine off (TM 5-3895-379-10). Loosen oil level check plug (Figure 1, Item 2) at 12 o'clock position through access hole. Start engine (TM 5-3895-379-10). Move roller (Figure 1, Item 1) until oil level check plug (Figure 1, Item 2) is at 6 o'clock position. Turn engine off (TM 5-3895-379-10).
12 1 9 6 3 2 3 4
POSITION FOR CHECKING SHOWN

M0393SWR
Figure 1. Propel Gearbox Service.
WARNING
NOTE
Use drain pan to catch any hydraulic oil that may drain from system. Dispose of oil IAW local policy and ordinances. Ensure that all spills are cleaned. 7. 8. 9. 10. Place container with 1 gal (3.8 Liters) minimum capacity under gearbox to catch draining oil. Remove oil level check plug (Figure 2, Item 3) and fill plug (Figure 2, Item 2) from gearbox (Figure 2, Item 4). Allow oil to drain completely from gearbox (Figure 2, Item 4). Clean and inspect oil level check plug (Figure 2, Item 3) and fill plug (Figure 2, Item 2).
0213-2
TM 5-3895-379-23-1
0213
DRAIN - Continued
1 2 3 4
POSITION FOR FILLING SHOWN
M0394SWR
Figure 2. END OF TASK CLEANING AND INSPECTION 1. 2. 3. 4. Clean plug with rag. Clean area around plug openings with rag.
Propel Gear Service.
Inspect threads for crossed or peeled condition. Replace damaged plug.
END OF TASK
0213-3
TM 5-3895-379-23-1
0213
FILL 1. 2. 3. 4. Start engine (TM 5-3895-379-10). Move roller (Figure 3, Item 1) until the opening for oil level check plug (Figure 3, Item 2) and fill plug (Figure 3, Item 4) are located at 9 and 12 o'clock positions. Turn engine off (TM5-3895-379-10). Remove fill plug (Figure 3, Item 4) at 12 o'clock position from the gearbox (Figure 3, Item 3) through access hole.
WARNING
CAUTION
Do not overfill gearbox or damage to equipment may result. 5. 6. 7. 8. 9. 10. Add oil (WP 0213) until oil level is at bottom of opening for the oil level check plug opening. Install fill plug (Figure 3, Item 4) through access hole in gearbox (Figure 3, Item 3). Start engine (TM 5-3895-379-10). Move roller (Figure 3, Item 1) until opening for the oil level check plug (Figure 3, Item 2) is at 12 o'clock position and fill plug (Figure 3, Item 4) is at 3 o'clock position. Turn engine off (TM 5-3895-379-10). Install oil level check plug (Figure 3, Item 2) through access hole in gearbox (Figure 3, Item 3).
M0395SWR
Figure 3. Propel Gearbox Service. END OF TASK
0213-4
TM 5-3895-379-23-1
0213
0213-5/6 blank
TM 5-3895-379-23-1
0214
FIELD MAINTENANCE SEPARATE AND CONNECT PROPEL MOTOR AND TORQUE HUB
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Lifting Strap and Hoist, Minimum Capacity 270 lb (122 kg) Link (Volume 2, WP 0289, Table 1, Item 22) Pan, Drain, 5 Gal Cap. (Volume 2, WP 0289, Table 1, Item 23) Materials/Parts O-ring (Volume 2, WP 0290, Table 1, Item 8) Qty: 1 Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figures 68 and 79 Equipment Condition Propel motor and torque hub removed. (WP 0205)
SEPARATE
NOTE
Front and rear propel motors and torque hubs are separated the same way. 1. Install two link brackets (Figure 1, Item 1) on torque hub (Figure 1, Item 2).
2
M0396SWR
Figure 1. Propel Motor and Torque Hub Separate.
0214-1
TM 5-3895-379-23-1
0214
SEPARATE - Continued
WARNING
NOTE
Weight of propel motor and torque hub is 270 lb (122 kg). 2. Using a lifting strap and hoist, raise and support propel motor (Figure 2, Item 2) and torque hub (Figure 2, Item 3).
NOTE
Use drain pan to catch any oil that may drain from torque hub. Dispose of oil IAW local policy and ordinances. Ensure all spills are cleaned up. Weight of propel motor is 55 lb (25 kg). 3. Remove two bolts (Figure 2, Item 1) and, with assistance, remove propel motor (Figure 2, Item 2) and O-ring (Figure 2, Item 4) from torque hub (Figure 2, Item 3). Discard O-ring.
2 1 3
4
M0397SWR
Figure 2. Propel Motor and Torque Hub Separate. END OF TASK CONNECT 1. Position new O-ring (Figure 3, Item 4) on torque hub (Figure 3, Item 3).
0214-2
TM 5-3895-379-23-1
0214
CONNECT - Continued
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. 2. With assistance, install propel motor (Figure 3, Item 2) on torque hub (Figure 3, Item 3) with two bolts (Figure 3, Item 1).
NOTE
Weight of propel motor is 55 lb (25 kg). Weight of propel motor and torque hub is 270 lb (122 kg). 3. Using lifting strap and hoist, raise and support propel motor (Figure 3, Item 2) and torque hub (Figure 3, Item 3).
2 1 3
4
M0397SWR
Figure 3. Propel Motor and Start Hub Connect.
0214-3
TM 5-3895-379-23-1
0214
CONNECT - Continued 4. Remove two link brackets (Figure 4, Item 1) from torque hub (Figure 4, Item 2).
2
M1169SWR
Figure 4. Propel Motor and Start Hub Connect. END OF TASK FOLLOW-ON MAINTENANCE Install propel motor and torque hub. (WP 0205) END OF TASK END OF WORK PACKAGE
0214-4
TM 5-3895-379-23-1
0215
FIELD MAINTENANCE UNIVERSAL JOINT AND SHAFT MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Goggles (Volume 2, WP 0289, Table 1, Item 13) Materials/Parts Lockwasher (Volume 2, WP 0290, Table 1, Item 109) Qty: 8 Packing, Preformed (Volume 2, WP 0290, Table 1, Item 1) Qty: 1 Personnel Required Construction Equipment Repairer 91L (2) References TM 5-3895-379-23P, Figures 81 and 133 Equipment Condition Drum assembly removed and disassembled. (Volume 2, WP 0265)
0215-1
TM 5-3895-379-23-1
0215
DISASSEMBLY
WARNING
Wear suitable eye protection during removal of snap rings. Failure to follow this warning may cause injury.
CAUTION
Do not clamp weaker center section of driveshaft. Avoid excessive force when holding driveshaft in a vice. If shaft or yoke is bent, the driveshaft may vibrate when returned to service.
NOTE
Procedure is same for both driveshafts. Scribe marks on yoke and universal joints prior to removal to assure proper assembly and driveshaft balancing. 1. 2. Remove eight bolts (Figure 1, Item 7) and lockwashers (Figure 1, Item 6) from universal yoke (Figure 1, Item 3). With assistance, remove driveshaft (Figure 1, Item 9) and universal yoke (Figure 1, Item 3) as an assembly from roller.
NOTE
Place driveshaft in vice. 3. 4. 5. 6. Remove four snap rings (Figure 1, Item 4) from bearing (Figure 1, Item 5) and remove universal yoke (Figure 1, Item 3). Remove four snap rings (Figure 1, Item 2), bearings (Figure 1, Item 1), and two universal joints (Figure 1, Item 8) from driveshaft (Figure 1, Item 9). Remove dust cap (Figure 1, Item 10) and preformed packing (Figure 1, Item 11), and separate driveshaft (Figure 1, Item 9). Discard preformed packing. If damaged, remove plug (Figure1, Item 12).
0215-2
TM 5-3895-379-23-1
0215
DISASSEMBLY - Continued
2 1 3
6 8 7
5 4
10 11 12
M0398SWR
Figure 1. Universal Joint and Shaft Disassembly. END OF TASK
0215-3
TM 5-3895-379-23-1
0215
ASSEMBLY 1. 2. If required, install plug (Figure 2, Item 12). Install new preformed packing (Figure 2, Item 11) and dust cap (Figure 2, Item 10) on driveshaft (Figure 2, Item 9). Do not tighten cap at this time.
NOTE
If necessary, apply a light coat of grease to splines to help assist in assembly. Avoid excess force when assembling driveshaft. If splines are damaged the shaft will not operate correctly when returned to service. 3. Spline driveshaft (Figure 2, Item 9) and tighten dust cap (Figure 2, Item 10).
WARNING
Wear suitable eye protection during removal of snap rings to protect your eyes in case a snap ring flies out of universal joint. Failure to follow this warning may cause injury. Apply a light coat of clean grease inside of bearings prior to assembly. 4. 5. 6. Install two universal joints (Figure 2, Item 8) on driveshaft with four bearings (Figure 2, Item 1) and snap rings (Figure 2, Item 2). Install two universal yokes (Figure 2, Item 3) at ends of driveshaft with four bearings (Figure 2, Item 5) and snap rings (Figure 2, Item 4). Position driveshaft on roller and install eight new lockwashers (Figure 2, Item 6) and bolts (Figure 2, Item 7) on universal yokes (Figure 2, Item 3).
0215-4
TM 5-3895-379-23-1
0215
ASSEMBLY - Continued
2 1 3
6 8 7
5 4
10 11 12
M1154SWR
Universal Joint and Shaft Assembly.
Assemble and install drum. (Volume 2, WP 0265) Operate roller and check for proper operation. (TM 5-3895-379-10)
0215-5/6 blank
TM 5-3895-379-23-1
0216
FIELD MAINTENANCE BRAKE CONTROL VALVE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 2, WP 0288, Table 1, Item 12) Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) O-ring (Volume 2, WP 0290, Table 1, Item 24) Qty: 2 O-ring (Volume 2, WP 0290, Table 1, Item 130) Qty: 1 O-ring (Volume 2, WP 0290, Table 1, Item 81) Qty: 3 O-ring (Volume 2, WP 0290, Table 1, Item 88) Qty: 4 O-ring (Volume 2, WP 0290, Table 1, Item 40) Qty: 4 Materials/Parts (cont.) O-ring (Volume 2, WP 0290, Table 1, Item 120) Qty: 3 O-ring (Volume 2, WP 0290, Table 1, Item 72) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 84 and 85 Equipment Condition Air cleaner assembly removed. (WP 0118)
0216-1
TM 5-3895-379-23-1
0216
REMOVAL
WARNING
NOTE
Tag and mark all hoses and wires prior to removal. Plug holes and cap fittings to prevent spilling oil. Inspect all hoses, lines, and fittings for cracks, bends, nicks, dents, stripped threads, and cuts. Replace all damaged parts. 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. Disconnect harness connectors (Figure 1, Items 5 and 6) from solenoid connectors (Figure 1, Items 7 and 8). Place container with 1 gal. (3.8 Liters) minimum capacity under brake control valve (Figure 1, Item 9). Remove hoses (Figure 1, Items 1 and 4) and O-rings (Figure 1, Item 2) from tee (Figure 1, Item 3). Discard O-rings.
1 2 3 2
5 6 8 7
M0399SWR
Figure 1. Brake Control Valve Removal.
0216-2
TM 5-3895-379-23-1
0216
REMOVAL - Continued 4. 5. Remove hose (Figure 2, Item 3) and O-ring (Figure 2, Item 2) from straight adapter (Figure 2, Item 1). Discard O-ring. Remove hose (Figure 2, Item 4) and O-ring (Figure 2, Item 5) from straight adapter (Figure 2, Item 6). Discard O-ring.
FUEL/WATER SEPARATOR SHOWN REMOVED FOR CLARITY 1 2 3
4
M0400SWR
Figure 2. 6.
Brake Control Valve Removal.
Remove hoses (Figure 3, Items 3 and 4) and O-rings (Figure 3, Item 2) from seal tee (Figure 3, Item 1). Discard O-rings.
2 4
M0401SWR
Figure 3.
0216-3
TM 5-3895-379-23-1
0216
REMOVAL - Continued 7. Remove hoses (Figure 4, Items 1 and 2) and O-rings (Figure 4, Item 3) from swivel tee (Figure 4, Item 4). Discard O-rings.
1
3 4 3 2
M0402SWR
Figure 4. Brake Control Valve Removal. 8. Remove hose (Figure 5, Item 3) and O-ring (Figure 5, Item 2) from elbow (Figure 5, Item 1). Discard O-ring.
FUEL/WATER SEPARATOR SHOWN REMOVED FOR CLARITY
3 2 1
M0403SWR
Figure 5. Brake Control Valve Removal. 9. 10. Remove hose (Figure 6, Item 1) and O-ring (Figure 6, Item 2) from elbow (Figure 6, Item 3). Discard O-ring. Remove two nuts (Figure 6, Item 5), washers (Figure 6, Item 4), screws (Figure 6, Item 9), washers (Figure 6, Item 8), and brake control valve (Figure 6, Item 7) from support bracket (Figure 6, Item 6).
0216-4
TM 5-3895-379-23-1
0216
REMOVAL - Continued
4 1 2 3
8 7
M0404SWR
Figure 6. 11. 12. 13. 14. 15.
Place brake control valve (Figure 7, Item 4) in soft-jawed vise. Remove tee (Figure 7, Item 6) and O-ring (Figure 7, Item 3) from brake control valve (Figure 7, Item 4). Discard O-ring. Remove elbow (Figure 7, Item 5) and O-ring (Figure 7, Item 3) from brake control valve (Figure 7, Item 4). Discard O-ring. Remove swivel tee (Figure 7, Item 1) and O-ring (Figure 7, Item 7) from seal connector (Figure 7, Item 2). Discard O-ring. Remove seal connector (Figure 7, Item 2) and O-ring (Figure 7, Item 3) from brake control valve (Figure 7, Item 4). Discard O-ring.
1 7 2 3 4 5 3 3
6
M0405SWR
Figure 7.
0216-5
TM 5-3895-379-23-1
0216
REMOVAL - Continued 16. 17. 18. 19. 20. Remove elbow (Figure 8, Item 1) and O-ring (Figure 8, Item 9) from brake control valve (Figure 8, Item 2). Discard O-ring. Remove seal tee (Figure 8, Item 8) and O-ring (Figure 8, Item 5) from brake control valve (Figure 8, Item 2). Discard O-ring. Remove straight adapter (Figure 8, Item 7) and O-ring (Figure 8, Item 5) from brake control valve (Figure 8, Item 2). Discard O-ring. Remove straight adapter (Figure 8, Item 6) and O-ring (Figure 8, Item 5) from brake control valve (Figure 8, Item 2). Discard O-ring. Remove plug (Figure 8, Item 4) and O-ring (Figure 8, Item 3) from brake control valve (Figure 8, Item 2). Discard O-ring.
9 5 8
3 5 7 6
M0406SWR
4 5
Figure 8. Brake Control Valve Removal. END OF TASK INSTALLATION 1. 2. 3. 4. 5. 6. Place brake control valve (Figure 9, Item 2) in a soft-jawed vise. Install new O-ring (Figure 9, Item 3) and plug (Figure 9, Item 4) in brake control valve (Figure 9, Item 2). Install new O-ring (Figure 9, Item 5) and straight adapter (Figure 9, Item 6) in brake control valve (Figure 9, Item 2). Install new O-ring (Figure 9, Item 5) and straight adapter (Figure 9, Item 7) in brake control valve (Figure 9, Item 2). Install new O-ring (Figure 9, Item 5) and seal tee (Figure 9, Item 8) in brake control valve (Figure 9, Item 2). Install new O-ring (Figure 9, Item 9) and elbow (Figure 9, Item 1) in brake control valve (Figure 9, Item 2).
0216-6
TM 5-3895-379-23-1
0216
9 5 8
3 5 7 6
M1216SWR
4 5
Figure 9. 7. 8. 9. 10. 11.
Brake Control Valve Installation.
Install new O-ring (Figure 10, Item 3) and seal connector (Figure 10, Item 2) in brake control valve (Figure 10, Item 4). Install new O-ring (Figure 10, Item 7) and swivel tee (Figure 10, Item 1) on seal connector (Figure 10, Item 2). Install new O-ring (Figure 10, Item 3) and elbow (Figure 10, Item 5) in brake control valve (Figure 10, Item 4). Install new O-ring (Figure 10, Item 3) and tee (Figure 10, Item 6) in brake control valve (Figure 10, Item 4). Remove brake control valve (Figure 10, Item 4) from soft-jawed vise.
1 7 2 3 4 5 3 3
6
M0407SWR
Figure 10.
0216-7
TM 5-3895-379-23-1
0216
INSTALLATION - Continued 12. Install brake control valve (Figure 11, Item 7) on mounting bracket (Figure 11, Item 6) with two washers (Figure 11, Item 8), screws (Figure 11, Item 9), washers (Figure 11, Item 4), and nuts (Figure 11, Item 5). Tighten nuts to 33-47 lb-ft (45-65 Nm). Install new O-ring (Figure 11, Item 2) and hose (Figure 11, Item 1) on elbow (Figure 11, Item 3).
13.
4 1 2 3
7
M1059SWR
Figure 11. Brake Control Valve Installation. 14. Install new O-ring (Figure 12, Item 2) and hose (Figure 12, Item 3) on elbow (Figure 12, Item 1).
FUEL/WATER SEPARATOR SHOWN REMOVED FOR CLARITY
3 2 1
M0409SWR
Figure 12. Brake Control Valve Installation.
0216-8
TM 5-3895-379-23-1
0216
INSTALLATION - Continued 15. Install two new O-rings (Figure 13, Item 3) and hoses (Figure 13, Items 1 and 2) on swivel tee (Figure 13, Item 4).
1
3 4 3 2
M0410SWR
Figure 13. 16.
Install two O-rings (Figure 14, Item 2) and hoses (Figure 14, Items 3 and 4) on seal tee (Figure 14, Item 1).
2 4
M0411SWR
Figure 14.
0216-9
TM 5-3895-379-23-1
0216
INSTALLATION - Continued 17. 18. Install new O-ring (Figure 15, Item 5) and hose (Figure 15, Item 4) on straight adapter (Figure 15, Item 6). Install new O-ring (Figure 15, Item 2) and hose (Figure 15, Item 3) on straight adapter (Figure 15, Item 1).
4
M0412SWR
Figure 15. Brake Control Valve Installation. 19. 20. Install two new O-rings (Figure 16, Item 2) and hoses (Figure 16, Items 1 and 4) on tee (Figure 16, Item 3). Connect harness connectors (Figure 16, Items 5 and 6) on solenoid connectors (Figure 16, Items 7 and 8).
1 2 3 2
5 6 8 7
M0413SWR
Figure 16. Brake Control Valve Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. Install air cleaner assembly. (WP 0118)
0216-10
TM 5-3895-379-23-1
0216
FOLLOW-ON MAINTENANCE - Continued 2. Start engine, operate roller, and check for leaks. (TM 5-3895-379-10)
0216-11/12 blank
TM 5-3895-379-23-1
0217
FIELD MAINTENANCE BRAKE CONTROL VALVE REPAIR
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 85 Equipment Condition Brake control valve removed. (WP 0216)
0217-1
TM 5-3895-379-23-1
0217
DISASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. 9. Bend tabs down on lock (Figure 1, Item 8). Remove nut (Figure 1, Item 7) from shift coil (Figure 1, Item 5). Remove nut (Figure 1, Item 7) from brake coil (Figure 1, Item 9). Remove lock (Figure 1, Item 8) and two washers (Figure 1, Item 6) from shift coil (Figure 1, Item 5) and brake coil (Figure 1, Item 9). Remove shift coil (Figure 1, Item 5) from shift valve cartridge (Figure 1, Item 4). Remove brake coil (Figure 1, Item 9) from brake valve cartridge (Figure 1, Item 13). Remove shift valve cartridge (Figure 1, Item 4), brake valve cartridge (Figure 1, Item 13), and check valve (Figure 1, Item 10) from manifold (Figure 1, Item 1). Remove three O-rings (Figure 1, Item 2) and two back-up O-rings (Figure 1, Item 3) from shift and brake cartridges (Figure 1, Items 4 and 13). Discard O-rings. Remove two O-rings (Figure 1, Item 12) and back-up O-ring (Figure 1, Item 11) from check valve (Figure 1, Item 10). Discard O-rings.
2 3 1 4
5 6 7 13 8 7 12 11 10 9 6
M0414SWR
Figure 1. Brake Control Valve Disassembly. END OF TASK
0217-2
TM 5-3895-379-23-1
0217
ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. Install two new O-rings (Figure 2, Item 12) and new back-up O-rings (Figure 2, Item 11) to check valve (Figure 2, Item 10). Install three new O-rings (Figure 2, Item 2) and two new back-up O-rings (Figure 2, Item 3) to shift valve cartridge (Figure 2, Item 4) and brake valve cartridge (Figure 2, Item 13). Install shift valve cartridge (Figure 2, Item 4), brake valve cartridge (Figure 2, Item 13), and check valve (Figure 2, Item 10) from manifold (Figure 2, Item 1). Install brake coil (Figure 2, Item 9) from brake valve cartridge (Figure 2, Item 13). Install shift coil (Figure 2, Item 5) from shift valve cartridge (Figure 2, Item 4). Install lock (Figure 2, Item 8) and two washers (Figure 2, Item 6) to shift coil (Figure 2, Item 5) and brake coil (Figure 2, Item 9). Install nut (Figure 2, Item 7) from shift coil (Figure 2, Item 5) and nut (Figure 2, Item 7) from brake coil (Figure 2, Item 9). Tighten to 48-70 lb-ft (65-94 Nm). Bend tabs up on lock (Figure 2, Item 8).
2 3 1 4
5 6 7 13 8 7 12 11 10 9 6
M1155SWR
Brake Control Valve Assembly.
0217-3
TM 5-3895-379-23-1
0217
FOLLOW-ON MAINTENANCE Install brake control valve. (WP 0216) END OF TASK END OF WORK PACKAGE
0217-4
TM 5-3895-379-23-1
0218
FIELD MAINTENANCE BRAKE HOSES, LINES, AND FITTINGS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Pan, Drain, 5 Gal Cap. (Volume 2, WP 0289, Table 1, Item 23) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 2, WP 0288, Table 1, Item 12) Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) Locknut (Volume 2, WP 0290, Table 1, Item 41) Qty: 4 O-ring (Volume 2, WP 0290, Table 1, Item 81) Qty: 16 O-ring (Volume 2, WP 0290, Table 1, Item 88) Qty: 1 Materials/Parts (cont.) O-ring (Volume 2, WP 0290, Table 1, Item 130) Qty: 10 O-ring (Volume 2, WP 0290, Table 1, Item 73) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 88 Equipment Condition Engine off. (TM 5-3895-379-10) Operator platform assembly raised. (Volume 2, WP 0235)
0218-1
TM 5-3895-379-23-1
0218
WARNING
NOTE
Tag and mark all hoses and wires prior to removal. Plug holes and cap fittings to prevent spilling oil. Use line wrenches to perform these tasks. INSPECTION Inspect all hoses, fittings, and elbows for cracks, bends, nicks, dents, stripped threads, and cuts. Replace all damaged parts.
M0415SWR
Brake Hoses, Lines, and Fittings Inspection.
0218-2
TM 5-3895-379-23-1
0218
MANUAL BRAKE RELEASE PUMP TO HYDRAULIC LINE REPLACEMENT
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. 3. 4. 5. Place container under manual brake release pump elbow (Figure 2, Item 5). Remove hose (Figure 2, Item 1) and O-ring (Figure 2, Item 4) from manual brake release pump elbow (Figure 2, Item 5) and allow oil to drain into container. Discard O-ring. Remove hose (Figure 2, Item 1) and preformed packing (Figure 2, Item 2) from tee (Figure 2, Item 3). Discard preformed packing. Install new preformed packing (Figure 2, Item 2) and hose (Figure 2, Item 1) on tee (Figure 2, Item 3). Install new O-ring (Figure 2, Item 4) and hose (Figure 2, Item 1) on manual brake release pump elbow (Figure 2, Item 5).
1 2 3 4 5
M0416SWR
Figure 2. Brake Hoses, Lines, and Fittings Replacement. END OF TASK
0218-3
TM 5-3895-379-23-1
0218
MANUAL BRAKE RELEASE PUMP TO BRAKE VALVE LINE REPLACEMENT 1. 2. Place container with 1 gal (3.8 Liters) minimum capacity under brake valve tee (Figure 3, Item 1). Remove hose (Figure 3, Item 3) and O-ring (Figure 3, Item 2) from brake valve tee (Figure 3, Item 1) and allow oil to drain into container. Discard O-ring.
1 2 3
M0417SWR
Figure 3. Brake Hoses, Lines, and Fittings Replacement. 3. Remove two screws (Figure 4, Item 1), plate (Figure 4, Item 5), clamp (Figure 4, Item 4), and hose (Figure 4, Item 2) from two screws (Figure 4, Item 3).
AIR CLEANER ASSEMBLY SHOWN REMOVED FOR CLARITY
3 4 5
M0418SWR
Figure 4. Brake Hoses, Lines, and Fittings Replacement.
0218-4
TM 5-3895-379-23-1
0218
MANUAL BRAKE RELEASE PUMP TO BRAKE VALVE LINE REPLACEMENT - Continued 4. 5. Remove hose (Figure 5, Item 3) and O-ring (Figure 5, Item 2) from manual brake release pump elbow (Figure 5, Item 1). Discard O-ring. Install new O-ring (Figure 5, Item 2) and hose (Figure 5, Item 3) on manual brake release pump elbow (Figure 5, Item 1).
M0419SWR
Figure 5. Brake Hoses, Lines, and Fittings Replacement. 6. 7. Place hose (Figure 4, Item 2) in clamp (Figure 4, Item 4) and install clamp and plate (Figure 4, Item 5) on two screws (Figure 4, Item 3) with two screws (Figure 4, Item 1). Install new O-ring (Figure 6, Item 2) and hose (Figure 6, Item 3) on brake valve tee (Figure 6, Item 1).
1 2 3
M0420SWR
Figure 6. Brake Hoses, Lines, and Fittings Replacement. END OF TASK
0218-5
TM 5-3895-379-23-1
0218
MANUAL BRAKE RELEASE PUMP TO FRONT PROPEL GEARBOX LINE REPLACEMENT 1. 2. Place container with 1 gal (3.8 Liters) minimum capacity under front propel gearbox fitting (Figure 7, Item 1). Remove hose (Figure 7, Item 3) and O-ring (Figure 7, Item 2) from front propel gearbox fitting (Figure 7, Item 1) and allow oil to drain into container. Discard O-ring.
2 3
M0421SWR
0218-6
TM 5-3895-379-23-1
0218
MANUAL BRAKE RELEASE PUMP TO FRONT PROPEL GEARBOX LINE REPLACEMENT - Continued 3. 4. 5. 6. Remove screw (Figure 8, Item 15), plate (Figure 8, Item 14), clamp (Figure 8, Item 13), and hose (Figure 8, Item 10) from screw (Figure 8, Item 1). Remove screw (Figure 8, Item 5), lockwasher (Figure 8, Item 4), clamp (Figure 8, Item 3), and hose (Figure 8, Item 10) from yoke (Figure 8, Item 2). Discard lockwasher. Remove two nuts (Figure 8, Item 8), washers (Figure 8, Item 9), screws (Figure 8, Item 11), washers (Figure 8, Item 12), plate (Figure 8, Item 7), and clamp (Figure 8, Item 6) from yoke (Figure 8, Item 2). Separate clamp (Figure 8, Item 6) and remove hose (Figure 8, Item 10).
2 4 3
5 8 9 7 6 10
13 10 14 15
2 12 11
M0422SWR
0218-7
TM 5-3895-379-23-1
0218
MANUAL BRAKE RELEASE PUMP TO FRONT PROPEL GEARBOX LINE REPLACEMENT - Continued 7. 8. Remove two nuts (Figure 9, Item 7), washers (Figure 9, Item 6), screws (Figure 9, Item 3), washers (Figure 9, Item 4), and plates (Figure 9, Item 1) from clamp (Figure 9, Item 2). Separate clamp (Figure 9, Item 2) and remove hose (Figure 9, Item 5).
1 5
3
M0423SWR
Figure 9. Brake Hoses, Lines, and Fittings Replacement. 9. 10. Remove two nuts (Figure 10, Item 1), washers (Figure 10, Item 8), screws (Figure 10, Item 4), washers (Figure 10, Item 5), and plates (Figure 10, Items 2 and 6) from clamp (Figure 10, Item 7). Separate clamp (Figure 10, Item 7) and remove hose (Figure 10, Item 3).
1 8 2
6 5
3
M0424SWR
Figure 10.
Brake Hoses, Lines and Fitting Replacement.
0218-8
TM 5-3895-379-23-1
0218
MANUAL BRAKE RELEASE PUMP TO FRONT PROPEL GEARBOX LINE REPLACEMENT - Continued 11. 12. Remove two nuts (Figure 11, Item 1), washers (Figure 11, Item 2), screws (Figure 11, Item 4), washers (Figure 11, Item 7), plate (Figure 11, Item 5), and clamp (Figure 11, Item 6) from frame (Figure 11, Item 3). Separate clamp (Figure 11, Item 6) and remove hose (Figure 11, Item 8).
6 5 4
M0425SWR
Figure 11. 13.
Brake Hoses, Lines, and Fittings Replacement.
Remove screw (Figure 12, Item 1), plate (Figure 12, Item 2), clamp (Figure 12, Item 5), and hose (Figure 12, Item 3) from screw (Figure 12, Item 4).
1 2
5 4
M0426SWR
Figure 12.
0218-9
TM 5-3895-379-23-1
0218
MANUAL BRAKE RELEASE PUMP TO FRONT PROPEL GEARBOX LINE REPLACEMENT - Continued 14. Remove screw (Figure 13, Item 5), plate (Figure 13, Item 4), clamp (Figure 13, Item 3), and hose (Figure 13, Item 2) from screw (Figure 13, Item 1).
2
M0427SWR
Figure 13. 15. 16.
Remove hose (Figure 14, Item 1) and O-ring (Figure 14, Item 3) from manual brake release pump tee (Figure 14, Item 2). Discard O-ring. Install new O-ring (Figure 14, Item 3) and hose (Figure 14, Item 1) on manual brake release pump tee (Figure 14, Item 2).
2 3
Figure 14.
M0428SWR
0218-10
TM 5-3895-379-23-1
0218
MANUAL BRAKE RELEASE PUMP TO FRONT PROPEL GEARBOX LINE REPLACEMENT - Continued 17. Place hose (Figure 15, Item 2) in clamp (Figure 15, Item 3) and install clamp and plate (Figure 15, Item 4) on screw (Figure 15, Item 1) with screw (Figure 15, Item 5).
2
M0429SWR
Figure 15. 18.
Place hose (Figure 16, Item 3) in clamp (Figure 16, Item 5) and install clamp and plate (Figure 16, Item 2) on screw (Figure 16, Item 4) with screw (Figure 16, Item 1).
1 2
5 4
M0430SWR
Figure 16.
0218-11
TM 5-3895-379-23-1
0218
MANUAL BRAKE RELEASE PUMP TO FRONT PROPEL GEARBOX LINE REPLACEMENT - Continued 19. 20. Place hose (Figure 17, Item 8) in clamp (Figure 17, Item 6). Install clamp (Figure 17, Item 6) and plate (Figure 17, Item 5) on frame (Figure 17, Item 3) with two washers (Figure 17, Item 7), screws (Figure 17, Item 4), washers (Figure 17, Item 2), and nuts (Figure 17, Item 1).
6 5 4
M0431SWR
Figure 17. 21. 22.
Place hose (Figure 18, Item 4) in clamp (Figure 18, Item 7). Install two plates (Figure 18, Item 3), washers (Figure 18, Item 6), screws (Figure 18, Item 5), washers (Figure 18, Item 1), and nuts (Figure 18, Item 2) on clamp (Figure 18, Item 7).
2 1 3
3 6
4
M0432SWR
Figure 18.
0218-12
TM 5-3895-379-23-1
0218
MANUAL BRAKE RELEASE PUMP TO FRONT PROPEL GEARBOX LINE REPLACEMENT - Continued 23. 24. Place hose (Figure 19, Item 5) in clamp (Figure 19, Item 2). Install two plates (Figure 19, Item 1), washers (Figure 19, Item 4), screws (Figure 19, Item 3), washers (Figure 19, Item 6), and nuts (Figure 19, Item 7) on clamp (Figure 19, Item 2).
1 5
Figure 19. 25. 26. 27. 28.
3
M0433SWR
Place hose (Figure 20, Item 10) in clamp (Figure 20, Item 6). Install clamp (Figure 20, Item 6) on yoke (Figure 20, Item 2) with plate (Figure 20, Item 7), two washers (Figure 20, Item 12), screws (Figure 20, Item 11), washers (Figure 20, Item 9), and nuts (Figure 20, Item 8). Place hose (Figure 20, Item 10) in clamp (Figure 20, Item 3) and install clamp on yoke (Figure 20, Item 2) with new lockwasher (Figure 20, Item 4) and screw (Figure 20, Item 5). Tighten screw securely. Place hose (Figure 20, Item 10) in clamp (Figure 20, Item 13) and install clamp and plate (Figure 20, Item 14) on screw (Figure 20, Item 1) with screw (Figure 20, Item 15).
2 4 3
5 8 9 7 6 10
13 10 14 15
2 12 11
M0434SWR
Figure 20.
0218-13
TM 5-3895-379-23-1
0218
MANUAL BRAKE RELEASE PUMP TO FRONT PROPEL GEARBOX LINE REPLACEMENT - Continued 29. Install new O-ring (Figure 21, Item 2) and hose (Figure 21, Item 3) on front propel gearbox fitting (Figure 21, Item 1).
2 3
M0435SWR
0218-14
TM 5-3895-379-23-1
0218
MANUAL BRAKE RELEASE PUMP TO REAR PROPEL GEARBOX LINE REPLACEMENT 1. 2. Place container with 1 gal (3.8 Liters) minimum capacity under rear propel gearbox fitting (Figure 22, Item 2). Remove hose (Figure 22, Item 1) and O-ring (Figure 22, Item 3) from rear propel gearbox fitting (Figure 22, Item 2) and allow oil to drain into container. Discard O-ring.
1
M0436SWR
Figure 22.
0218-15
TM 5-3895-379-23-1
0218
MANUAL BRAKE RELEASE PUMP TO REAR PROPEL GEARBOX LINE REPLACEMENT - Continued 3. 4. Remove screw (Figure 23, Item 6), washer (Figure 23, Item 5), clamp (Figure 23, Item 3), and hose (Figure 23, Item 4) from screw (Figure 23, Item 8). Remove plate (Figure 23, Item 7), screw (Figure 23, Item 8), clamp (Figure 23, Item 9), and hose (Figure 23, Item 2) from screw (Figure 23, Item 1).
9 9 2 8 7 3 4
M0437SWR
Figure 23.
0218-16
TM 5-3895-379-23-1
0218
MANUAL BRAKE RELEASE PUMP TO REAR PROPEL GEARBOX LINE REPLACEMENT - Continued 5. Remove screw (Figure 24, Item 4), washer (Figure 24, Item 5), clamp (Figure 24, Item 3), and hose (Figure 24, Item 2) from frame (Figure 24, Item 1).
4 2 3 5 1
M0438SWR
Figure 24.
0218-17
TM 5-3895-379-23-1
0218
MANUAL BRAKE RELEASE PUMP TO REAR PROPEL GEARBOX LINE REPLACEMENT - Continued 6. 7. 8. Remove hose (Figure 25, Item 1) and O-ring (Figure 25, Item 7) from elbow (Figure 25, Item 6). Discard O-ring. Remove hose (Figure 25, Item 4) and O-ring (Figure 25, Item 3) from elbow (Figure 25, Item 6). Discard O-ring. Remove locknut (Figure 25, Item 5) and elbow (Figure 25, Item 6) from frame (Figure 25, Item 2). Discard locknut.
2 4 3
7 5
6
M0439SWR
Figure 25.
0218-18
TM 5-3895-379-23-1
0218
MANUAL BRAKE RELEASE PUMP TO REAR PROPEL GEARBOX LINE REPLACEMENT - Continued 9. Remove screw (Figure 26, Item 3), plate (Figure 26, Item 4), clamp (Figure 26, Item 5), and hose (Figure 26, Item 2) from frame (Figure 26, Item 1).
M0440SWR
Figure 26.
0218-19
TM 5-3895-379-23-1
0218
MANUAL BRAKE RELEASE PUMP TO REAR PROPEL GEARBOX LINE REPLACEMENT - Continued 10. Remove screw (Figure 27, Item 5), plate (Figure 27, Item 4), clamp (Figure 27, Item 3), and hose (Figure 27, Item 1) from screw (Figure 27, Item 2).
3 4 5
M0441SWR
Figure 27. 11. 12.
Remove screw (Figure 28, Item 5), plate (Figure 28, Item 6), clamp (Figure 28, Item 4), and two hoses (Figure 28, Items 7 and 9) from screw (Figure 28, Item 3). Remove plate (Figure 28, Item 8), screw (Figure 28, Item 3), clamp (Figure 28, Item 2), and hose (Figure 28, Item 10) from screw (Figure 28, Item 1).
9 10
M0442SWR
Figure 28.
0218-20
TM 5-3895-379-23-1
0218
MANUAL BRAKE RELEASE PUMP TO REAR PROPEL GEARBOX LINE REPLACEMENT - Continued 13. 14. Remove screw (Figure 29, Item 10), plate (Figure 29, Item 9), and two hoses (Figure 29, Items 7 and 8) from screw (Figure 29, Item 3). Remove plate (Figure 29, Item 2), screw (Figure 29, Item 3), clamp (Figure 29, Item 4), and hose (Figure 29, Item 6) from screw (Figure 29, Item 5).
10 9 8 7 6
M0443SWR
Figure 29. 15. 16.
Remove hose (Figure 30, Item 1) and O-ring (Figure 30, Item 2) from manual brake release pump tee (Figure 30, Item 3). Discard O-ring. Install new O-ring (Figure 30, Item 2) and hose (Figure 30, Item 1) on manual brake release pump tee (Figure 30, Item 3).
1 2 3
M0444SWR
Figure 30.
0218-21
TM 5-3895-379-23-1
0218
MANUAL BRAKE RELEASE PUMP TO REAR PROPEL GEARBOX LINE REPLACEMENT - Continued 17. 18. 19. 20. 21. Place hose (Figure 29, Item 6) in clamp (Figure 29, Item 4) and install clamp and plate (Figure 29, Item 2) on screw (Figure 29, Item 5) with screw (Figure 29, Item 3). Place hoses (Figure 29, Items 7 and 8) in clamp (Figure 29, Item 1) and install clamp and plate (Figure 29, Item 9) on screw (Figure 29, Item 3) with screw (Figure 29, Item 10). Place hose (Figure 28, Item 10) in clamp (Figure 28, Item 2) and install clamp and plate (Figure 28, Item 8) on screw (Figure 28, Item 1) with screw (Figure 28, Item 3). Place two hoses (Figure 28, Items 7 and 9) in clamp (Figure 28, Item 4) and install clamp and plate (Figure 28, Item 6) on screw (Figure 28, Item 3) with screw (Figure 28, Item 5). Place hose (Figure 31, Item 1) in clamp (Figure 31, Item 3) and install clamp and plate (Figure 31, Item 4) on screw (Figure 31, Item 2) with screw (Figure 31, Item 5).
3 4 5
M0445SWR
Figure 31. 22.
Place hose (Figure 32, Item 2) in clamp (Figure 32, Item 5) and install clamp and plate (Figure 32, Item 4) on frame (Figure 32, Item 1) with screw (Figure 32, Item 3). Tighten screw securely.
0218-22
TM 5-3895-379-23-1
0218
MANUAL BRAKE RELEASE PUMP TO REAR PROPEL GEARBOX LINE REPLACEMENT - Continued
M0446SWR
Figure 32. 23. 24. 25.
Install elbow (Figure 33, Item 6) on frame (Figure 33, Item 2) with new locknut (Figure 33, Item 5). Install new O-ring (Figure 33, Item 3) and hose (Figure 33, Item 4) on elbow (Figure 33, Item 6). Install new O-ring (Figure 33, Item 7) and hose (Figure 33, Item 1) on elbow (Figure 33, Item 6).
2 4 3
7 5
6
M0447SWR
Figure 33.
0218-23
TM 5-3895-379-23-1
0218
MANUAL BRAKE RELEASE PUMP TO REAR PROPEL GEARBOX LINE REPLACEMENT - Continued 26. Place hose (Figure 34, Item 2) in clamp (Figure 34, Item 3) and install clamp on frame (Figure 34, Item 1) with washer (Figure 34, Item 5) and screw (Figure 34, Item 4). Tighten screw securely.
4 2 3 5 1
M0448SWR
Figure 34.
0218-24
TM 5-3895-379-23-1
0218
MANUAL BRAKE RELEASE PUMP TO REAR PROPEL GEARBOX LINE REPLACEMENT - Continued 27. 28. Place hose (Figure 35, Item 2) in clamp (Figure 35, Item 9) and install clamp on screw (Figure 35, Item 1) with screw (Figure 35, Item 8) and plate (Figure 35, Item 7). Install hose (Figure 35, Item 4) and clamp (Figure 35, Item 3) on screw (Figure 35, Item 8) with washer (Figure 35, Item 5) and screw (Figure 35, Item 6).
9 9 2 8 7 3 4
M0449SWR
Figure 35.
0218-25
TM 5-3895-379-23-1
0218
MANUAL BRAKE RELEASE PUMP TO REAR PROPEL GEARBOX LINE REPLACEMENT - Continued 29. Install new O-ring (Figure 36, Item 3) and hose (Figure 36, Item 1) on rear propel gearbox fitting (Figure 36, Item 2).
1 3
M0450SWR
BRAKE VALVE TO STEERING PUMP LINE REPLACEMENT 1. 2. Place container with 1 gal (3.8 Liters) minimum capacity under steering pump fitting (Figure 37, Item 1). Remove hose (Figure 37, Item 3) and O-ring (Figure 37, Item 2) from steering pump fitting (Figure 37, Item 1) and allow oil to drain into container. Discard O-ring.
M0451SWR
Figure 37.
0218-26
TM 5-3895-379-23-1
0218
BRAKE VALVE TO STEERING PUMP LINE REPLACEMENT - Continued 3. 4. Remove hose (Figure 38, Item 3) and preformed packing (Figure 38, Item 2) from brake valve fitting (Figure 38, Item 1). Discard preformed packing. Install new preformed packing (Figure 38, Item 2) and hose (Figure 38, item 3) on brake valve fitting (Figure 38, Item 1).
3 2 1
M0452SWR
Figure 38. 5.
Install new O-ring (Figure 39, Item 2) and hose (Figure 39, Item 3) on steering pump fitting (Figure 39, Item 1).
M0453SWR
0218-27
TM 5-3895-379-23-1
0218
VIBRATORY VALVE TO BRAKE VALVE LINE REPLACEMENT 1. 2. Place container with 1 gal (3.8 Liters) minimum capacity under vibratory valve fitting (Figure 40, Item 3). Remove hose (Figure 40, Item 1) and preformed packing (Figure 40, Item 2) from vibratory valve fitting (Figure 40, Item 3) and allow oil to drain into container. Discard preformed packing.
1
2 3
M0454SWR
Figure 40. 3. 4.
Remove hose (Figure 41, Item 3) and preformed packing (Figure 41, Item 2) from brake valve fitting (Figure 41, Item 1). Discard preformed packing. Install new preformed packing (Figure 41, Item 2) and hose (Figure 41, Item 3) on brake valve fitting (Figure 41, Item 1).
1 2 3
M0455SWR
Figure 41.
0218-28
TM 5-3895-379-23-1
0218
VIBRATORY VALVE TO BRAKE VALVE LINE REPLACEMENT - Continued 5. Install new preformed packing (Figure 42, Item 2) and hose (Figure 42, Item 1) on vibratory valve fitting (Figure 42, Item 3).
2 3
M0456SWR
0218-29
TM 5-3895-379-23-1
0218
BRAKE VALVE TO REAR PROPEL GEARBOX LINE REPLACEMENT 1. 2. Place container with 1 gal (3.8 Liters) minimum capacity under rear propel gearbox fitting (Figure 43, Item 2). Remove hose (Figure 43, Item 1) and O-ring (Figure 43, Item 3) from rear propel gearbox fitting (Figure 43, Item 2) and allow oil to drain into container. Discard O-ring.
M0457SWR
Figure 43.
0218-30
TM 5-3895-379-23-1
0218
BRAKE VALVE TO REAR PROPEL GEARBOX LINE REPLACEMENT - Continued 3. 4. Remove screw (Figure 44, Item 6), washer (Figure 44, Item 5), clamp (Figure 44, Item 3), and hose (Figure 44, Item 4) from screw (Figure 44, Item 8). Remove plate (Figure 44, Item 7), screw (Figure 44, Item 8), clamp (Figure 44, Item 9), and hose (Figure 44, Item 2) from screw (Figure 44, Item 1).
9 9 2 8 7 3 4
M0458SWR
Figure 44.
0218-31
TM 5-3895-379-23-1
0218
BRAKE VALVE TO REAR PROPEL GEARBOX LINE REPLACEMENT - Continued 5. Remove screw (Figure 45, Item 4), washer (Figure 45, Item 5), clamp (Figure 45, Item 3), and hose (Figure 45, Item 2) from frame (Figure 45, Item 1).
4 2 3 5 1
M0459SWR
Figure 45. 6. 7. 8.
Remove hose (Figure 46, Item 1) and O-ring (Figure 46, Item 7) from elbow (Figure 46, Item 6). Discard O-ring. Remove hose (Figure 46, Item 5) and O-ring (Figure 46, Item 4) from elbow (Figure 46, Item 6). Discard O-ring. Remove locknut (Figure 46, Item 3) and elbow (Figure 46, Item 6) from frame (Figure 46, Item 2). Discard locknut.
2 3 1 7 6 5 4
M0460SWR
Figure 46.
0218-32
TM 5-3895-379-23-1
0218
BRAKE VALVE TO REAR PROPEL GEARBOX LINE REPLACEMENT - Continued 9. Remove screw (Figure 47, Item 3), plate (Figure 47, Item 4), clamp (Figure 47, Item 5), and hose (Figure 47, Item 2) from frame (Figure 47, Item 1).
2 1
M0461SWR
Figure 47.
0218-33
TM 5-3895-379-23-1
0218
BRAKE VALVE TO REAR PROPEL GEARBOX LINE REPLACEMENT - Continued 10. Remove screw (Figure 48, Item 5), plate (Figure 48, Item 4), clamp (Figure 48, Item 3), and hose (Figure 48, Item 1) from screw (Figure 48, Item 2).
3 4 5
M0462SWR
Figure 48.
0218-34
TM 5-3895-379-23-1
0218
BRAKE VALVE TO REAR PROPEL GEARBOX LINE REPLACEMENT - Continued 11. 12. Remove screw (Figure 49, Item 5), plate (Figure 49, Item 6), clamp (Figure 49, Item 4), and two hoses (Figure 49, Items 7 and 9) from screw (Figure 49, Item 3). Remove plate (Figure 49, Item 8), screw (Figure 49, Item 3), clamp (Figure 49, Item 2), and hose (Figure 49, Item 10) from screw (Figure 49, Item 1).
9 10
M0463SWR
Figure 49. 13. 14.
Remove screw (Figure 50, Item 10), plate (Figure 50, Item 9), clamp (Figure 50, Item 1), and two hoses (Figure 50, Items 7 and 8) from screw (Figure 50, Item 3). Remove plate (Figure 50, Item 2), screw (Figure 50, Item 3), clamp (Figure 50, Item 4), and hose (Figure 50, Item 6) from screw (Figure 50, Item 5).
10 9 8 7 6
M0464SWR
Figure 50.
0218-35
TM 5-3895-379-23-1
0218
BRAKE VALVE TO REAR PROPEL GEARBOX LINE REPLACEMENT - Continued 15. Remove screw (Figure 51, Item 5), plate (Figure 51, Item 4), clamp (Figure 51, Item 3), and hose (Figure 51, Item 2) from screw (Figure 51, Item 1).
AIR CLEANER ASSEMBLY SHOWN REMOVED FOR CLARITY 1
2
M0465SWR
Figure 51. 16. 17.
Brake Hoses, Lines, and Replacement.
Remove hose (Figure 52, Item 3) and O-ring (Figure 52, Item 2) from brake valve fitting (Figure 52, Item 1). Discard O-ring. Install new O-ring (Figure 52, Item 2) and hose (Figure 52, Item 3) on brake valve fitting (Figure 52, Item 1).
1 2 3
M0466SWR
Figure 52. 18.
Place hose (Figure 51, Item 2) in clamp (Figure 51, Item 3) and install clamp and plate (Figure 51, Item 4) on screw (Figure 51, Item 1), with screw (Figure 51, Item 5).
0218-36
TM 5-3895-379-23-1
0218
BRAKE VALVE TO REAR PROPEL GEARBOX LINE REPLACEMENT - Continued 19. 20. Place hose (Figure 53, Item 6) in clamp (Figure 53, Item 4) and install clamp on screw (Figure 53, Item 5) with screw (Figure 53, Item 3) and plate (Figure 53, Item 2). Place two hoses (Figure 53, Items 7 and 8) in clamp (Figure 53, Item 1) and install clamp and plate (Figure 53, Item 9) on screw (Figure 53, Item 3) with screw (Figure 53, Item 10).
10 9 8 7 6
M0467SWR
Figure 53. 21. 22.
Place hose (Figure 54, Item 10) in clamp (Figure 54, Item 2) and install clamp on screw (Figure 54, Item 1) with screw (Figure 54, Item 3) and plate (Figure 54, Item 8). Place two hoses (Figure 54, Items 7 and 9) in clamp (Figure 54, Item 4) and install clamp and plate (Figure 54, Item 6) on screw (Figure 54, Item 3) with screw (Figure 54, Item 5).
9 10
M0468SWR
Figure 54.
0218-37
TM 5-3895-379-23-1
0218
BRAKE VALVE TO REAR PROPEL GEARBOX LINE REPLACEMENT - Continued 23. Place hose (Figure 55, Item 1) in clamp (Figure 55, Item 3) and install clamp and plate (Figure 55, Item 4) on screw (Figure 55, Item 2) with screw (Figure 55, Item 5).
3 4 5
M0469SWR
Figure 55. 24.
Place hose (Figure 56, Item 2) in clamp (Figure 56, Item 5) and install clamp and plate (Figure 56, Item 4) on frame (Figure 56, Item 1) with screw (Figure 56, Item 3). Tighten securely.
2 1
M0470SWR
Figure 56.
0218-38
TM 5-3895-379-23-1
0218
BRAKE VALVE TO REAR PROPEL GEARBOX LINE REPLACEMENT - Continued 25. 26. 27. Install elbow (Figure 57, Item 6) on frame (Figure 57, Item 2) with new locknut (Figure 57, Item 3). Install new O-ring (Figure 57, Item 4) and hose (Figure 57, Item 5) on elbow (Figure 57, Item 6). Install new O-ring (Figure 57, Item 7) and hose (Figure 57, Item 1) on elbow (Figure 57, Item 6).
2 3 1 7 6 5 4
M0471SWR
Figure 57. 28.
Place hose (Figure 58, Item 2) in clamp (Figure 58, Item 3) and install clamp on frame (Figure 58, Item 1) with washer (Figure 58, Item 5) and screw (Figure 58, Item 4). Tighten securely.
4 2 3 5 1
M0472SWR
Figure 58. 29.
Place hose (Figure 59, Item 2) in clamp (Figure 59, Item 9) and install clamp on screw (Figure 59, Item 1) with screw (Figure 59, Item 8) and plate (Figure 59, Item 7).
0218-39
TM 5-3895-379-23-1
0218
BRAKE VALVE TO REAR PROPEL GEARBOX LINE REPLACEMENT - Continued 30. Place hose (Figure 59, Item 4) in clamp (Figure 59, Item 3) and install clamp on screw (Figure 59, Item 8) with washer (Figure 59, Item 5) and screw (Figure 59, Item 6).
9 9 2 8 7 3 4
6
M0473SWR
Figure 59.
0218-40
TM 5-3895-379-23-1
0218
BRAKE VALVE TO REAR PROPEL GEARBOX LINE REPLACEMENT - Continued 31. Install new O-ring (Figure 60, Item 3) and hose (Figure 60, Item 1) on rear propel gearbox fitting (Figure 60, Item 2).
M0474SWR
Lower operator platform assembly. (Volume 2, WP 0235) Service hydraulic oil level. (TM 5-3895-379-10) Start engine, operate roller, and check for leaks. (TM 5-3895-379-10)
0218-41/42 blank
TM 5-3895-379-23-1
0219
FIELD MAINTENANCE MANUAL BRAKE RELEASE PUMP MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Gloves, Rubber (Volume 2, WP 0289, Table 1, Item 12) Goggles (Volume 2, WP 0289, Table 1, Item 13) Pan, Drain, 5 Gal Cap. (Volume 2, WP 0289, Table 1, Item 23) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 2, WP 0288, Table 1, Item 12) Cleaning Compound, Solvent (Volume 2, WP 0288, Table 1, Item 13, 14, 15) Lubricating Oil, Engine, 15W40 Grade (Volume 2, WP 0288, Table 1, Item 29, 30, 31) Rag, Wiping (Volume 2, WP 0288, Table 1, Item 60) Tag, Marker (Volume 2, WP 0288, Table 1, Item 70) O-ring (Volume 2, WP 0290, Table 1, Item 72) Qty: 5 Materials/Parts (cont.) O-ring (Volume 2, WP 0290, Table 1, Item 81) Qty: 5 O-ring (Volume 2, WP 0290, Table 1, Item 130) Qty: 1 Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 82 Equipment Condition Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10) Left-side door assembly opened. (TM 5-3895-379-10)
0219-1
TM 5-3895-379-23-1
0219
REMOVAL
WARNING
CAUTION
Cap all hoses and fittings to prevent contamination that can cause damage to equipment.
NOTE
Tag and mark all hoses prior to removal. Inspect all hoses, lines, and fittings for cracks, bends, nicks, dents, stripped threads, and cuts. Replace all damaged parts. Use drain pan to catch any hydraulic oil that may drain from system. Dispose of oil In Accordance With (IAW) local policy and ordinances. Ensure all spills are cleaned up. 1. 2. Remove hose (Figure 1, Item 1) and O-ring (Figure 1, Item 2) from elbow (Figure 1, Item 3). Discard O-ring. Remove hose (Figure 1, Item 6) and O-ring (Figure 1, Item 5) from elbow (Figure 1, Item 4). Discard O-ring.
6
Figure 1.
M0645SWR
Manual Brake Release Pump Removal.
0219-2
TM 5-3895-379-23-1
0219
REMOVAL - Continued 3. 4. Remove hose (Figure 2, Item 6) and O-ring (Figure 2, Item 5) from tee (Figure 2, Item 4). Discard O-ring. Remove hose (Figure 2, Item 1) and O-ring (Figure 2, Item 2) from tee (Figure 2, Item 3). Discard O-ring.
1 2 3
4 6 5
M0646SWR
Figure 2. 5.
Remove two bolts (Figure 3, Item 4), washers (Figure 3, Item 1), and manual brake release pump (Figure 3, Item 3) from frame assembly (Figure 3, Item 2).
M0647SWR
Figure 3.
0219-3
TM 5-3895-379-23-1
0219
REMOVAL - Continued 6. 7. 8. 9. 10. 11. 12. 13. 14. Place manual brake release pump (Figure 4, Item 6) in a soft-jawed vise. Remove elbow (Figure 4, Item 7) and O-ring (Figure 4, Item 8) from globe valve (Figure 4, Item 9). Discard O-ring. Remove globe valve (Figure 4, Item 9) and O-ring (Figure 4, Item 10) from adapter (Figure 4, Item 11). Discard O-ring. Remove adapter (Figure 4, Item 11) and O-ring (Figure 4, Item 12) from connector (Figure 4, Item 13). Discard O-ring. Remove connector (Figure 4, Item 13) and O-ring (Figure 4, Item 14) from tee (Figure 4, Item 15). Discard O-ring. Remove tee (Figure 4, Item 15) and O-ring (Figure 4, Item 1) from tee (Figure 4, Item 2). Discard O-ring. Remove tee (Figure 4, Item 2) and O-ring (Figure 4, Item 5) from manual brake release pump (Figure 4, Item 6). Discard O-ring. Remove elbow (Figure 4, Item 3) and O-ring (Figure 4, Item 4) from manual brake release pump (Figure 4, Item 6). Discard O-ring. Remove manual brake release pump (Figure 4, Item 6) from soft-jawed vise.
1 2
15 14 13 12 11 10 9
8 7
M0648SWR
0219-4
TM 5-3895-379-23-1
0219
DISASSEMBLY 1. Place manual brake release pump (Figure 5, Item 1) in soft-jawed vise.
NOTE
Hand pump is not serviceable on the CB534C Roller. 2. 3. 4. 5. 6. On CB534B Roller, loosen nut (Figure 5, Item 5) and remove hand pump (Figure 5, Item 6) from manual brake release pump (Figure 5, Item 1). On CB534C Roller, remove knob. Remove two check valves (Figure 5, Item 2) from manual brake release pump (Figure 5, Item 1). On CB534C Roller remove plug (Figure 5, Item 4) and O-ring (Figure 5, Item 3) from manual brake release pump (Figure 5, Item 1). Discard O-ring. On CB534B Roller, remove expansion plug (Figure 5, Item 7) from manual brake release pump (Figure 5, Item 1). Remove manual brake release pump (Figure 5, Item 1) from soft-jawed vise.
1 2 3 4
6
M0649SWR
Figure 5. Manual Brake Release Pump Disassembly. END OF TASK
0219-5
TM 5-3895-379-23-1
0219
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. 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. 1. 2. 3. 4. 5. 6. 7. 8. Clean all metal parts with cleaning compound, solvent. Thoroughly clean O-ring grooves in valve body. Use compressed air to dry valve body. Check bores for scratches or damage. Check valve body for cracks or damage. Check all threads for peeled or crossed condition. Inspect hand pump (CB534B) for cracks, nicks, or stripped threads. Replace all damaged parts.
END OF TASK
0219-6
TM 5-3895-379-23-1
0219
ASSEMBLY 1. 2. 3. 4. 5. 6. Place manual brake release pump (Figure 6, Item 1) in soft-jawed vise. On CB534B Roller, install expansion plug (Figure 6, Item 7) in manual brake release pump (Figure 6, Item 1). Install new O-ring (Figure 6, Item 3) (CB534C) and plug (Figure 6, Item 4) in manual handle release pump (Figure 6, Item 1). Install two check valves (Figure 6, Item 2) in manual brake release pump (Figure 6, Item 1). On CB534B Roller, lubricate area of hand pump (Figure 6, Item 6) that will be located inside the manual brake release pump (Figure 6, Item 1) with clean lubricating oil. On CB534B Roller, install hand pump (Figure 6, Item 6) in manual brake release pump (Figure 6, Item 1) and tighten nut (Figure 6, Item 5).
1 2 3 4
6
M0650SWR
Manual Brake Release Pump Assembly.
0219-7
TM 5-3895-379-23-1
0219
INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. Place manual brake release pump (Figure 7, Item 6) in a soft-jawed vise. Install new O-ring (Figure 7, Item 4) and elbow (Figure 7, Item 3) on manual brake release pump (Figure 7, Item 6). Install new O-ring (Figure 7, Item 5) and tee (Figure 7, Item 2) on manual brake release pump (Figure 7, Item 6). Install new O-ring (Figure 7, Item 1) and tee (Figure 7, Item 15) on tee (Figure 7, Item 2). Install new O-ring (Figure 7, Item 14) and connector (Figure 7, Item 13) on tee (Figure 7, Item 15). Install new O-ring (Figure 7, Item 12) and adapter (Figure 7, Item 11) on connector (Figure 7, Item 13). Install new O-ring (Figure 7, Item 10) and globe valve (Figure 7, Item 9) on adapter (Figure 7, Item 11). Install new O-ring (Figure 7, Item 8) and elbow (Figure 7, Item 7) on globe valve (Figure 7, Item 9). Remove manual brake release pump (Figure 7, Item 6) from soft-jawed vise.
1 2
15 14 13 12 11 10 9
8 7
M1075SWR
Figure 7. Manual Brake Release Pump Installation.
0219-8
TM 5-3895-379-23-1
0219
INSTALLATION - Continued 10. Install manual brake release pump (Figure 8, Item 3) on frame assembly (Figure 8, Item 2) with two washers (Figure 8, Item 1) and bolts (Figure 8, Item 4).
M0651SWR
Figure 8. Manual Brake Release Pump Installation.
0219-9
TM 5-3895-379-23-1
0219
INSTALLATION - Continued 11. 12. Install new O-ring (Figure 9, Item 2) and hose (Figure 9, Item 1) on tee (Figure 9, Item 3). Install new O-ring (Figure 9, Item 5) and hose (Figure 9, Item 6) on tee (Figure 9, Item 4).
1 2 3
4 6 5
M0652SWR
Figure 9. Manual Brake Release Pump Installation. 13. 14. Install new O-ring (Figure 10, Item 5) and hose (Figure 10, Item 6) on elbow (Figure 10, Item 4). Install new O-ring (Figure 10, Item 2) and hose (Figure 10, Item 1) on elbow (Figure 10, Item 3).
M0653SWR
Manual Brake Release Pump Installation.
0219-10
TM 5-3895-379-23-1
0219
FOLLOW-ON MAINTENANCE 1. 2. 3. Close left-side door assembly. (TM 5-3985-379-10) Start engine, operate roller, and check for leaks. (TM 5-3895-379-10) Remove chocks. (TM 5-3895-379-10)
0219-11/12 blank
TM 5-3895-379-23-1
0220
FIELD MAINTENANCE BRAKE CONTROL VALVE COIL REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figure 85 Equipment Condition Drums chocked. (TM 5-3895-379-10)
0220-1
TM 5-3895-379-23-1
0220
REMOVAL 1. 2. 3. 4. 5. Disconnect electrical connectors (Figure 1, Items 2 and 6). Bend tabs up on lock (Figure 1, Item 7). Remove nut (Figure 1, Item 5) from shift coil (Figure 1, Item 3) and nut (Figure 1, Item 5) from brake coil (Figure 1, Item 8). Remove lock (Figure 1, Item 7) and two washers (Figure 1, Item 4) from coils (Figure 1, Items 3 and 8). Remove shift coil (Figure 1, Item 3) and brake coil (Figure 1, Item 8) from control valve (Figure 1, Item 1).
1 3 2 4 5 6
5 5 8 4 7
M0654SWR
Figure 1. Brake Control Valve Coil Removal. END OF TASK
0220-2
TM 5-3895-379-23-1
0220
INSTALLATION 1. 2. 3. 4. 5. Install brake coil (Figure 2, Item 8) and shift coil (Figure 2, Item 3) to control valve (Figure 2, Item 1). Install lock (Figure 2, Item 7) and two washers (Figure 2, Item 4) to coils (Figure 2, Items 3 and 8). Install two nuts (Figure 2, Item 5) to shift coil (Figure 2, Item 3) and brake coil (Figure 2, Item 8). Tighten nuts to 48-70 lb-ft (65-95 Nm). Bend tabs back on lock (Figure 2, Item 7). Connect electrical connectors (Figure 2, Items 2 and 6).
1 3 2 4 5 6
5 5 8 4 7
M1156SWR
Figure 2. Brake Control Valve Coil Installation. END OF TASK FOLLOW-ON MAINTENANCE Remove chocks. (TM 5-3895-379-10) END OF TASK END OF WORK PACKAGE
0220-3/4 blank
TM 5-3895-379-23-1
0221
FIELD MAINTENANCE STEERING WHEEL AND COLUMN REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 2, WP 0289, Table 1, Item 39) Wrench, Torque, 20-100 ft-lb (Volume 2, WP 0289, Table 1, Item 42) Materials/Parts Lubricating Oil, Engine, 15W40 Grade (Volume 2, WP 0288, Table 1, Item 29, 30, 31) Personnel Required Construction Equipment Repairer 91L References TM 5-3895-379-23P, Figures 87 and 102 Equipment Condition Vandal guard removed. (Volume 2, WP 0239) Engine off. (TM 5-3895-379-10) Drums chocked. (TM 5-3895-379-10)
0221-1
TM 5-3895-379-23-1
0221
REMOVAL
NOTE
Steering wheel is replaced the same way for CB534B and CB534C Rollers. CB534B Roller is shown. 1. 2. 3. Remove three screws (Figure 1, Item 3) and identification plate (Figure 1, Item 2) from steering wheel (Figure 1, Item 1). Remove nut (Figure 1, Item 4) from steering column (Figure 1, Item 5). Remove steering wheel (Figure 1, Item 1) from steering column (Figure 1, Item 5) with steering wheel puller.
3 2 4 1 5
M0656SWR
Figure 1.
Steering Wheel and Column Removal.
0221-2
TM 5-3895-379-23-1
0221
REMOVAL - Continued 4. 5. 6. Remove four bolts (Figure 2, Item 9), washers (Figure 2, Item 8), and cover (Figure 2, Item 7) from station (Figure 2, Item 10). Remove three bolts (Figure 2, Item 3) and washers (Figure 2, Item 2) that fasten console (Figure 2, Item 1) to steering column (Figure 2, Item 5), and move console out of the way. While holding steering control unit (Figure 2, Item 6), remove four bolts (Figure 2, Item 4) and washers (Figure 2, Item 11) that fasten steering control unit and steering column (Figure 2, Item 5) to console (Figure 2, Item 1). Remove steering control unit (Figure 2, Item 6) from steering column (Figure 2, Item 5). Remove steering column (Figure 2, Item 5) from console (Figure 2, Item 1).
7. 8.
2 3 4 5 6 11
10 9
8
M0657SWR
Steering Wheel and Column Removal.
0221-3
TM 5-3895-379-23-1
0221
INSTALLATION
NOTE
Do not oil threads of column. 1. 2. 3. Install steering column (Figure 3, Item 5) to console (Figure 3, Item 1). Install steering control unit (Figure 3, Item 6) to steering column (Figure 3, Item 5). While holding steering control unit (Figure 3, Item 6), install four washers (Figure 3, Item 11) and bolts (Figure 3, Item 4) to steering control unit (Figure 3, Item 6), steering column (Figure 3, Item 5), and console (Figure 3, Item 1). Tighten bolts to 19 lb-ft (26 Nm). Install three washers (Figure 3, Item 2) and bolts (Figure 3, Item 3) that fasten console (Figure 3, Item 1) to steering column (Figure 3, Item 5). Install four washers (Figure 3, Item 8), bolts (Figure 3, Item 9), and cover (Figure 3, Item 7) to station (Figure 3, Item 10).
4. 5.
2 3 4 5 6 11
10 9 8
M1160SWR
Figure 3. Steering Wheel and Column Installation.
0221-4
TM 5-3895-379-23-1
0221
INSTALLATION - Continued 6. 7. 8. 9. Apply a few drops of oil to spline of steering column (Figure 4, Item 5). Align steering wheel (Figure 4, Item 1) with one spoke facing downward. Install steering wheel (Figure 4, Item 1) on steering column (Figure 4, Item 5) with nut (Figure 4, Item 4). Tighten nut to 30-40 lb-ft (41-54 Nm). Install identification plate (Figure 4, Item 2) on steering wheel (Figure 4, Item 1) with three screws (Figure 4, Item 3). Tighten screws securely.
3 2 4 1 5
M1159SWR
Figure 4. Steering Wheel and Column Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install vandal guard. (Volume 2, WP 0239) Remove chocks. (TM 5-3895-379-10)
0221-5/6 blank
TM 5-3895-379-23-1
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
DRUM SELECT SWITCH REPLACEMENT..................................................................... WP 0158-1
E
ENGINE ASSEMBLY 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................................................................... WP 0078-1 WP 0007-1 WP 0008-1 WP 0009-1 WP 0010-1 WP 0011-1 WP 0012-1 WP 0013-1 WP 0079-1
Index-1
03/15/2011 Rel(1.8) root(aindx) wpno(INDEX)
TM 5-3895-379-23-1
Subject
WP Sequence No.-Page No. 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
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).........................................................
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 ENGINE MOUNT REPLACEMENT..................................................................... FRONT WIRING HARNESS REPLACEMENT................................................................. FUEL CAP ASSEMBLY REPAIR...................................................................................... FUEL FILTER ASSEMBLY REPLACEMENT................................................................... FUEL GAUGE DOES NOT WORK................................................................................... FUEL INJECTION PUMP GEAR REPLACEMENT.......................................................... 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 0146-1 WP 0145-1 WP 0147-1 WP 0026-1 WP 0086-1 WP 0087-1 WP 0213-1 WP 0080-1 WP 0197-1 WP 0126-1 WP 0127-1 WP 0027-1 WP 0111-1 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
Index-2
TM 5-3895-379-23-1
Subject
WP Sequence No.-Page No.
G
GAUGE ROD (DIPSTICK) TUBE ASSEMBLY REPLACEMENT..................................... GENERAL INFORMATION............................................................................................... GENERAL WIRING REPAIR............................................................................................ GROUND CABLE REPLACEMENT................................................................................. WP 0099-1 WP 0001-1 WP 0195-1 WP 0194-1
H
HORN ASSEMBLY REPLACEMENT............................................................................... HORN DOES NOT WORK................................................................................................ HORN SWITCH REPLACEMENT.................................................................................... HOURMETER PRESSURE SWITCH REPLACEMENT................................................... HYDRAULIC OIL PRESSURE IS LOW (WARNING LIGHT AND WARNING HORN ON)................................................................................................................................... HYDRAULIC OIL TEMPERATURE IS HIGH (WARNING LIGHT AND WARNING HORN ON)................................................................................................................................... HYDRAULIC OIL TEMPERATURE SENSOR REPLACEMENT...................................... HYDRAULIC PUMP DRIVE REPLACEMENT.................................................................. WP 0189-1 WP 0028-1 WP 0188-1 WP 0171-1 WP 0038-1 WP 0039-1 WP 0185-1 WP 0212-1
I
IDLER GEAR AND HUB REPLACEMENT....................................................................... INSTRUMENT WIRING HARNESS REPLACEMENT...................................................... INTAKE MANIFOLD REPLACEMENT.............................................................................. INTERMITTENT WATER SPRAY TIMER REPLACEMENT............................................ WP 0091-1 WP 0199-1 WP 0105-1 WP 0163-1
L
LIGHTS CIRCUIT BREAKER REPLACEMENT............................................................... LOW IDLE SPEED ADJUSTMENT................................................................................... WP 0173-1 WP 0132-1
M
MAIN RELAY REPLACEMENT........................................................................................ MAIN WIRING HARNESS REPLACEMENT (CB534B).................................................... MAIN WIRING HARNESS REPLACEMENT (CB534C)................................................... MANUAL BRAKE RELEASE PUMP MAINTENANCE...................................................... MUFFLER AND TAILPIPE REPLACEMENT.................................................................... WP 0154-1 WP 0200-1 WP 0201-1 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................................................. WP 0102-1 WP 0103-1 WP 0021-1 WP 0093-1 WP 0104-1
Index-3
TM 5-3895-379-23-1
Subject
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.................................................................................................. 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 0044-1 WP 0045-1 WP 0156-1 WP 0040-1 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.............................................................................. REAR ENGINE MOUNT REPLACEMENT....................................................................... REAR PROPEL MOTOR REPLACEMENT...................................................................... REAR WIRING HARNESS REPLACEMENT................................................................... RELAY 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.......... WP 0137-1 WP 0136-1 WP 0138-1 WP 0081-1 WP 0204-1 WP 0198-1 WP 0155-1 WP 0090-1 WP 0089-1 WP 0041-1 WP 0030-1 WP 0042-1 WP 0053-1
S
SEPARATE AND CONNECT PROPEL MOTOR AND TORQUE HUB............................ SEPARATE AND CONNECT VIBRATORY AND PROPEL PUMPS................................ SERVICE METER REPLACEMENT................................................................................. SERVICE UPON RECEIPT.............................................................................................. WP 0214-1 WP 0202-1 WP 0169-1 WP 0075-1
Index-4
TM 5-3895-379-23-1
Subject
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 WHEEL AND COLUMN REPLACEMENT.....................................................
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 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.................................. 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 0004-1 WP 0005-1 WP 0123-1 WP 0122-1 WP 0121-1
U
UNIVERSAL JOINT AND SHAFT MAINTENANCE.......................................................... WP 0215-1
V
VALVE COVER AND BREATHER TUBE REPLACEMENT............................................. VALVE LASH (CLEARANCE) ADJUSTMENT.................................................................. 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......................................... WP 0101-1 WP 0088-1 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
Index-5
TM 5-3895-379-23-1
Subject
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 SYSTEM ENGAGES HARSHLY.................................................................
WP 0170-1 WP 0035-1 WP 0203-1 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 PUMP REPLACEMENT...................................................................................... WATER SPRAY OCCURS ON ONE DRUM ONLY.......................................................... WATER SPRAY PRESSURE IS LOW.............................................................................. WATER SPRAY SWITCH 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 0036-1 WP 0186-1 WP 0180-1 WP 0068-1 WP 0144-1 WP 0069-1 WP 0070-1 WP 0157-1 WP 0182-1 WP 0178-1 WP 0179-1 WP 0162-1 WP 0037-1
Index-6
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
TM Number
PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER
Date of the TM
Title of the TM
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
Your Phone Number
Your Signature
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 PUBLICATION/FORM NUMBER DATE Field Maintenance Manual for Roller, Motorized, Vibrating 4 September 2012 TM 5-3895-379-23-1 Tandem Steel Drums Caterpiller Model CB534B and 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 PUBLICATION/FORM NUMBER DATE Field Maintenance Manual for Roller, Motorized, Vibrating 4 September 2012 TM 5-3895-379-23-1 Tandem Steel Drums Caterpiller Model CB534B 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 PUBLICATION/FORM NUMBER DATE Field Maintenance Manual for Roller, Motorized, Vibrating 4 September 2012 TM 5-3895-379-23-1 Tandem Steel Drums Caterpiller Model CB534B and Caterpiller Model CB534C ITEM PAGE PARAGRAPH LINE FIGURE TABLE NO. RECOMMENDED CHANGES AND REASON
SIGNATURE
APD V4.00
DATE
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
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS TITLE PUBLICATION/FORM NUMBER DATE Field Maintenance Manual for Roller, Motorized, Vibrating 4 September 2012 TM 5-3895-379-23-1 Tandem Steel Drums Caterpiller Model CB534B and Caterpiller Model CB534C ITEM PAGE PARAGRAPH LINE FIGURE TABLE NO. RECOMMENDED CHANGES AND REASON
SIGNATURE
APD V4.00
DATE
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

1220601
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 5-3895-379-23-1.
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 Lb 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 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=0.386 Sq Miles CUBIC MEASURE 1 Cu Centimeter=1000 Cu Millimeters=0.06 Cu Inches 1 Cu Meter=1,000,000 Cu Centimeters=35.31 Cu Feet TEMPERATURE 5/9 (F 32) = C 212Fahrenheit is equivalent to 100Celsius 90Fahrenheit is equivalent to 32.2Celsius 32Fahrenheit is equivalent to 0Celsius 9/5 (C + 32) = F
APPROXIMATE CONVERSION FACTORS

15
TO CHANGE Inches . . . . . . . . . . . Feet . . . . . . . . . . . . . Yards . . . . . . . . . . . . Miles . . . . . . . . . . . . Square Inches . . . . Square Feet . . . . . . . Square Yards . . . . . . Square Miles . . . . . . Acres . . . . . . . . . . . . Cubic Feet . . . . . . . . Cubic Yards . . . . . . . Fluid Ounces . . . . . . Pints. . . . . . . . . . . . . Quarts . . . . . . . . . . . Gallons. . . . . . . . . . . Ounces . . . . . . . . . . Pounds . . . . . . . . . . . Short Tons . . . . . . . . Pound-Feet . . . . . . . Pounds/Sq Inch . . . . Miles per Gallon . . . . Miles per Hour . . . . . TO CHANGE Centimeters . . . . . . . Meters . . . . . . . . . . . Meters . . . . . . . . . . . Kilometers . . . . . . . . Sq Centimeters . . . . Square Meters . . . . . Square Meters . . . . . Square Kilometers . . Sq Hectometers . . . . Cubic Meters . . . . . . Cubic Meters . . . . . . Milliliters . . . . . . . . . . Liters . . . . . . . . . . . . Liters . . . . . . . . . . . . Liters . . . . . . . . . . . . Grams . . . . . . . . . . . Kilograms . . . . . . . . . Metric Tons . . . . . . . Newton-Meters. . . . . Kilopascals. . . . . . . . Km per Liter . . . . . . . Km per Hour . . . . . .
TO
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 0.425 1.609
Inches . . . . . . . . . . . . . . . . . . . . . Feet . . . . . . . . . . . . . . . . . . . . . . . Yards . . . . . . . . . . . . . . . . . . . . . . Miles . . . . . . . . . . . . . . . . . . . . . . Square Inches . . . . . . . . . . . . . . . Square Feet. . . . . . . . . . . . . . . . . Square Yards . . . . . . . . . . . . . . . . Square 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 . . . . . . . . . . . . . . .
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 2.354 0.621
TO
MULTIPLY BY
1 CM. 2
INCHES
Centimeters . . . . . . . . . . . . . . . . . Meters . . . . . . . . . . . . . . . . . . . . . Meters . . . . . . . . . . . . . . . . . . . . . Kilometers . . . . . . . . . . . . . . . . . . Square Centimeters . . . . . . . . . . Square Meters . . . . . . . . . . . . . . . Square Meters . . . . . . . . . . . . . . . Square Kilometers. . . . . . . . . . . . Square Hectometers . . . . . . . . . . Cubic Meters . . . . . . . . . . . . . . . . Cubic Meters . . . . . . . . . . . . . . . . Milliliters. . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . Grams . . . . . . . . . . . . . . . . . . . . . Kilograms. . . . . . . . . . . . . . . . . . . Metric Tons . . . . . . . . . . . . . . . . . Newton-Meters . . . . . . . . . . . . . . Kilopascals . . . . . . . . . . . . . . . . . Kilometers per Liter . . . . . . . . . . . Kilometers per Hour . . . . . . . . . .
13
14
11
12
10
PIN: 087180-000

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*TM 5-3895-379-23-1

TECHNICAL MANUAL FIELD MAINTENANCE FOR

HEADQUARTERS, DEPARTMENT OF THE ARMY 4 September 2012

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GENERAL SAFETY WARNINGS DESCRIPTION

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ENGINE SURGES (SPEED CHANGES)..................................................................................................... WP 0018 Figure 1. Fuel Lines............................................................................................................................. 0018-3

OIL LEAKING FROM EXHAUST................................................................................................................. WP 0021 Figure 1. Turbocharger........................................................................................................................ 0021-3

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PROPEL MOTOR IS NOISY....................................................................................................................... WP 0046 PROPEL MOTOR LEAKS OIL..................................................................................................................... WP 0047

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